Dataset on forming-induced thickness variations and structural responses in arched thin-shell metal alloys

This dataset encompasses numerical simulation outputs and experimental measurements of thickness variations and mechanical responses in arched thin-shell metal components under forming processes. The simulation data were generated using explicit dynamic finite element analysis in Abaqus, incorporating eight isotropic material models (MONEL Alloy 400 and other alloys) and 42,669 geometric configurations derived from a full factorial Design of Experiments. Geometric parameters varied across four radii (20 mm, 40 mm, 80 mm, 160 mm), three initial thicknesses (0.1 mm, 0.2 mm, 0.4 mm), and three arch rises (15%, 30%, 60% of radius), ensuring adherence to thin-shell theory (thickness-to-radius ratio << 0.05). Each configuration produced nodal data on radial paths, yielding raw points exceeding 129,600, subsampled to focus on core and radial thickness profiles, stress and strain fields, stress triaxiality, plastic dissipated energy, vibration modes, buckling loads, and rupture characteristics. Material parameters included density, Young's modulus, Poisson's ratio, and Johnson-Cook plasticity constants (yield strength, hardening modulus, exponent, strain-rate sensitivity). Simulations accounted for room-temperature conditions (20°C) with coupled thermo-mechanical effects from plastic dissipation.Experimental data were collected from 36 MONEL Alloy 400 specimens (diameter 100 mm, initial thickness 0.1 mm), formed pneumatically at room temperature using a custom bench with air compression, control cabinet, clamping flange, and assembly. High-pressure gas from a large buffer tank (20°C) was introduced gradually for isothermal mixing over at least 60 seconds. Specimens covered three arch heights (7.5 mm, 15 mm, 23.5 mm), measuring thickness at 12 radial points (five replicates each) using a 0.1 μm resolution micrometer. Rupture tests (18 forward, 18 reverse) recorded pressures via calibrated gauges (4 MPa range, 0.4% accuracy), with six replicates per configuration for repeatability.The dataset includes CSV files of simulation outputs (thickness distributions, stress/strain tensors, energy metrics per configuration), Abaqus input/output files, experimental thickness profiles, rupture pressures with timestamps, and uncertainty calculations (Type A/B uncertainties, expanded values at 95% confidence). Raw images of post-rupture morphologies and buckling patterns are provided in JPEG format.Reuse potential lies in benchmarking finite element models for thin-shell forming, validating surrogate methodologies like Kriging, or training machine learning algorithms for material performance prediction. The data support applications in pressure relief device design, allowing extraction of parametric trends for isotropic alloys or extension to anisotropic cases via recalibration. All files are archived in a public repository for direct access and replication.