scholarly journals Internal shear cracking in bulk metal forming

2016 ◽  
Vol 233 (4) ◽  
pp. 603-614
Author(s):  
P Christiansen ◽  
CV Nielsen ◽  
N Bay ◽  
PAF Martins
Keyword(s):  
Metal Forming ◽  
Three Dimensional ◽  
Stress Triaxiality ◽  
Propagation Path ◽  
Shear Cracks ◽  
Bulk Metal ◽  
Surface Cracking ◽  
Bulk Metal Forming ◽  
Scope Of Application ◽  
Shear Cracking

This paper presents an uncoupled ductile damage criterion for modelling the opening and propagation of internal shear cracks in bulk metal forming. The criterion is built upon the original work on the motion of a hole subjected to shear with superimposed tensile stress triaxiality and its overall performance is evaluated by means of side-pressing formability tests in Aluminium AA2007-T6 subjected to different levels of pre-strain. Results show that the new proposed criterion is able to combine simplicity with efficiency for predicting the onset of fracture and the crack propagation path for the entire set of test cases regardless the amount of pre-strain derived from previous upsetting under near frictionless conditions. The new proposed criterion can be easily implemented in existing finite element programs and its scope of application allows extending previous work on the opening modes in surface cracking to internal cracks formed under three-dimensional states of stress that are typical of bulk metal forming.

Application of Rigid/Visco-Plastic Element Free Galerkin Method in Three-Dimensional Bulk Metal Forming Processes

2009 ◽  
Vol 419-420 ◽  
pp. 457-460
Author(s):  
Ping Lu ◽  
Xin Wu ◽  
Guo Qun Zhao ◽  
Kai Yong Jiang ◽  
Yan Jin Guan
Keyword(s):  
Galerkin Method ◽  
Metal Forming ◽  
Three Dimensional ◽  
Element Free Galerkin Method ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Finite Element Software ◽  
Element Free Galerkin ◽  
Plastic Element ◽  
Element Free

Combining element free Galerkin method with rigid/visco-plastic flow theory, the paper establishes the three-dimensional rigid/visco-plastic element free Galerkin method, and introduces it to analyze three-dimensional bulk metal forming processes. The velocity field is approximated by MLS method. Employing the incomplete generalized variation principle, stiffness matrix equation and solution formulas are derived. And STL format discrete triangular patches are used to describe the mould cavity. An analysis program for simulating three-dimensional bulk metal forming processes is developed. The program is capable of simulating three-dimensional unsteady bulk metal forming processes with severe deformation and arbitrarily shaped dies. A numerical example is analyzed. Numerical results such as material flow patterns and distributions of the effective stress are obtained. The effectiveness and validity of the proposed method and techniques are demonstrated by comparing with results obtained by using commercial finite element software.

New methodology for the characterization of failure by fracture in bulk forming

2018 ◽  
Vol 53 (4) ◽  
pp. 242-247 ◽  
Author(s):  
Joao P Magrinho ◽  
Maria Beatriz Silva ◽  
Luis M Alves ◽  
AG Atkins ◽  
Paulo AF Martins
Keyword(s):  
Metal Forming ◽  
Stress Triaxiality ◽  
Image Correlation ◽  
Principal Strain ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Aisi 1045 ◽  
Steel Aisi ◽  
Strain Paths ◽  
Strain Space

This article is focused on the formability limits by fracture obtained from standard bulk metal forming tests performed with cylindrical, tapered and flanged specimens. A total of two novel features are presented: the use of digital image correlation to determine strain paths and immersion of steel specimens in liquid nitrogen after the onset of crack formation to reveal the mode of fracture. A new methodology to determine the fracture loci in principal strain space is proposed based on the combination of experimental force–displacement evolutions with in-plane strain measurements. The experimental work is performed in cold-drawn steel AISI 1045 and two new formability tests with different values of stress triaxiality are proposed for obtaining strains at fracture in regions of principal strain space that are not sufficiently well covered by standard bulk metal forming tests.

Sheet-Bulk Metal Forming of Symmetric and Asymmetric Parts

2013 ◽  
Vol 769 ◽  
pp. 229-236 ◽  
Author(s):  
Valerian Salfeld ◽  
Richard Krimm ◽  
Sven Hübner ◽  
Thorsten Matthias ◽  
Milan Vucetic
Keyword(s):  
Metal Forming ◽  
Material Flow ◽  
Three Dimensional ◽  
Positive Influence ◽  
Sheet Metals ◽  
Functional Elements ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
New Machine

The unique process of sheet-bulk metal forming (SBMF) represents a combination of sheet and bulk metal forming by inducing a three-dimensional material flow in sheet metals in a single forming stage. Within this paper two different applications of sheet-bulk metal forming are demonstrated. Hereby two different combined drawing and upsetting processes to realize parts with symmetrically and asymmetrically arranged functional elements are analysed. Finally, this contribution introduces a new machine technique which provides an improvement of the working accuracy of a forming machine and thus has a positive influence on the parts quality. The idea is to use electromagnetic ram guidance to counteract the displacement of the ram due to horizontal forming forces while forming of asymmetric parts.

A new test for determining the mechanical and fracture behavior of materials in sheet-bulk metal forming

2015 ◽  
Vol 231 (8) ◽  
pp. 693-703 ◽  
Author(s):  
CMA Silva ◽  
MB Silva ◽  
LM Alves ◽  
PAF Martins
Keyword(s):  
Fracture Toughness ◽  
Metal Forming ◽  
Three Dimensional ◽  
Strain Curve ◽  
Shear Zones ◽  
Shear Stresses ◽  
Stress Strain Curve ◽  
Stress Strain ◽  
Bulk Metal ◽  
Bulk Metal Forming

This paper presents a new experimental test for determining the stress–strain curve and the fracture toughness of sheets to be used in sheet-bulk metal forming (SBMF) applications. The test is based on the utilization of double-notched specimens loaded in shear and combines the plane stress loading conditions of sheet metal forming with the three-dimensional plastic flow conditions of bulk metal forming, which are commonly found in SBMF processes. The methodology to obtain the stress–strain curve involves calculation of the shear stresses and strains along the two symmetric plastic shear zones of the test specimens up to point where cracks start to propagate along the ligaments that connect each pair of opposite notches. The determination of fracture toughness involves characterization of the evolution of load with displacement for a number of test cases performed with specimens having different ligaments between the two symmetric opposite notches. The work is performed on aluminium alloy EN AW 5754 H111 sheets with 5 mm thickness and the results obtained by means of the new proposed test are compared against those from conventional mechanical and fracture characterization tests.

scholarly journals Development of a numerical compensation framework for geometrical deviations in bulk metal forming exploiting a surrogate model and computed compatible stresses

2021 ◽  
Author(s):  
Lorenzo Scandola ◽  
Christoph Büdenbender ◽  
Michael Till ◽  
Daniel Maier ◽  
Michael Ott ◽  
...  
Keyword(s):  
Finite Element ◽  
Surrogate Model ◽  
Metal Forming ◽  
Computer Aided Design ◽  
Transition Process ◽  
Reference Points ◽  
Compensation Method ◽  
Tool Geometry ◽  
Bulk Metal ◽  
Bulk Metal Forming

AbstractThe optimal design of the tools in bulk metal forming is a crucial task in the early design phase and greatly affects the final accuracy of the parts. The process of tool geometry assessment is resource- and time-consuming, as it consists of experience-based procedures. In this paper, a compensation method is developed with the aim to reduce geometrical deviations in hot forged parts. In order to simplify the transition process between the discrete finite-element (FE) mesh and the computer-aided-design (CAD) geometry, a strategy featuring an equivalent surrogate model is proposed. The deviations are evaluated on a reduced set of reference points on the nominal geometry and transferred to the FE nodes. The compensation approach represents a modification of the displacement-compatible spring-forward method (DC-SF), which consists of two elastic FE analyses. The compatible stress originating the deviations is estimated and subsequently applied to the original nominal geometry. After stress relaxation, an updated nominal geometry of the part is obtained, whose surfaces represent the compensated tools. The compensation method is verified by means of finite element simulations and the robustness of the algorithm is demonstrated with an additional test geometry. Finally, the compensation strategy is validated experimentally.

Fundamental investigations on the material flow at combined sheet and bulk metal forming processes

CIRP Annals ◽  
2011 ◽  
Vol 60 (1) ◽  
pp. 283-286 ◽  
Author(s):  
M. Merklein ◽  
J. Koch ◽  
S. Opel ◽  
T. Schneider
Keyword(s):  
Metal Forming ◽  
Material Flow ◽  
Bulk Metal ◽  
Bulk Metal Forming

Amorphous Carbon Coatings for Locally Adjusted Tribological Properties in Sheet Bulk Metal Forming

2012 ◽  
Vol 504-506 ◽  
pp. 969-974 ◽  
Author(s):  
Harald Hetzner ◽  
Stephan Tremmel ◽  
Sandro Wartzack
Keyword(s):  
Amorphous Carbon ◽  
Tribological Properties ◽  
Metal Forming ◽  
Friction And Wear ◽  
Wear Properties ◽  
Carbon Coatings ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Friction And Wear Properties ◽  
Amorphous Carbon Coatings

In sheet bulk metal forming, locally adapted friction properties of the contact tool/workpiece are an appropriate means for the targeted enhancement of the material flow, enabling an improved form filling and lowered forming forces. However, the implementation of desirable friction conditions is not trivial. And further, friction is inseparably linked to wear and damage of the contacting surfaces. This calls for a methodological approach in order to consider tribology as a whole already in the early phases of process layout, so that tribological measures which allow fulfilling the requirements concerning local friction and wear properties of the tool surfaces, can already be selected during the conceptual design of the forming tools. Thin tribological coatings are an effective way of improving the friction and wear properties of functional surfaces. Metal-modified amorphous carbon coatings, which are still rather new to the field of metal forming, allow tackling friction and wear simultaneously. Unlike many other types of amorphous carbon, they have the mechanical toughness to be used in sheet bulk metal forming, and at the same time their friction properties can be varied over wide ranges by proper choice of the deposition parameters. Based on concrete research results, the mechanical, structural and special tribological properties of tungsten-modified hydrogenated amorphous carbon coatings (a-C:H:W) are presented and discussed against the background of the tribological requirements of a typical sheet bulk metal forming process.

Sign in / Sign up

Export Citation Format

Share Document