Key Engineering Materials Vols. 504-506

Abstract: In the last decade the industrial use of solid state welding processes based on frictional forces work decaying into heat is continuously increasing due to their strong advantages with respect to traditional fusion techniques. Several advances have been proposed by the scientific community regarding process mechanics, material flow and also the computer aided engineering of the operation with the aim to maximize the mechanical performances of the welded joints. In the paper Friction Stir Welding (FSW) and Linear Friction Welding (LFW) operations are considered and a review of the most relevant research issues and results is provided.

Abstract: Forming limit strains are used to construct a forming limit diagram (FLD), which is a diagram in the principal strain space, traditionally used for designing forming operations of sheet metals. A line indicating the boundary between safe and unsafe strains is often called the forming limit curve (FLC). FLDs are also used to evaluate results from finite element simulations. Therefore consistency and reproducibility are important. This paper deals with the experimental determination of forming limit strains from Marciniak-Kuczynski (MK) tests. The material tested is AA6016 aluminum alloy in three different conditions: virgin material and material subjected to 5% and 8% deformation by rolling. Strains were measured by the use of digital image correlation (DIC) technique. Forming limit strains were determined by the use of two automated methods. The results from the two methods are compared and evaluated regarding their applicability to the Marciniak-Kuczynski test and ability to capture actual forming limit strains.

Abstract: The mechanical behavior of metallic materials during sheet forming processes must be related to their anisotropic properties and their formability aptitude. So, in this paper, channel die compression experiments are proposed to analyze the anisotropy of an AA2024 thick sheet. A modified quadratic Hill criterion based on the variation of the coefficients with the cumulated plastic strain is proposed. To compare and to validate the identified Hill coefficients values, classical tensile tests are also analyzed. The results are validated via finite element simulations of the tensile tests and channel die compression experiments using the commercial code LS-DYNA.

Abstract: Sheet metal forming processes are well-established in production technology for the manufacturing of large quantities. To increase the formability, the processing limit of a single forming process can be enhanced by a combination of quasi-static and high-speed forming process. The forming limits for both operations for the aluminum alloy EN AW 6082 T6 obtained via simulations and experiment are investigated in a research cooperation between the Institute of Materials Science (IW) and the Institute of Applied Mechanics (IFAM). Significant changes in forming limits with higher strain rates are indicated by the experimental results. Here, the forming limit curves move to the lower right hand side. The processes are simulated and the FLD at fracture are predicted by means of finite element analysis. The constitutive model is based on the multiplicative split of the deformation gradient. It is coupled with ductile damage and combines nonlinear kinematic and isotropic hardening. The kinematic hardening component represents a continuum extension of the classical rheological model of Armstrong–Frederick kinematic hardening. The coupling of damage and viscoplasticity is carried out following the well-known concept of effective stress and the principle of strain equivalence. Using these powerful tools the simulation of dynamic effects and the prediction of forming limit diagrams at fracture shows good correlation with the experiments.

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: In current forming simulations, Ghosh or Hockett-Sherby extrapolation functions are used to model strain hardening effects of sheet metals. When it comes to stochastic simulations, the respective parameters have to be recalculated according to the scattering of the mechanical material properties like yield or tensile strength. As present stochastic samplings for deep drawing simulations only consider yield strength and tensile strength, it is non-trivial securing the extrapolated area of strain hardening curves due to lack of data beyond uniform strain. It is current practice to improve the description of the flow curve beyond uniform elongation point by using the maximum force criterion, which takes into account the gradient of the yield curve at the last known point. The corresponding system of equations has to be solved numerically. We propose a method for adjusting parameters of the Ghosh or Hockett-Sherby extrapolation functions, which overcomes the need of numerical calculations and keeps flow curve information from the extrapolated interval, even if the stochastic sampling doesn’t incorporate any data regarding that area.

Abstract: The evaluation of forming simulation by using the forming limit curve has only limited validity if it is applied on car body components with non-linear strain paths. If modern high strength materials are used, the forming limit criteria can also provide invalid predictions. Especially high strength multiphase steels show a specific behaviour in forming, necking and crack initiation. If bending loads are applied to these materials, the onset of cracking occurs partially not within the range of the forming limit curve (FLC). The stress limit indicates the failure beginning more accurate. It is independent of the forming history and should be less sensitive to the behaviour of high strength steels. In the post processing of a simulation it could be used similar to the forming limit. A limit curve applied on the in-plane-stress-diagram of an analysed component defines areas that are more vulnerable for cracking. The required stress limit curve will be obtained in this research by applying a stretch-bending-test. It is selected in order to reach loads, which are comparable to the forming process in the components’ production. The forming state that is affecting the specimen is a combination of bending and stretching load. Different load conditions can be applied at the test by altering the stamp-radius and the specimen geometry. Since stresses cannot be measured directly in the experiment, the test is modelled in the simulation where the stresses can be calculated for a given material model. Finally the stress limit criterion was applied on the test parts’ stress distribution diagram. Occurring stresses above the stress limit curve are displayed on the simulation. Thereby it is possible to show a good correlation in critical areas between the failure prediction in the simulation and occurring rupture on the test component.

Abstract: Three experimental methods have been used to establish flow curves for a low carbon steel under biaxial stress conditions: the hydraulic bulge test, the stack compression test and the biaxial tensile test. The individual tests are discussed and the results for a DC06 IF steel grade compared. Initially the results appear to be different but after compensation, including strain rate and temperature correction, the true hardening curves are coinciding.

Abstract: Deformation behavior of high strength steel with a tensile strength of 590 MPa under biaxial tension was investigated for a work equivalent plastic strain range of 0.002 0.16. The test material was bent and laser welded to fabricate a tubular specimen with an inner diameter of 44.6mm and wall thickness of 1.2 mm. Using a servo-controlled tension-internal pressure testing machine, many linear stress paths in the first quadrant of stress space were applied to the tubular specimens. Moreover, biaxial tensile tests using a cruciform specimen were performed to precisely measure the deformation behavior of the test material for a small strain range following initial yielding. True stress-true plastic strain curves, contours of plastic work in stress space and the directions of plastic strain rates were measured and compared with those calculated using selected yield functions. The plastic deformation behavior up to an equivalent plastic strain of 0.16 was successfully measured. The Yld2000-2d yield function most closely predicts the general work contour trends and the directions of plastic strain rates of the test material.