Determination of the yield loci of four sheet materials (AA6111-T4, AC600, DX54D+Z, and H220BD+Z) by using uniaxial tensile and hydraulic bulge tests)

In sheet metal forming simulation, a flow curve and a yield criterion are vital requirements for obtaining reliable numerical results. It is more appropriate to determine a flow curve by using biaxial stress condition tests, such as the hydraulic bulge test, than a uniaxial test because hardening proceeds higher strains before necking occurs. In a uniaxial test, higher strains are extrapolated, which might lead to incorrect results. The bulge test, coupled with the digital image correlation (DIC) system, is used to obtain stress–strain data. In the absence of the DIC system, analytical methods are used to estimate hardening. Typically, such models incorporate a correction factor to achieve correlation to experimental data. An example is the Chakrabarty and Alexander method, which uses a correction factor based on the n value. Here, the Chakrabarty and Alexander approach was modified using a correction factor based on normal anisotropy. When compared with DIC data, the modified model was found to be able to better predict the hardening curves for the materials examined in this study. Because a biaxial flow curve is required to compute the biaxial yield stress, which is an essential input to advanced yield functions, the effects of the various approaches used to determine the biaxial stress–strain data on the shape of the BBC2005 yield loci were also investigated. The proposed method can accurately predict the magnitude of the biaxial yield stress, when compared with DIC data, for all materials investigated in this study

The strain fields present during the bending of ultra-high strength steels

Ultra high strength steels (UHSS) have an ultimate tensile strength of greater than 1GPa. Typically, their ambient temperature elongation is less than 10% and as a result, they are rarely used in stamping applications. However, the continuous demand for the weight reduction of structures built for the transport sector means that such materials are attractive because they can be used for parts with thinner cross-sections while maintaining required in-service performance. One way to overcome the ambient temperature ductility of these materials is to roll-form them, particularly with emerging flexible roll forming technology. Using numerically-controlled actuators, the rolls on each stand are designed with sufficient degrees of freedom to form parts that curve, vary in depth and width along their lengths. This makes flexibly roll-formed parts attractive to the transport, particularly the automotive, sector. Roll forming deforms a material through incremental, localised bending, which is known to suppress the necking response, resulting in deformations that are higher than in stretch deformation. Recent work, such as Le Maoût, Thuillier & Manach, Eng. Frac. Mech., Vol. 76, p.1202 (2009), focussed on the development of ductile fracture models to explain failure but their validation was limited to load displacement and surface strain data. This work aims to characterise the strain field during bending more comprehensively. Using the digital image correlation technique, the macroscopic strain distribution in UHSS in the thickness of the sheet and the strain partitioning in its microstructure is measured during bending. The data provides a detailed explanation of the strain distribution during bending

Evolution of residual stresses in linear deposition wire-based cladding of Ti-6Al-4V

Neutron diffraction and curvature measurements were conducted to investigate the residual stresses associated with Plasma Transferred Arc Cladding (PTA) of Ti-6Al-4V on a substrate of the same material. The wire-feed PTA coupled with 3-axis CNC machine was used as an Additive Manufacturing (AM) technique to build parts. A combination of the process parameters was chosen to investigate their effects on residual stress evolution. Neutron Diffraction (ND) measurements of residual strains were performed on the SALSA instrument at the Institut Laue-Langevin (ILL), Grenoble, France. Longitudinal stresses were also inferred by using a Coordinate Measurement Machine (CMM) and Euler-Bernoulli beam theorem. Furthermore, Optical Microscopy (OM) of the cross section of the parts was used to analyse the microstructural evolution. The results show the effect of shorter and longer ‘dwell time’ between layers on the evolution of residual stresses

Predicting the Warm Forming Behavior of WE43 and AA5086 Alloys

In the present work, we have studied the formability behaviour of two types of magnesium alloys, WE43 hot rolled and WE43 cold rolled by carrying out uniaxial tensile test at elevated temperatures of 350 °C to 500 °C both experimentally and numerically at a constant strain rate of 10-3s-1. Finite element (FE) model is simulated in ABAQUS/CAE 6.7-6 using coupled temperature-displacement step at higher temperature considering material's property to be isotropic in nature. The effect of temperature on maximum flow stress and major strain at onset of necking is discussed. The true stress-strain behaviour and necking evolution through strain mapping are predicted from FE model and compared with the experimental results. The results show that with increase in temperature, the maximum flow stress decreases and necking delays with increase in limiting major strain for the Magnesium alloys. The work has been extended to predict the forming limit strains of Al 5086 alloy only on the negative minor strain region using M-K (Marciniak and Kuczynski) concept. An FE model based on M-K concept is simulated at 20 °C, 150 °C and 200 °C using coupled temperature-displacement step considering anisotropic sheet material. A groove is created in the middle of the model with an optimized f value of 0.99, after much iteration. The forming limit strains from such FE simulations are compared with the available experimental data. The results are encouraging providing scope for further improvements in modelling

Understanding capacity fade in silicon based electrodes for lithium-ion batteries using three electrode cells and upper cut-off voltage studies

Commercial Li-ion batteries are typically cycled between 3.0 and 4.2 V. These voltages limits are chosen based on the characteristics of the cathode (e.g. lithium cobalt oxide) and anode (e.g. graphite). When alternative anode/cathode chemistries are studied the same cut-off voltages are often, mistakenly, used. Silicon (Si) based anodes are widely studied as a high capacity alternative to graphite for Lithium-ion batteries. When silicon-based anodes are paired with high capacity cathodes (e.g. Lithium Nickel Cobalt Aluminium Oxide; NCA) the cell typically suffers from rapid capacity fade. The purpose of this communication is to understand how the choice of upper cut-off voltage affects cell performance in Si/ NCA cells. A careful study of three-electrode cell data will show that capacity fade in Si/NCA cells is due to an ever-evolving silicon voltage profile that pushes the upper voltage at the cathode to >4.4 V (vs. Li/Liþ). This behaviour initially improves cycle efficiency, due to liberation of new lithium, but ultimately reduces cycling efficiency, resulting in rapid capacity fade

Damage in dual phase steel DP1000 investigated using digital image correlation and microstructure simulation

Microstructure failure mechanisms and void nucleation in dual-phase (DP) steels during deformation have been studied using a combination of in situ tensile testing in a scanning electron microscope (SEM), digital image correlation (DIC) and finite element (FE) modelling. SEM images acquired during in situ tests were used to follow the evolution of damage within the microstructure of a DP1000 steel. From these images, strain maps were generated using DIC and used as boundary conditions for a FE model to investigate the stress state of martensite and ferrite before the onset of the martensite phase cracking. Based on the simulation results, a maximum principal stress of about 1700 MPa has been estimated for crack initiation in the martensite of the investigated DP1000 steel. The SEM image observations in combination with the FE analyses provide new insights for the development of physically-based damage models for DP-steels

Experimental and modelling study of fatigue crack initiation in an aluminium beam with a hole under 4-point bending

Slip band formation and crack initiation during cyclic fatigue were investigated by in-situ experiments and non-local CPFEM simulations systematically. Experimental techniques including EBSD, digital image correlation (DIC) and SEM have been used to obtain consistent grain orientations, local strains, as well as the locations where slip bands and micro-cracks form on the sample surface. The realistic microstructure based on the EBSD map has been generated and used for finite element modelling. An advanced non-local crystal plasticity model, which considers the isotropic and kinematic hardening of the plastic strain gradient, has been adopted. The simulation results match well the corresponding experimental results. It was found that total strain and averaged slip on all slip systems, combined with accumulated slip on specific slip planes help predict the location and orientation of slip bands and micro-crack initiation correctly. Furthermore, a fatigue indicating parameter based on competition between maximum slip and the total slip has been proposed to reproduce the experimental observations