Parameter identification of a mechanical ductile damage using Artificial Neural Networks in sheet metal forming.

In this paper, we report on the developed and used of finite element methods, have been developed and used for sheet forming simulations since the 1970s, and have immensely contributed to ensure the success of concurrent design in the manufacturing process of sheets metal. During the forming operation, the Gurson–Tvergaard–Needleman (GTN) model was often employed to evaluate the ductile damage and fracture phenomena. GTN represents one of the most widely used ductile damage model. In this investigation, many experimental tests and finite element model computation are performed to predict the damage evolution in notched tensile specimen of sheet metal using the GTN model. The parameters in the GTN model are calibrated using an Artificial Neural Networks system and the results of the tensile test. In the experimental part, we used an optical measurement instruments in two phases: firstly during the tensile test, a digital image correlation method is applied to determinate the full-field displacements in the specimen surface. Secondly a profile projector is employed to evaluate the localization of deformation (formation of shear band) just before the specimen’s fracture. In the validation parts of this investigation, the experimental results of hydroforming part and Erichsen test are compared with their numerical finite element model taking into account the GTN model. A good correlation was observed between the two approaches

Effect of Ductile Damage Evolution in Sheet Metal Forming: Experimental and Numerical Investigations

The numerical simulation based on the Finite Element Method (FEM) is widely used in academic institutes and in the industry. It is a useful tool to predict many phenomena present in the classical manufacturing forming processes such as necking, fracture, springback, buckling and wrinkling. But, the results of such numerical model depend strongly on the parameters of the constitutive behavior model. In the first part of this work, we focus on the traditional identification of the constitutive law using oriented tensile tests (0°, 45°, and 90° with respect to the rolling direction). A Digital Image Correlation (DIC) method is used in order to measure the displacements on the surface of the specimen and to analyze the necking evolution and the instability along the shear band. Therefore, bulge tests involving a number of die shapes (circular and elliptic) were developed. In a second step, a mixed numerical–experimental method is used for the identification of the plastic behavior of the stainless steel metal sheet. The initial parameters of the inverse identification were extracted from a uniaxial tensile test. The optimization procedure uses a combination of a Monte-Carlo and a Levenberg-Marquardt algorithm. In the second part of this work, according to some results obtained by SEM (Scaning Electron Microscopy) of the crack zones on the tensile specimens, a Gurson Tvergaard Needleman (GTN) ductile model of damage has been selected for the numerical simulations. This model was introduced in order to give informations concerning crack initiations during hydroforming. At the end of the paper, experimental and numerical comparisons of sheet metal forming applications are presented and validate the proposed approach

Analysis of the thinning phenomenon variations in sheet metal forming process

In many manufacturing areas such as the automotive industry (outer panels, inner panels, stiffeners etc...), the packaging industry (petfood containers, beverage cans etc...) and the household appliances industry (housings etc...), the control of the thinning variations in sheet metal forming process is a major point to study in order to ameliorate the final quality of the produced parts. In this framework, several bulge tests have been developed in order to study the thinning phenomenon during sheet metal forming processes. In this presentation, measurement of the thickness of the deformed specimens has been done using the ImageAnalyser software (based on an image analysis technique) developed by the CMAO research group in the LGP. The AISI 304L stainless steel has been selected as the tested material. Both a cylindrical and an elliptical die allowing the analysis of the thickness variation versus the load ratio and the anisotropy of sheet have been used in this work. In a second part of this communication, we present a numerical model based on the Hill 1948 anisotropic material model. The numerical results are discussed and compared with the experiments

Micro-scale modeling of carbon-fiber reinforced thermoplastic materials

Thin-walled textile-reinforced composite parts possess excellent properties, including lightweight, high specific strength, internal torque and moment resistance which offer opportunities for applications in mass transit and ground transportation. In particular the composite material is widely used in aerospace and aircraft structure. In order to estimate accurately the parameters of the constitutive law of woven fabric composite, it is recommended to canvass multi-scale modeling approaches: meso, micro and macro. In the present investigation, based on the experimental results established by carrying out observations by Scanning electron microscope (SEM), we developed a micro-scale FEM model of carbon-fiber reinforced thermoplastic using a commercial software ABAQUS. From the SEM cartography, one identified two types of representative volume elementary (RVE): periodic and random distribution of micro-fibers in the yarn. Referring to homogenization method and by applying the limits conditions to the RVE, we have extracted the coefficients of the rigidity matrix of the studied composites. In the last part of this work, we compare the results obtained by random and periodic RVE model of carbon/PPS and we compute the relative error assuming that random model gives the right value

Micro-Scale Modeling of Carbon-Fiber Reinforced Thermoplastic Materials

Thin-walled textile-reinforced composite parts possess excellent properties, including lightweight, high specific strength, internal torque and moment resistance which offer opportunities for applications in mass transit and ground transportation. In particular, the composite material is widely used in aerospace and aircraft structure. In order to estimate accurately the parameters of the constitutive law of woven fabric composite, it is recommended to canvass multi-scale modeling approaches: meso, micro and macro. In the present investigation, based on the experimental results established by carrying out observations by Scanning electron microscope (SEM), we developed a micro-scale FEM model of carbon-fiber reinforced thermoplastic using a commercial software ABAQUS. From the SEM cartography, one identified two types of representative volume elementary (RVE): periodic and random distribution of micro-fibers in the yarn. Referring to homogenization method and by applying the limits conditions to the RVE, we have extracted the coefficients of the rigidity matrix of the studied composites. In the last part of this work, we compare the results obtained by random and periodic RVE model of carbon/PPS and we compute the relative error assuming that random model gives the right value

Numerical and Experimental Investigations on Deep Drawing of G1151 Carbon Fiber Woven Composites

This study proposes to simulate the deep drawing on carbon woven composites in order to reduce the manufacturing cost and waste of composite material during the stamping process, The multi-scale anisotropic approach of woven composite was used to develop a finite element model for simulating the orientation of fibers accurately and predicting the deformation of composite during mechanical tests and forming process. The proposed experimental investigation for bias test and hemispherical deep drawing process is investigated in the G1151 Interlock. The mechanical properties of carbon fiber have great influence on the deformation of carbon fiber composites. In this study, shear angle–displacement curves and shear load–shear angle curves were obtained from a bias extension test. Deep drawing experiments and simulation were conducted, and the shear load–displacement curves under different forming depths and shear angle–displacement curves were obtained. The results showed that the compression and shear between fibers bundles were the main deformation mechanism of carbon fiber woven composite, as well as the maximum shear angle for the composites with G1151 woven fiber was 58°. In addition, during the drawing process, it has been found that the forming depth has a significant influence on the drawing force. It increases rapidly with the increasing of forming depth. In this approach the suitable forming depth deep drawing of the sheet carbon fiber woven composite was approximately 45 mm

Critical assessment of the bonded single lap joint exposed to cyclic tensile loading

open access articleSingle shear or single lap joints are the most prevalent type of adhesive joints used in advanced engineering applications, where they are exposed to fatigue loadings in their services. Although their mechanical performances under static loading have been investigated extensively, the studies related to the fatigue performances were limited. For that purpose, single lap joint's (SLJ's) reaction to fatigue tensile loading was studied by varying the adherend thickness (3 mm to 6 mm) and fatigue load (3250 N to 1500 N). ABAQUS/Standard was used to create its advanced FE model. To represent the progressive damage in the adhesive layer, the fatigue damage model via the Paris Law, which links the rate of the crack expansion to the strain energy release rate (SERR), was integrated into the cohesive zone model having a bi-linear traction–separation characteristics. The model was written in a UMAT subroutine. The developed model was vali-dated using experimental data from the literature. The crack initiation cycle (Ni), the failure cycle (Nf), the fatigue load limit, the strain energy release rate, the crack propagation rate, and varia-tion of stress components with their dependency to design parameters were investigated in depth. It was found that the service life of the SLJs with thicker adherends was more responsive to the amount of stress applied. When exposed to lesser loads, the SLJs' life span changed more noticeably

Failure analysis based on microvoid growth for sheet metal during uniaxial and biaxial tensile tests

The aim of the presented investigations is to perform an analysis of fracture and instability during simple and complex load testing by addressing the influence of ductile damage evolution in necking processes. In this context, an improved experimental methodology was developed and successfully used to evaluate localization of deformation during uniaxial and biaxial tensile tests. The biaxial tensile tests are carried out using cruciform specimen loaded using a biaxial testing machine. In this experimental investigation, Stereo-Image Correlation technique has is used to produce the heterogeneous deformations map within the specimen surface. Scanning electron microscope is used to evaluate the fracture mechanism and the micro-voids growth. A finite element model of uniaxial and biaxial tensile tests are developed, where a ductile damage model Gurson-Tvergaard-Needleman (GTN) is used to describe material deformation involving d`amage evolution. Comparison between the experimental and the simulation results show the accuracy of the finite element model to predict the instability phenomenon. The advanced measurement techniques contribute to understand better the ductile fracture mechanism

Sensitivity analysis of composite forming process parameters using numerical hybrid discrete approach

The aim of this study is to investigate the influence of some important parameters in composite forming using a hybrid discrete hypoelastic computational model developed for simulation of the deformation behaviour of fibres materials. This model is based on elementary cell of shell or membrane type reinforced by nonlinear connectors. Moreover, it can follow the rotation of the fiber during the forming process. The constitutive model has been implemented in a commercial FE code (Abaqus Explicit) via a user material subroutine VUMAT. It has been shown that the forming simulation is affected by the process parameters like the binder force, the coefficient of friction and forming speed on the shear angle distribution

Experimental study of 48600 Carbons fabrics behavior using marks tracking technique method

Lightweight and energy saving are the main challenges in the aircraft industry production, that explain the increase of composite demand and the diversity of its applications. The investigation of the shear behavior and stiffness of technical woven fabric are essential to guarantee the performance of the final product. In case of forming process (for example RTM process), the in-plane deformability of the woven fabric is necessary for forming without creating defects. The change of the fiber orientation (warp and weft) have a significant impact on final mechanical properties. In this study, the use of marks tracking technique allow the determination of the rigidity of 48600 C 1300 carbon fabrics, and allow calculation of their shear angle, lock angle during tensile and bias-extension tests