Sheet forming simulations of automotive parts using different yield functions

In this work, the influence of the yield function on finite element (FE) forming simulation results for two auto-body panels, hood inner and door outer, was investigated. Simulations were conducted with different yield functions, Hill's1948. Yld91 and Yld2000-2d, which are available in the PAM-STAMP and LS-DYNA commercial codes. Although moderate, some differences in the results were observed.open111Nsciescopu

Modeling of plastic anisotropy with reduced polycrystalline models. Application to aluminum alloys

From the issue entitled "Proceedings of the 11th ESAFORM Conference on Material Forming, Lyon (France), 23-25 April 2008, edited by P. Boisse, F. Morestin, E. Vidal-Sallé, LaMCoS, INSA de Lyon)"International audienceThe modeling of deviations from isotropic hardening still is a difficult task for macroscopic models, in particular for non-proportional loading paths. The alternative polycrystalline models suffer from large CPU time in FE analyses and do not always give simultaneously a good description of flow stresses and transverse strain rates. Due to a specific parameter calibration procedure, a “reduced” polycrystalline model with 8 orientations only is in excellent agreement with all experimental curves for a 2090-T3 aluminum sheet. FE calculations of a punch test with contact and friction give CPU times only 15% larger than with a macroscopic model

Plastic instability in complex strain paths predicted by advanced constitutive equations

The present paper aims at predicting plastic instabilities under complex loading histories using an advanced sheet metal forming limit model. The onset of localized necking is computed using the Marciniak-Kuczinslcy (MK) analysis [I] with a physically-based hardening model and the phenomenological anisotropic yield criterion Yld2000-2d [2]. The hardening model accounts for anisotropic work-hardening induced by the microstructural evolution at large strains, which was proposed by Teodosiu and Hu [3]. Simulations are carried out for linear and complex strain paths. Experimentally, two deep-drawing quality sheet metals are selected: a bake-hardening steel (BH) and a DC06 steel sheet. The validity of the model is assessed by comparing the predicted and experimental forming limits. The remarkable accuracy of the developed software to predict the forming limits under linear and non-linear strain path is obviously due to the performance of the advanced constitutive equations to describe with great detail the material behavior. The effect of strain-induced anisotropy on formability evolution under strain path changes, as predicted by the microstructural hardening model, is particularly well captured by the model.open1134Nsciescopu

Evaluation of constitutive models for springback prediction in U-draw/bending of DP and TRIP steel sheets

U-draw/bending experiments and simulations were performed to investigate the characteristics of springback in sheet metals. The finite element method is frequently used for the simulation of springback, but the predictions are strongly influenced by the constitutive models such as yield criteria and hardening laws. In the present study, springback of DP and TRIP steel sheets after U-draw/bending was predicted with a finite element analysis. Various yield functions were considered, namely, the isotropic von Mises and anisotropic Hill models. For strain hardening, isotropic, non-linear kinematic and combined isotropic-kinematic hardening models were considered. In order to characterize the isotropic hardening behavior, both uniaxial and balanced biaxial (hydraulic bulge) tension tests were carried out. For the characterization of the combined isotropic-kinematic hardening model, forward-reverse simple shear tests were conducted. The springback predictions were greatly influenced by the choice of the hardening model but slightly affected by the choice of the yield criterion. The kinematic hardening and combined isotropic-kinematic hardening models provided satisfactory predictions for DP590 and TRIP590 sheets, respectively. Due to an extended measurable strain range, the use of the flow curves from the hydraulic bulge test led to more reliable results than those of uniaxial tension.ope

Material modelling and springback analysis for multi-stage rotary draw bending of thin-walled tube using homogeneous anisotropic hardening model

The aim of this paper is to compare several hardening models and to show their relevance for the prediction of springback and deformation of an asymmetric aluminium alloy tube in multi-stage rotary draw bending process. A three-dimensional finite-element model of the process is developed using the ABAQUS code. For material modelling, the newly developed homogeneous anisotropic hardening model is adopted to capture the Bauschinger effect and transient hardening behaviour of the aluminium alloy tube subjected to non-proportional loading. The material parameters of the hardening model are obtained from uniaxial tension and forward-reverse shear test results of tube specimens. This work shows that this approach reproduces the transient Bauschinger behaviour of the material reasonably well. However, a curve-crossing phenomenon observed for this material cannot be captured by the homogeneous anisotropic hardening model. For comparison purpose, the isotropic and combined isotropic-kinematic hardening models are also adopted for the analysis of the same problem. The predictions of springback and cross-section deformation based on these models are discussed. (C) 2014 The Authors. Published by Elsevier Ltd.open1134Nsciescopu

On the determination of flow stress using bulge test and mechanical measurement

The standard uniaxial tensile test is a widely accepted method to obtain relevant properties of sheet metal materials. These fundamental parameters can be used in numerical modeling of sheet forming operations to predict and assess formability and failure analysis. However the range of strain obtained from tensile test is limited and therefore if one will need further information on material behavior, extrapolation of tensile data is performed. The bulge test is an alternative to obtain ranges of deformation higher than tensile test, thus being possible to obtain non-extrapolated data for material behavior. Several methods may be used to obtain stress-strain data from bulge test, but a common concept is behind them, which needs the measurement of bulge pressure, curvature of bulge specimen, its thickness at the pole and the application of membrane theory. Concerning such measurements, optical methods are being used recently but classical mechanical methods are still an alternative with its own strengths. This paper presents the use and development of a mechanical measuring system to be incorporated in a hydraulic bulge test for flow curve determination, which permits real-time data acquisition under controlled strain rates up to high levels of plastic deformation. Numerical simulations of bulge test using FEM are performed and a sensitivity analysis is done for some influencing variables used in measurements, thus giving some directions in the design and use of the experimental mechanical system. Also, first experimental results are presented, showing an efficient testing procedure method for real time data acquisition with a stable evaluation of the flow curve.open11617Nsciescopu

Numerical simulation of the mechanical response during strain path change: application to Zn alloys.

The microstructure-based hardening model (Beyerlein and Tome, 2007), that accounts for the dislocation reversal-related mechanisms and the cut-through effect, is extended to HCP metals. This model, which is embedded in the visco-plastic self-consistent framework, is applied in this work to predict the mechanical response of Zn alloy during strain path change. The predicted mechanical behavior and texture evolution during pre-loading and reloading is in good agreement with experimental observations. The change in hardening behavior after reloading is well reproduced by this model. The contributions of the different mechanisms are also analyzed. (C) 2014 Published by Elsevier Ltd.open1111Nsciescopu

Hole Expansion Simulations of TWIP Steel Sheet Sample

In this work, the stretch flangeability of a TWIP steel sheet sample was investigated both experimentally and numerically through the hole expansion test. Uniaxial tension and disk compression tests were performed to characterize the flow behavior and plastic anisotropy for the TWIP steel sheet sample. The punch load-stroke curve, hole diameter and specimen surface strain distribution near the hole was measured. Then finite element simulations of the hole expansion test were carried out using the finite element code ABAQUS with three yield criteria: von Mises, Hill 1948 and Yld2000-2d. The predicted and experimental results were compared in terms of the final hole radii and the strain distribution.open111Nsciescopu

Mechanical behaviour of TWIP steel under shear loading

Twinning induced plasticity steels (TWIP) are very good candidate for automotive industry applications because they potentially offer large energy absorption before failure due to their exceptional strain hardening capability and high strength. However, their behaviour is drastically influenced by the loading conditions. In this work, the mechanical behaviour of a TWIP steel sheet sample was investigated at room temperature under monotonic and reverse simple shear loading. It was shown that all the expected features of load reversal such as Bauschinger effect, transient strain hardening with high rate and permanent softening, depend on the prestrain level. This is in agreement with the fact that these effects, which occur during reloading, are related to the rearrangement of the dislocation structure induced during the pre-deformation. The homogeneous anisotropic hardening (HAH) approach proposed by Barlat et al. (2011) [1] was successfully employed to predict the experimental results.110Ysciescopu

The formability prediction of twinning-induced plasticity steels

The proposal of this work is to predict and analyse the formability of twinning-induced plasticity steels through the Marciniak-Kuczinsky approach with emphasis on the solutions for improving the prediction results. The selected constitutive equations involve the Yld2000-2d plane stress yield function and the Swift strain-hardening power law. To understand the formability of the TWIP steel and the factors influencing it, a sensitive study on the effect of the mechanical properties of the TWIP steel on the Marciniak-Kuczinsky (MK) theory concept and the predicted forming limits is performed.publishe