The implementation of the vegter yield criterion and a physically based hardening rule in finite elements

A new material description for sheet metal forming using Finite Elements has been developed. The description consists of a yield criterion and a hardening rule. In contrast to most former criteria the new criterion is based on multi-axial stress states. The yield criterion is extended with a physically based hardening rule, in which the flow stress depends on the strain and strain rate. A Limiting Dome Height test is used to examine the material description

Validation of Modified Lemaitre's Anisotropic Damage Model with the Cross Die Drawing Test

Dual Phase (DP) steels are widely replacing the traditional forming steels in automotive industry. Advanced damage models are required to accurately predict the formability of DP steels. In this work, Lemaitre’s anisotropic damage model has been slightly modified for sheet metal forming applications and for strain rate dependent materials. The damage evolution law is adapted to take into account the strain rate dependency and negative triaxialities. The damage parameters for pre-production DP600 steel were determined. The modified damage models (isotropic and anisotropic) were validated using the cross die drawing test. The anisotropic damage model predicts the crack direction more accurately

Material Induced Anisotropic Damage

The anisotropy in damage can be driven by two different phenomena; anisotropic defor-mation state named Load Induced Anisotropic Damage (LIAD) and anisotropic (shape and/or distribution) second phase particles named Material Induced Anisotropic Damage (MIAD). Most anisotropic damage models are based on LIAD. This work puts emphasis on the presence of MIAD in DP600 steel. Scanning Electron Microscopic (SEM) analysis was carried out on undeformed and deformed tensile specimens. The martensite morphology showed anisotropy in size and orientation. Consequently, significant MIAD was observed in the deformed tensile specimens. A through thickness shear failure is observed in the tensile specimen, which is pulled along the rolling direction (RD), whereas a dominant ductile fracture is observed when pulled perpendicular to RD. The Modified Lemaitre’s (ML) anisotropic damage model is improved to account for MIAD in a phenomenological manner. The MIAD parameters are determined from tensile tests carried out in 0o, 45o and 90o to the RD. The formability of DP600 is lower in the RD compared to that in 90o to the RD, due to the phenomenon of MIAD

Advanced friction modeling in sheet metal forming

The Coulomb friction model is frequently used for sheet metal forming simulations. This model incorporates a constant coefficient of friction and does not take the influence of important parameters such as contact pressure or deformation of the sheet material into account. This article presents a more advanced friction model for large-scale forming simulations based on the surface changes on the micro-scale. When two surfaces are in contact, the surface texture of a material changes due to the combination of normal loading and stretching. Consequently, shear stresses between contacting surfaces, caused by the adhesion and ploughing effect between contacting asperities, will change when the surface texture changes. A friction model has been developed which accounts for these microscopic dependencies and its influence on the friction behavior on the macro-scale. The friction model has been validated by means of finite element simulations on the micro-scale and has been implemented in a finite element code to run large scale sheet metal forming simulations. Results showed a realistic distribution of the coefficient of friction depending on the local process conditions

Numerical Modeling of Advanced materials

The finite element (FE) method is widely used to numerically simulate forming processes. The accuracy of an FE analysis strongly depends on the extent to which a material model can represent the real material behavior. The use of new materials requires complex material models which are able to describe complex material behavior like strain path sensitivity and phase transformations. Different yield loci and hardening laws are presented in this article, together with experimental results showing this complex behavior. Recommendations on how to further improve the constitutive models are given. In the area of damage and fracture behavior, a non-local damage model is presented, which provides a better prediction of sheet failure than the conventional Forming Limit Diagram