Analysis of damage and fracture formulations in cold extrusion

In forming processes, components generally undergo large deformations. This induces the evolution of damage, which can influence material and product properties. To capture these effects, a continuum damage mechanics (CDM) model, based on the work of Lemaitre [8] and Soyarslan [13, 14] as well as different fracture criteria according to Cockcroft and Latham [2], Freudenthal [4] and Oyane [10] are implemented and in- vestigated. While the CDM theory considers the evolution of damage and the associated softening, fracture criteria do not affect the results of the mechanical finite element (FE) analysis. However, a coupling is generally possible via element deletion, but material softening cannot be depicted in the simulation. Tensile tests with notched specimens are performed in order to obtain the material parameters associated with these models by inverse parameter identification processes. The optimized set of parameters is finally ap- plied to the damage and fracture models used for the FE simulations of a cold extrusion process, which are investigated in terms of damage evolution and material failure. It is demonstrated that the CDM model predicts the evolution of damage observed for differ- ent process parameters in cold extrusion quantitatively. The prediction of the failure by the fracture criteria does not agree well with the experiments

Comparison of gurson and lemaitre model in the context of blanking simulation of a high strength steel

The process of blanking takes place in a short band with high accumulated strain undergoing various stress triaxialities. Enhanced implementations for shear and compressive loads of Gurson’s and Lemaitre’s model are directly compared for the same blanking setup. For a dual phase steel DP600 the Lemaitre parameters are identified completely by an inverse strategy, while the parameters of the Gurson’s porous plasticity model are predominantly gained from analysis with a scanning electron microscopy (SEM). The models are validated by comparison of force-displacement curves, time point and location of crack initiation. Advantages and disadvantages of both approaches are discussed with respect to prediction accuracy and costs of parameter identification. Both of the models deliver an exact prediction for the location of the crack and a good prediction of the punch displacement at the onset of cracking

Testing of Formed Gear Wheels at Quasi-Static and Elevated Strain Rates

Geared components can be manufactured from sheet metals by sheet-bulk metal forming. One relevant load case in service are overload events, which might induce elevated strain rates. To determine the characteristic hardening and fracture behavior, specimens manufactured from the deep-drawing steel DC04 were tested with strain rates ranging from 0.0001 to 5 s−1. The gear wheels manufactured by sheet-bulk metal forming are tested at crosshead velocities of 0.08 mm/s and 175 mm/s. The tests are analyzed by measuring deformed geometry and hardness. While the tensile tests results show obvious strain-rate dependency, the hardness measurements show no strain-rate depended effect. The analyses are complemented by finite-element-simulations, which assess the homogeneity of deformation and point out the mechanisms of failure. Both coupled and uncoupled ductile damage models are able to predict the critical areas for crack initiation. The coupled damage model has slight advantages regarding deformed shape prediction

Phenomenological modeling of anisotropy induced by evolution of the dislocation structure on the macroscopic and microscopic scale \ud

This work focuses on the modeling of the evolution of anisotropy induced by the development of the dislocation microstructure. A model formulated at the engineering scale in the context of classical metal plasticity and a model formulated in the context of crystal plasticity are presented. Images obtained by transmission-electron microscopy (TEM) show the influence of the strain path on the evolution of anisotropy for the case of two common materials used in sheet metal forming, DC06 and AA6016-T4. Both models are capable of accounting for the transient behavior observed after changes in loading path for fcc and bcc metals. The evolution of the internal variables of the models is correlated with the evolution of the dislocation structure observed by TEM investigations

Validation of Simple Shear Tests for Parameter Identification Considering the Evolution of Plastic Anisotropy

The evolution of plastic anisotropy plays a key role for an accurate computational springback prediction in complex, multistage forming processes. In many studies, the identification of material parameters is based on experimental results from shear testing because this technique allows for large plastic deformations without facing stability problems that occur, for instance, during uniaxial tensile testing. However, little is known about the   comparability of different shear test setups. In this study, we systematically compare two quite different and widelyused setups for the simple shear test, the Miyauchi setup and the Twente setup. In the shear tests performed on an AA6016 aluminum alloy sheet, we observed a good agreement for the flow stresses measured with the two different   setups. We then use the mechanical data for the identification of a phenomenological model of the evolution of plastic anisotropy, and we demonstrate the importance of consistent and reliable experimental data studying a model for combined isotropic-kinematic hardening

Microstructural characterization and simulation of damage for geared sheet components

The evolution of damage in geared components manufactured from steel sheets was investigated, to analyse the influence of damage caused by the sheet-bulk-metal forming. Due to the inhomogeneous and multi-axial deformation in the investigated parts, different aspects such as the location-dependent shape and size of voids are analysed by means of various microscopic methods. In particular, a method to characterize the state of damage evolution, i. e. void nucleation, growth and coalescence using scanning electron microscopy (SEM) is applied. The investigations reveal a strong dependence of the void area fraction, shape of voids and thus damage evolution on the loading mode. The microstructural analysis is complemented with FEM simulations using material models which consider the characteristics of the void evolution. © Published under licence by IOP Publishing Ltd

Investigations of ductile damage in DP600 and DC04 deep drawing steel sheets during punching

The paper presents numerical and microstructural investigations on a punching process of 2 mm thick steel sheets. The dual phase steel DP600 and the mild steel DC04 exhibit different damage and fracture characteristics. To distinguish the void development and crack initiation for both materials, interrupted tests at varied punch displacements are analyzed. The void volume fractions in the shearing zone are identified by scanning electron microscopy (SEM). The Gurson model family, which is recently extended for shear fracture, is utilized to model the elastoplastic behavior with ductile damage. The effect of the shear governing void growth parameter, introduced by Nahshon and Hutchinson (2008), is discussed

Advanced material model for shear cutting of metal sheets

A finite-element simulation of the shear cutting process is used to predict thegeometry of the cutting surface. A fully-coupled Lemaitre-type model is used in the process model for the description of the material behaviour. The extended Lemaitre model considers the influence of shear and compression-dominated stress states on the propagation of damage. Tensile tests with and without notches are used for the identification of material parameters. These methods are advantageous for the analysis of different blanking processes. Since damage parameters have a strong influence on the cutting surface quality, a numerical study isconducted to analyse their influence. The results of the simulations are compared with experimental data

Increase in consumption of alcohol-based hand rub in German acute care hospitals over a 12 year period

Background: Hand hygiene plays a crucial role in the transmission of pathogens and the prevention of healthcare-associated infections. In 2007, a voluntary national electronic surveillance tool for the documentation of consumption of alcohol-based hand rub (AHC) was introduced as a surrogate for hand hygiene compliance (HAND-KISS) and for the provision of benchmark data as feedback.The aim of the study was to determine the trend in alcohol-based hand rub consumption between 2007 and 2018. Materials and methods: In this cohort study, AHC and patient days (PD) were documented on every ward in participating hospitals by trained local staff. Data was collected and validated in HAND-KISS. Intensive care units (ICU), intermediate care units (IMC), and regular wards (RW) that provided data during the study period between 2007 until 2018 were included into the study. Results: In 2018, 75.2% of acute care hospitals in Germany (n=1.460) participated. On ICUs (n=1998) mean AHC increased 1.74 fold (95%CI 1.71, 1.76; p<.0001) from 79.2ml/PD to 137.4ml/PD. On IMCs (n=475) AHC increased 1.69 fold (95%CI 1.60, 1.79; p<.0001) from 41.4ml/PD to 70.6ml /PD..On RWs (n=14,857) AHC was 19.0ml/PD in 2007 and increased 1.71 fold (95%CI 1.70, 1.73; p<.0001) to 32.6ml/PD in 2018. Conclusions: AHC in German hospitals increased on all types of wards during the past 12years. Surveillance of AHC is widely established in German hospitals. Large differences among medical specialties exist and warrant further investigation