Papers by Keyword: Kinematic Hardening

Abstract: Predicting the final shape of automotive structural components after springback is a challenge to the inclusion of high strength aluminum alloys into the vehicle body-in-white. Complex deformation paths and reverse loading of sheet material during forming operations can induce significant Bauschinger effects and kinematic hardening behaviour. Capturing the through-thickness stress gradient is critical when predicting springback, which is governed by tooling dynamics, frictional forces, and material plasticity. In this study, the anisotropic behaviour of a AA6xxx-T4 aluminum alloy was characterized to calibrate a BBC2005 yield function, kinematic hardening effects were characterized through a novel uniaxial compression-tension technique, and a technology demonstrator U-shaped rail component was formed and scanned to assess the final shape after springback. Multiple model variations were analyzed in AutoForm R12, modifying simulation control parameters, binder loading condition (uniform vs. column), friction model (Coulomb vs. TriboForm), and hardening model (isotropic vs. kinematic). The use of column binder loading paired with TriboForm friction model provided the most significant improvement for thinning and springback prediction accuracy with kinematic hardening being a second order effect compared to accounting for friction and binder force.

Abstract: The hardening models have a significant influence on the accuracy of finite element analysis (FEA). Although, isotropic hardening models are the most widely used, it is known that kinematic hardening models (describing the Bauschinger effect and permanent softening) can significantly improve the accuracy of FEA results. However, when considering sheet metal materials, the parameters of kinematic hardening models are difficult to identify due to the challenges of obtaining experimental results from test with strain path inversions. This work considers an experimental procedure that enables the analysis of the mechanical behaviour of sheet metal materials submitted to reverse loadings. A miniaturized test device was developed to perform tension and compression tests, with reverse loadings, for sheet metal materials. This specimen design has two main advantages: (1) reduces buckling during compression (compared to standard tensile test specimens) and, consequently, (2) enables the characterization of the mechanical behaviour under reverse tension-compression strain paths changes. The small size of the specimens, with 2 x 2 mm gauge area, poses the main challenge of the current methodology, namely the measurement of the strain field distribution using the Digital Image Correlation (DIC) technique. The results obtained from tension-compression tests with mini-specimens are validated by comparison with standard tensile and shear (reverse loading) and tests.

Abstract: Springback is one of the major defects that continuously concerns the sheet metal experts’ community. It is has long been known that the sheet thickness, the bending angle and the yield stress of the material primarily affect the angle change after the tools’ release. Besides, the consideration of the kinematic hardening (KH) model has powerful influence on the modelling results, too. In this study, we overviewed several possible factors on the springback with finite element modeling of a simple V-die bending operation, highlighting the effect of the material variables on the final shape. AutoForm® R7 software and the built-in theory of kinematic hardening were used for the material characterization, coupled with the Hockett-Sherby isotropic hardening rule as well as the Yld89 yield criterion. The material data for modeling kinematic hardening behavior were obtained by cyclic tension-compression tests, whilst the isotropic hardening and the yield surface parameters were acquired by simple uniaxial tension tests. The simulation results were compared to the experimental springback observations obtained by a CNC bending machine, without using springback compensation. A detailed parametric study was also carried out to highlight the level of criticality of the applied material variables on the final angle change.

Abstract: A fully coupled micro-macro interaction model is proposed for the grain refinement caused by severe plastic deformation of cell-forming metallic materials. The model is a generalization of a previously proposed two-phase composite model suggested for the evolution of dislocation populations corresponding to the interior of the dislocation cells and dislocation cell walls. Just as within the original framework, the evolution of the material microstructure depends on the applied hydrostatic pressure, strain rate, and the loading path. Backstresses are used to define a measure of the strain path change. Thereby, the model can describe the experimentally observed dissolution of dislocation cells and the reduction of dislocation densities occurring shortly after load path changes. The large strain kinematics is accounted for in a geometrically exact manner using the nested split of the deformation gradient tensor, proposed by Lion. Within the extended model, the macroscopic strength of the material depends on the microstructural parameters. In that sense, the new model is fully coupled. It is thermodynamically consistent, objective, and w-invariant under isochoric changes of the reference configuration. A physical interpretation is provided for the nested multiplicative split in terms of the two-phase microstructure composite model.

Abstract: This study deals with the effect of the loading history on the cyclic behavior and the fatigue life of a 304L stainless steel at room temperature. The experiments have been performed using two specimens’ categories. The first one (virgin) has been submitted to only classical fatigue tests while in the second category, prior to the fatigue test; the specimen was subjected to a pre-hardening process under either monotonic or cyclic strain control. Cyclic softening followed by cyclic hardening are observed for the virgin specimens while only cyclic softening is exhibited by the pre-hardened specimens. The obtained results show that fatigue life is strongly influenced by the pre-hardening: the latter seems beneficial under stress control but detrimental under strain control, even in the presence of a compressive mean stress. The results are discussed regarding the cyclic evolution of the elastic modulus as well as the isotropic and kinematic parts of the strain hardening in different configurations: with or without pre-hardening, stress or strain control.

Abstract: The identification of the material models which are used in the finite element analysis for the forming operation and springback are very important in terms of accurate predictions. The aim of this paper is to characterize both the anisotropy and the hardening of the ultra-high strength steel such as martensitic steel (MS steel) in order to identify material parameters of constitutive equation, which able to reproduce the mechanical behavior. Uniaxial tensile tests were carried out for characterizing the anisotropic plastic behavior of the MS steel. Cyclic tests under tension-compression load were also carried out for characterizing the Bauschinger effect during reverse deformation. Yoshida-Uemori hardening model associated with orthotropic yield criterion Hill’s 1948 is used to represent the in-plane mechanical behavior of the martensitic steel. The resented results show a very good agreement between model predictions and experiments: flow stresses during loading and reverse loading are well reproduced.

Abstract: This paper takes the ultra-high pressure (103.5MPa) valve body as the research object and adopts the finite element method to perform simulation analysis on the three bearing conditions involved with the valve body, i.e., autofrettage pressure, discharge and working pressure. The simulation shows identical results with the theoretical calculation. The relationship between the maximum equivalent stress and autofrettage pressure during the operation of the valve is obtained from the simulation results; therefore the best autofrettage pressure is determined. When determining the maximum value of autofrettage pressure, the maximum pressure, at which reverse yield does not happen, and the complete yield pressure shall be taken into consideration, with the smaller value of the two taken after comparison and analysis. When the size of the valve body is fixed at certain value, the best autofrettage pressure is not a fixed value, but it varies with the change of working pressure.

Abstract: In this paper, yield surface distortion was studied by considering the combination of nonlinear kinematic hardening model of Chaboche and a new anisotropic continuum damage evolution model. The constitutive relations for anisotropic damage of elastoplasic materials were developed based on irreversible thermodynamics. The internal state manifold which consists of internal variables to specify the thermodynamic state of solids was described by a 2nd rank symmetric damage tensor, the kinematic hardening tensor and tensor of movement of damage potential surface. In order to describe the damage state, the fictitious continuum domain was considered and the consistent relations between real and fictitious domains were developed. It was indicated that the combination of the Chaboche’s model and model of anisotropic continuum damage leads to the well description of the subsequent yield surface.

Abstract: This paper discusses a finite element analysis of cylinder on flat contact configuration subjected to constant normal load and reciprocating tangential displacement with linear kinematic hardening models based on bi-modal Ti-6Al-4V cyclic stress-strain curves. The predicted evolution of plastic deformation such as the equivalent plastic strain, tangential plastic strain and shear plastic strain distributions on the contact region has been studied along with its respective predicted stress distributions. The effect of applied forward and backward sliding displacement movements on predicted stress and strain distributions have also been looked at. It is found that the stress distributions predicted for kinematic hardening model is similar for forward and backward movements while the predicted plastic strain distribution is increasing with reciprocating sliding movement. The predicted value keep increasing when it moves forward, backward and finally moves forward again. This is due to large strain effect of the model and its dependant on the displacement movement amount.

Abstract: Finite element models optimizing cold forged products have to incorporate the complete manufacturing pathway. Virtual process design as a method based on a multistep operation approach can describe interacting phenomena. Thus, inheritance effects like residual stress and damage evolution can be tracked throughout the processing chain. Besides the influence of the deformation direction (Bauschinger Effect) on material flow can be predicted. Using intermediate step optimization may also extend geometrical limits. Furthermore it may increase life time and improve material efficiency for a given component. The exploitation of these coupling effects may also form a basis for further product and process innovations.