Failure modelling in metal forming by means of an anisotropic hyperelastic-plasticity model with damage

2014 ◽  
Vol 23 (8) ◽  
pp. 1096-1132 ◽  
Author(s):  
Ivaylo N Vladimirov ◽  
Michael P Pietryga ◽  
Yalin Kiliclar ◽  
Vivian Tini ◽  
Stefanie Reese
Keyword(s):  
Metal Forming ◽  
Plastic Anisotropy ◽  
Forming Limit Diagram ◽  
Ductile Damage ◽  
Forming Limit ◽  
Isotropic Hardening ◽  
Work Piece ◽  
Plasticity Model ◽  
Anisotropic Plasticity ◽  
Isotropic Damage

In metal forming, formability is limited by the evolution of ductile damage in the work piece. The accurate prediction of material failure requires, in addition to the description of anisotropic plasticity, the inclusion of damage in the finite element simulation. This paper discusses the application of an anisotropic hyperelastic-plasticity model with isotropic damage to the numerical simulation of fracture limits in metal forming. The model incorporates plastic anisotropy, nonlinear kinematic and isotropic hardening and ductile damage. The constitutive equations of the proposed model are numerically integrated both implicitly and explicitly, and the model is implemented as a user material subroutine UMAT in the commercial solvers ABAQUS/Standard and LS-DYNA, respectively. The numerical examples investigate the potential of the constitutive framework regarding the prediction of failure in metal forming processes such as, e.g. cross-die deep drawing. In particular, simulations of the Nakazima stretching test with varying specimen geometry are utilized to simulate the forming limit diagram at fracture and the numerical results are compared to experimental data for aluminium alloy sheets.

Constitutive Modelling of Anisotropy, Hardening and Failure of Sheet Metals

2011 ◽  
Vol 473 ◽  
pp. 631-636 ◽  
Author(s):  
Ivaylo N. Vladimirov ◽  
Yalin Kiliclar ◽  
Vivian Tini ◽  
Stefanie Reese
Keyword(s):  
Kinematic Hardening ◽  
Plastic Anisotropy ◽  
Forming Limit Diagram ◽  
Material Model ◽  
Constitutive Modelling ◽  
Forming Limit ◽  
Isotropic Hardening ◽  
Continuum Damage ◽  
Aluminium Sheets ◽  
Good Agreement

The paper discusses the application of a newly developed coupled material model of finite anisotropic multiplicative plasticity and continuum damage to the numerical prediction of the forming limit diagram at fracture (FLDF). The model incorporates Hill-type plastic anisotropy, nonlinear Armstrong-Frederick kinematic hardening and nonlinear isotropic hardening. The numerical examples investigate the simulation of forming limit diagrams at fracture by means of the so-called Nakajima stretching test. Comparisons with test data for aluminium sheets display a good agreement between the finite element results and the experimental data.

Surrogate POD Models for Parametrized Sheet Metal Forming Applications

2013 ◽  
Vol 554-557 ◽  
pp. 919-927 ◽  
Author(s):  
Hamdaoui Mohamed ◽  
Guénhaël Le Quilliec ◽  
Piotr Breitkopf ◽  
Pierre Villon
Keyword(s):  
Finite Element ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Optimization Problems ◽  
Strain Tensor ◽  
Forming Limit ◽  
Work Piece ◽  
Displacement Fields ◽  
Lagrange Strain

The aim of this work is to present a POD (Proper Orthogonal Decomposition) based surrogate approach for sheet metal forming parametrized applications. The final displacement field for the stamped work-piece computed using a finite element approach is approximated using the method of snapshots for POD mode determination and kriging for POD coefficients interpolation. An error analysis, performed using a validation set, shows that the accuracy of the surrogate POD model is excellent for the representation of finite element displacement fields. A possible use of the surrogate to assess the quality of the stamped sheet is considered. The Green-Lagrange strain tensor is derived and forming limit diagrams are computed on the fly for any point of the design space. Furthermore, the minimization of a cost function based on the surrogate POD model is performed showing its potential for solving optimization problems.

Identification for Technological Capabilities of Titanium and Aluminum Alloys in Deep Drawing Process

2020 ◽  
Vol 299 ◽  
pp. 628-633 ◽  
Author(s):  
S.I. Feoktistov ◽  
Kyaw Zayar Soe
Keyword(s):  
Aluminum Alloys ◽  
Deep Drawing ◽  
Forming Limit Diagram ◽  
Forming Limit ◽  
Work Piece ◽  
Drawing Ratio ◽  
Drawing Process ◽  
Variable Parameters ◽  
Deep Drawing Process ◽  
The Moment

The paper describes a method which has been developed for obtaining the limiting drawing ratio of titanium and aluminum alloys, and determines the moment of failure of the work-piece. This method is based not only on the use of Forming Limit Diagram (FLD) in predicting the failure of the blank, but also the using method of variable parameters of elasticity in determining the stress-strain state in deep drawing process.

Forming limit diagrams by including the M–K model in finite element simulation considering the effect of bending

2016 ◽  
Vol 232 (8) ◽  
pp. 625-636 ◽  
Author(s):  
Mostafa Habibi ◽  
Ramin Hashemi ◽  
Ahmad Ghazanfari ◽  
Reza Naghdabadi ◽  
Ahmad Assempour
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Metal Forming ◽  
Forming Limit Diagram ◽  
Element Model ◽  
Forming Limit ◽  
Finite Element Models ◽  
Element Simulation ◽  
Simple Tension ◽  
Out Of Plane

Forming limit diagram is often used as a criterion to predict necking initiation in sheet metal forming processes. In this study, the forming limit diagram was obtained through the inclusion of the Marciniak–Kaczynski model in the Nakazima out-of-plane test finite element model and also a flat model. The effect of bending on the forming limit diagram was investigated numerically and experimentally. Data required for this simulation were determined through a simple tension test in three directions. After comparing the results of the flat and Nakazima finite element models with the experimental results, the forming limit diagram computed by the Nakazima finite element model was more convenient with less than 10% at the lower level of the experimental forming limit diagram.

Advances in Plastic Anisotropy and Forming Limits in Sheet Metal Forming

2016 ◽  
Vol 138 (9) ◽  
Author(s):  
Dorel Banabic
Keyword(s):  
Numerical Simulation ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Constitutive Modeling ◽  
Metal Forming ◽  
Plastic Anisotropy ◽  
Forming Limit ◽  
Simulation Tools ◽  
The One ◽  
Forming Limit Curves

In the last decades, numerical simulation has gradually extended its applicability in the field of sheet metal forming. Constitutive modeling and formability are two domains closely related to the development of numerical simulation tools. This paper is focused, on the one hand, on the presentation of new phenomenological yield criteria developed in the last decade, which are able to describe the anisotropic response of sheet metals, and, on the other hand, on new models and experiments to predict/determine the forming limit curves.

Reliability Analysis of the Tube Hydroforming Process Based on Forming Limit Diagram

2005 ◽  
Vol 128 (3) ◽  
pp. 402-407 ◽  
Author(s):  
Bing Li ◽  
Don R. Metzger ◽  
Tim J. Nye
Keyword(s):  
Automotive Industry ◽  
Metal Forming ◽  
Tube Hydroforming ◽  
Forming Limit Diagram ◽  
Probability Of Failure ◽  
Alternative Methods ◽  
Forming Limit ◽  
Forming Process ◽  
Hydroforming Process ◽  
Free Bulging

Tube hydroforming is an attractive manufacturing process in the automotive industry because it has several advantages over alternative methods. In order to determine the reliability of the process, a new method to assess the probability of failure is proposed in this paper. The method is based on the reliability theory and the forming limit diagram, which has been extensively used in metal forming as the criteria of formability. From the forming limit band in the forming limit diagram, the reliability of the forming process can be evaluated. A tube hydroforming process of free bulging is then introduced as an example to illustrate the approach. The results show this technique to be an innovative approach to avoid failure during tube hydroforming.

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