Ultra-Thin Sheet Forming Analyses Considering Size Effects

2019 ◽  
Vol 794 ◽  
pp. 295-304
Author(s):  
Bon Young Ghoo ◽  
Jun Ho Son ◽  
Yasuyoshi Umezu ◽  
Tei Hirashima ◽  
Yuko Watanabe
Keyword(s):  
Flow Stress ◽  
Constitutive Equation ◽  
Size Effect ◽  
Size Effects ◽  
Thin Sheet ◽  
Scale Factor ◽  
Fe Analysis ◽  
Forming Process ◽  
Deformation Modes ◽  
Sheet Deformation

Based on robust numerical formulations and various material models, finite element (FE) analysis becomes a powerful tool in conventional sheet metal forming process. Unfortunately, the present constitutive equations irrelevant to thickness that describe well conventional sheet deformation modes have difficulties being applied directly to ultra-thin sheet deformation modes. In the present study, a constitutive equation considering size effect is established by introducing a scale factor that represents size effects through thickness and width directions. Uniaxial tensile tests were used to evaluate the scale factor of different thicknesses together with the parameter identification. The developed constitutive equation reveals that thickness is the most important factor effecting on the constitutive relation of ultra-thin sheet. 2D draw forming process of C7035 ultra-thin sheet is analyzed using JSTAMP/NV introducing the developed constitutive equation. The analysis results show that there are obvious differences in the punch forces and loading geometries according to the size effect through thickness direction. Specimen width has slight effect on the flow stress although specimen thickness has strong effect on the flow stress. It is expected that the proposed constitutive equation gives good applicability to FE analysis of micro-scale forming.

Modeling of Size Effects on the Flow Stress of Type 304 Stainless Steel and Application in Coining Process

2007 ◽  
Author(s):  
Gap-Yong Kim ◽  
Muammer Koc ◽  
Jun Ni
Keyword(s):  
Grain Size ◽  
Stainless Steel ◽  
Flow Stress ◽  
Size Effect ◽  
Size Effects ◽  
Specimen Size ◽  
304 Stainless Steel ◽  
Length Scales ◽  
Type 304 ◽  
Type 304 Stainless Steel

Application of microforming in various research areas has received much attention due to the increased demand for miniature metallic parts that require mass production. For the accurate analysis and design of microforming process, proper modeling of material behavior at the micro/meso-scale is necessary by considering the size effects. Two size effects are known to exist in metallic materials. One is the “grain size” effect, and the other is the “feature/specimen size” effect. This study investigated the “feature/specimen size” effect and introduced a scaling model which combined both feature/specimen and grain size effects. Predicted size effects were compared with experiments obtained from previous research and showed a very good agreement. The model was also applied to forming of micro-features by coining. A flow stress model for Type 304 stainless steel taking into consideration the effect of the grain and feature size was developed and implemented into a finite element simulation tool for an accurate numerical analysis. The scaling model offered a simple way to model the size effect down to length scales of a couple of grains and extended the use of continuum plasticity theories to micro/meso-length scales.

FE Analysis of Size Effect on Deformation Behavior of Metal Microtube Considering Surface Roughness in Flaring Test

2009 ◽  
Vol 623 ◽  
pp. 79-87 ◽  
Author(s):  
Mohammad Ali Mirzai ◽  
Kenichi Manabe
Keyword(s):  
Surface Roughness ◽  
Size Effect ◽  
Wall Thickness ◽  
Size Effects ◽  
Fe Analysis ◽  
Material Behavior ◽  
Test Results ◽  
Feature Size ◽  
Analysis And Design ◽  
Smoothing Process

Reliable test results that show the material characteristics of a micromaterial are necessary for the accurate analysis and design of microforming processes. The size effects in the microforming are predicted to have a significant impact on the material behavior. Two size effects are explored in metallic materials. One is the grain size effect, and the other is the feature/specimen size effect. In this study, the feature size effect on the smoothing process with the consideration of tool surface roughness is investigated numerically for metal microtubes by the flaring test. Stainless-steel (SUS 316L) microtubes with the same outer diameter of 500 μm and different wall thicknesses of 50, 25 and 10 μm were used in the FE analysis to study the feature size effect on the microscale by the flaring test. The surface roughnesses of the inner and outer surfaces of the microtube, as well as the surface asperity of the conical tool, were modeled in the cyclic concave-convex configuration. It is found, in the flaring test with using rough and fine tools, that the smoothing process on the inner surface of the microtube (ISM), as well as the plastic strain in the wall thickness of microtube, is affected owing to the rigidity of the microtube, which decreases as the wall thickness of the microtube decreases. These results suggest that the feature size affects the flaring test results for the metal microtube.

scholarly journals Constitutive Model of Thin Metal Sheet in Bulging Test Considering Strain Gradient Hardening

2020 ◽  
Vol 26 (4) ◽  
pp. 415-425
Author(s):  
Wei LIANG ◽  
Tieping WEI ◽  
Xiaoxiang YANG
Keyword(s):  
Constitutive Equation ◽  
Size Effect ◽  
Strain Gradient ◽  
Large Deviation ◽  
Thin Sheet ◽  
Second Order ◽  
Thin Metal Sheet ◽  
Brass Sheet ◽  
Bulging Test ◽  
Stress Variations

The study of the size effect was one of the most important subjects in the field of micro-forming. To investigate the stress of the thin sheet in the bulging test with the second order size effect, a constitutive equation considering the strain gradient hardening was proposed. Based on the equation, the stress of the thin sheet during the bulging test was calculated by the finite element method. The bulging tests with various thicknesses of brass sheets and radiuses of punching balls were performed to verify the proposed equation. The results showed that the constitutive equation could capture the stress variations, while the simulation using the constitutive equation from the conventional theory of plasticity showed the results with large deviation from those of the experiment. It was found that the stress was sensitive to the thickness of the sheet and the radius of the punching ball in bulging test of thin brass sheet. The bulging of the thin brass sheet with a thickness below ten times of its material intrinsic length would cause the generation of the geometrically necessary dislocations, which induced the strain gradient hardening. Besides that, the decrement of the punching ball radius would also increase the inhomogeneous deformation and enhance the strain gradient hardening during the thin sheet bulging process. The strain gradient hardening during the thin sheet bulging test was related to the strain of the sheet. The hardening effect of the strain gradient was obvious when the strain was small. The strain gradient hardening should be considered in the thin sheet bulging test with the second order size effect.

Explanation of the size effect on the flow stress of thin sheet based on the size of dislocation cell

2019 ◽  
Vol 766 ◽  
pp. 138331
Author(s):  
Peng Zhang ◽  
Han Wang ◽  
ChuanJie Wang ◽  
Qiang Zhu ◽  
Gang Chen
Keyword(s):  
Flow Stress ◽  
Size Effect ◽  
Thin Sheet ◽  
Dislocation Cell

The Effects of Grain Size and Lubrication on Micro Curl Forming Process of Metallic Thin Sheet

2015 ◽  
Vol 661 ◽  
pp. 55-61
Author(s):  
Chang Cheng Chen ◽  
Huey Lin Ho
Keyword(s):  
Mechanical Properties ◽  
Grain Size ◽  
Size Effect ◽  
Deformation Behavior ◽  
Thin Sheet ◽  
Grain Size Effect ◽  
Forming Process ◽  
Grain Sizes ◽  
Different Temperatures ◽  
Different Thickness

This article aims at the discussion of deformation behavior considering size effect on curl forming process of sheet metal. In this study, the test specimens were made by phosphor bronze sheets for curl forming test. The specimens with different thickness were firstly heated at different temperatures for obtaining the objective grain sizes. And the mechanical properties of specimen were acquired by using tensile test. Through the curl forming test with a curl forming machine, the curled angles, springback and curling load were measured and analyzed for investigating the grain size effect of the chamfer and carbon lubricant during the curl forming process.

scholarly journals Hot Deformation Behavior and Processing Maps of a New Ti-6Al-2Nb-2Zr-0.4B Titanium Alloy

Materials ◽  
2021 ◽  
Vol 14 (9) ◽  
pp. 2456
Author(s):  
Zhijun Yang ◽  
Weixin Yu ◽  
Shaoting Lang ◽  
Junyi Wei ◽  
Guanglong Wang ◽  
...  
Keyword(s):  
Titanium Alloy ◽  
Flow Stress ◽  
Constitutive Equation ◽  
Deformation Mechanism ◽  
Power Dissipation ◽  
Hot Deformation ◽  
Dissipation Rate ◽  
Dynamic Recovery ◽  
Processing Maps ◽  
Temperature Range

The hot deformation behaviors of a new Ti-6Al-2Nb-2Zr-0.4B titanium alloy in the strain rate range 0.01–10.0 s−1 and temperature range 850–1060 °C were evaluated using hot compressing testing on a Gleeble-3800 simulator at 60% of deformation degree. The flow stress characteristics of the alloy were analyzed according to the true stress–strain curve. The constitutive equation was established to describe the change of deformation temperature and flow stress with strain rate. The thermal deformation activation energy Q was equal to 551.7 kJ/mol. The constitutive equation was ε ˙=e54.41[sinh (0.01σ)]2.35exp(−551.7/RT). On the basis of the dynamic material model and the instability criterion, the processing maps were established at the strain of 0.5. The experimental results revealed that in the (α + β) region deformation, the power dissipation rate reached 53% in the range of 0.01–0.05 s−1 and temperature range of 920–980 °C, and the deformation mechanism was dynamic recovery. In the β region deformation, the power dissipation rate reached 48% in the range of 0.01–0.1 s−1 and temperature range of 1010–1040 °C, and the deformation mechanism involved dynamic recovery and dynamic recrystallization.

Particle size effects in the selective hydrogenation of cinnamaldehyde over supported palladium catalysts

RSC Advances ◽  
2016 ◽  
Vol 6 (79) ◽  
pp. 75541-75551 ◽  
Author(s):  
Feng Jiang ◽  
Jian Cai ◽  
Bing Liu ◽  
Yuebing Xu ◽  
Xiaohao Liu
Keyword(s):  
Particle Size ◽  
Size Effect ◽  
Selective Hydrogenation ◽  
Size Effects ◽  
Palladium Catalysts ◽  
Particle Size Effect ◽  
Particle Size Effects ◽  
Supported Palladium Catalysts ◽  
Supported Palladium ◽  
Palladium Particles

Palladium particles of different sizes obtained directly and indirectly by various methods were studied to clarify the particle size effect in the selective hydrogenation of cinnamaldehyde (CAL).

Microstructure Integrated Modeling of Multiscan Laser Forming

2002 ◽  
Vol 124 (2) ◽  
pp. 379-388 ◽  
Author(s):  
Jin Cheng ◽  
Y. Lawrence Yao
Keyword(s):  
Flow Stress ◽  
Numerical Models ◽  
Flow Behavior ◽  
Fem Simulation ◽  
Constitutive Models ◽  
Low Carbon Steel ◽  
Laser Forming ◽  
Low Carbon ◽  
Forming Process ◽  
Heating And Cooling

Laser forming of steel is a hot forming process with high heating and cooling rate, during which strain hardening, dynamic recrystallization, and phase transformation take place. Numerical models considering strain rate and temperature effects only usually give unsatisfactory results when applied to multiscan laser forming operations. This is mainly due to the inadequate constitutive models employed to describe the hot flow behavior. In this work, this limitation is overcome by considering the effects of microstructure change on the flow stress in laser forming processes of low carbon steel. The incorporation of such flow stress models with thermal mechanical FEM simulation increases numerical model accuracy in predicting geometry change and mechanical properties.

Study of the Size Effects and Friction Conditions in Microextrusion—Part II: Size Effect in Dynamic Friction for Brass-Steel Pairs

2007 ◽  
Vol 129 (4) ◽  
pp. 677-689 ◽  
Author(s):  
Lapo F. Mori ◽  
Neil Krishnan ◽  
Jian Cao ◽  
Horacio D. Espinosa
Keyword(s):  
Grain Size ◽  
Friction Coefficient ◽  
Size Effect ◽  
Contact Pressure ◽  
Size Effects ◽  
Numerical Models ◽  
Kolsky Bar ◽  
Experimental Results ◽  
Material Response ◽  
Dynamic Coefficients

In this paper, the results of experiments conducted to investigate the friction coefficient existing at a brass-steel interface are presented. The research discussed here is the second of a two-part study on the size effects in friction conditions that exist during microextrusion. In the regime of dimensions of the order of a few hundred microns, these size effects tend to play a significant role in affecting the characteristics of microforming processes. Experimental results presented in the previous companion paper have already shown that the friction conditions obtained from comparisons of experimental results and numerical models show a size effect related to the overall dimensions of the extruded part, assuming material response is homogeneous. Another interesting observation was made when extrusion experiments were performed to produce submillimeter sized pins. It was noted that pins fabricated from large grain-size material (211μm) showed a tendency to curve, whereas those fabricated from billets having a small grain size (32μm), did not show this tendency. In order to further investigate these phenomena, it was necessary to segregate the individual influences of material response and interfacial behavior on the microextrusion process, and therefore, a series of frictional experiments was conducted using a stored-energy Kolsky bar. The advantage of the Kolsky bar method is that it provides a direct measurement of the existing interfacial conditions and does not depend on material deformation behavior like other methods to measure friction. The method also provides both static and dynamic coefficients of friction, and these values could prove relevant for microextrusion tests performed at high strain rates. Tests were conducted using brass samples of a small grain size (32μm) and a large grain size (211μm) at low contact pressure (22MPa) and high contact pressure (250MPa) to see whether there was any change in the friction conditions due to these parameters. Another parameter that was varied was the area of contact. Static and dynamic coefficients of friction are reported for all the cases. The main conclusion of these experiments was that the friction coefficient did not show any significant dependence on the material grain size, interface pressure, or area of contact.

Deformation Behavior and Constitutive Equation of 42CrMo Steel at High Temperature

Metals ◽  
2021 ◽  
Vol 11 (10) ◽  
pp. 1614
Author(s):  
Hongqiang Liu ◽  
Zhicheng Cheng ◽  
Wei Yu ◽  
Gaotian Wang ◽  
Jie Zhou ◽  
...  
Keyword(s):  
High Temperature ◽  
Flow Stress ◽  
Strain Rate ◽  
Thermal Processing ◽  
Deformation Behavior ◽  
Reduction Process ◽  
Ann Model ◽  
Forming Process ◽  
Temperature Reduction ◽  
42Crmo Steel

High-temperature reduction pretreatment (HTRP) is a process that can significantly improve the core quality of a billet. The existing flow stress data cannot meet the needs of simulation due to lack of high temperature data. To obtain the hot forming process parameters for the high-temperature reduction pretreatment process of 42CrMo steel, a hot compression experiment of 42CrMo steel was conducted on Gleeble-3500 thermal-mechanical at 1200–1350 °C with the rates of deformation 0.001–10 s−1 and the deformation of 60%, and its deformation behavior at elevated temperature was studied. In this study, the effects of flow stress temperature and strain rate on austenite grain were investigated. Moreover, two typical constitutive models were employed to describe the flow stress, namely the Arrhenius constitutive model of strain compensation and back propagation artificial neural network (BP ANN) model. The performance evaluation shows that BP ANN model has high accuracy and stability to predict the curve. The thermal processing maps under strains of 0.1, 0.2, 0.3, and 0.4 were established. Based on the analysis of the thermal processing map, the optimal high reduction process parameter range of 42CrMo is obtained: the temperature range is 1250–1350 °C, and the strain rate range is 0.01–1 s−1.

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