Papers by Author: Tudor Balan

Abstract: Forming limit curves are sensitive to the strain-path. Numerous methods were proposed in the literature since the 1970’s to the last decades for taking into account this sensitivity. The aim of this work is to consistently compare these methods with practical application in mind. First, a literature review revealed that many available methods are different in form but all rely on the empirical assumption of iso-equivalent failure strain for all strain paths sharing the same final strain mode, independently of the strain path leading to it. The models relying on this hypothesis are summarized. A significantly different approach, called here “interpolation method”, relies on different hypotheses – also empirical. The two approaches are further compared in order to identify the similarities and differences between the two. It appears that most stress-based approaches for the correction of FLC strain-path dependence rely on the same hypothesis as the iso-equivalent-strain method and they reduce to it under the assumption of isotropic hardening. The iso-strain method and the “interpolation” approach provide similar predictions in a series of configurations, while they significantly differ for other configurations. No theoretical or experimental proof is available to further discriminate the most accurate approach for strain-path correction of FLCs; the research opens new directions for the investigation of the topic.

Abstract: Advanced hardening models accurately describe the transient plastic behavior (reyielding, stagnation, resumption...) after various strain-path changes (reverse, orthogonal...). However, a common drawback of these models is that they usually predict monotonic loading with lower accuracy than the regular isotropic hardening models. Consequently, the finite element predictions using these models may sometimes lose in accuracy, in spite of their tremendous theoretical superiority. This drawback has been eliminated in the literature for the Chaboche isotropic-kinematic hardening model. In this work, a generic approach is proposed for advanced hardening models. Arbitrary models could be successfully compensated to preserve rigorously identical predictions under monotonic loading. A physically-based model involving a 4^th order tensor and two 2^nd order tensors was used for the demonstration. The parameter identification procedure was greatly simplified by rigorously decoupling the identification of isotropic hardening parameters from the other parameters.

Abstract: In this paper, a new elastic viscoplastic micromechanical modelling is proposed to represent the semi-solid behaviour and predict the ductile-brittle transition of the C38LTT near the solidus. It is based on a viscoplastic modelling previously presented in [1]. The originality of the new model comes from three main enhancements: the transition between the solid state and the semi-solid state was included meaning that the material properties were taken temperature-dependent, the elastic properties was taken into account similarly as [2] and the evolution of the internal variable describing the degree of agglomeration of the solid phase was enhanced. The model was implemented in the commercial software FORGE©. Tensile tests representing the experimental thermal conditions and obtained using a GLEEBLE© machine were simulated. The comparison of the predicted and experimental results shows that, for the first time to our knowledge, the three steps of the load-displacement response and ductile-brittle transition were successfully described.

Abstract: The automobile manufacturing industry, until recent years, has been using steel for car body components and the main method for joining these components has always been Resistance Spot Welding. However, since the global trends toward CO₂ reduction and resource efficiency have significantly increased, the importance and usage of lightweight materials has enhanced as well. New lightweight materials such as aluminum and magnesium alloys, carbon-fiber-reinforced plastics, etc., have become a reality, thanks to the new fastening technologies. Flow drill screw driving (FDS) is a one–sided thermomechanical assembly process based on heat generation by frictional force and plastic deformation. A special screw, known as hole forming and self-tapping screw, is used in this process as both fastener and tool. Moreover, rotational and translation movements are applied to the screw to create special friction conditions with the workpiece. Furthermore, unlike traditional drilling and thread milling processes, there is no chip or waste of material in FDS and the machining operations are realized through plastic deformation. This paper explores flow drilling steps and the parameters which influence heating and local softening of the aluminum sheet 5182-0. An experimental study has been carried out by varying process parameters (rotational speed, drilling force), coating and geometry of the screw. As a result, an increase of rotational speed and drilling force allows significant reduction in drilling time and introduce an important variation of the torque installation. In addition, a strong dependence is observed between drilling time and torque on the one hand, and related to the screw parameters geometry and coating on the other hand. Finally, an evaluation of the heating effect on the thread forming operation is also undertaken.

Abstract: This paper shows that non-linearity of mechanical behaviour of metal in the elastic regime has an influence on the forming process. Discrete Dislocation Dynamics simulations show that pure elastic behaviour is altered when reversible dislocation displacements occur even in the very beginning of the elastic stage. The influence of such a non-linearity has an impact on the results of numerical simulations of industrial forming of very thin metal sheets of copper.

Abstract: A physically based elasto-visco-plastic constitutive model is presented and compared to experimental results for three different mild steels. The experiments consist of tensile tests at strain rates up to 103 s-1 and reverse shear tests. The model requires significantly fewer material parameters compared to other visco-plasticity models from the literature while exhibiting very good accuracy. Accordingly, the parameter identification is simple and intuitive, requiring a relatively small set of experiments. The strain-rate sensitivity modeling is not restricted to a particular hardening law and thus provides a general framework in which advanced hardening equations can be adopted. The model was eventually used as the basis for a homogenization approach at the phase scale; preliminary investigations showed the benefit of such an approach, where microstructure-relevant data can explicitly enter the model and may be used for material design simulations.

Abstract: Strain localization, which occurs in metallic materials in the form of shear bands during forming processes, is one of the major causes of defective parts produced in the industry. Various instability criteria have been developed in the literature to predict the occurrence of these plastic instabilities. In this work, we propose to couple a GTN-type model [1,2], known for its widespread use to describe damage evolution in metallic materials, to the Rice’s [3] localization criterion. The implementation of the constitutive modeling is achieved via a user material (UMAT) subroutine in the commercial finite element code ABAQUS. Large deformations are taken into account within a three dimensional co-rotational framework. The effectiveness of the proposed coupling for the prediction of the formability of stretched metal sheets is shown and Forming Limit Diagrams (FLDs) are plotted for different materials. References [1] Gurson, A.L., Continuum theory of ductile rupture by void nucleation and growth: Part I- yield criteria and flow rules for porous ductile media. Journal of Engineering Materials and Technology, 99(1):2–15 (1977). [2] Needleman A., V. Tvergaard, An analysis of ductile rupture in notched bars, Journal of the Mechanics and Physics of Solids, 32, 461-490 (1984). [3] Rice, J. R., The localization of plastic deformation. Theoretical and applied mechanics. Koiter ed., 207-227 (1976).

Abstract: This contribution investigates the springback behavior of several advanced high-strength sheet steels (TRIP, Dual-Phase, ferrite-bainite) with thicknesses up to 4 mm. Samples were tested by means of the bending-under-tension (BUT) test. This test proved very useful to discriminate constitutive models, while avoiding the interference of friction in the springback investigations [1,2]. However, the interpretation and numerical simulation of the test have to be carefully performed [3,4]. The applicability of several guidelines from the literature was investigated experimentally and numerically, in the context of thick AHS sheets. The monotonic decrease of springback as back force increased was confirmed for this category of sheet steels, and a general trend for the non-linear influence of the tool radius was observed. The influence of numerical factors on the predicted values of springback was investigated. Conclusions and simple guidelines are drawn from the analysis with industrial sheet forming applications in mind. References [1] T. Kuwabara, S. Takahashi, K. Akiyama, Y. Miyashita, SAE Technical paper 950691 (1995) 1-10. [2] I.N. Vladimirov, M.P. Pietryga, S. Reese, Prediction of springback in sheet forming by a new finite strain model with nonlinear kinematic and isotropic hardening, Journal of Materials Processing Technology 209 (2009) 4062-4075. [3] W.D. Carden, L.M. Geng, D.K. Matlock, R.H. Wagoner, Measurement of springback, International Journal of Mechanical Sciences 44 (2002) 79-101. [4] K.P. Li, W.P. Carden, R.H. Wagoner, Simulation of springback, International Journal of Mechanical Sciences 44 (2002) 103-122.