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Title: Damage Prediction in Sheet Metal Forming

Abstract

Ductile (or plastic) damage often occurs during sheet metal forming processes due to the large plastic flow localization. Accordingly, it is crucial for numerical tools, used in the simulation of that processes, to use fully coupled constitutive equations accounting for both hardening and damage. This can be used in both cases, namely to overcome the damage initiation during some sheet metal forming processes as deep drawing, ... or to enhance the damage initiation and growth as in sheet metal cutting. In this paper, a fully coupled constitutive equations accounting for combined isotropic and kinematic hardening as well as the ductile damage is implemented into the general purpose Finite Element code for metal forming simulation. First, the fully coupled anisotropic constitutive equations in the framework of Continuum Damage Mechanics are presented. Attention is paid to the strong coupling between the main mechanical fields as elasto-viscoplasticity, mixed hardening, ductile isotropic damage and contact with friction. The anisotropy of the plastic flow is taken into account using various kinds of quadratic or non quadratic yield criteria in the framework of non associative finite plasticity theory with two types of normality rules. The associated numerical aspects concerning both the local integration of the coupledmore » constitutive equations as well as the (global) equilibrium integration schemes are presented. The local integration is outlined thanks to the Newton iterative scheme applied to a reduced system of 2 equations. For the global resolution of the initial and boundary value problem, the classical dynamic explicit (DE) scheme with an adaptive time step control is used. The numerical implementation of the damage is made in such a manner that calculations can be executed with or without damage effect, i.e. fully coupled or uncoupled calculations. For the 2D processes an advanced adaptive meshing procedure is used in order to enhance the numerical solution and to kill the fully damaged elements in order to describe the macroscopic crack propagation. Various 2D and 3D examples are given in order to show the capability of the methodology to predict the damage initiation and growth during various sheet metal forming processes.« less

Authors:
;  [1]
  1. Department of Engineering Mechanics and Mechanics of Materials, ICD/LASMIS, FRE 2848 CNRS, University of Technology of Troyes, BP 2060, 10010 Troyes Cedex (France)
Publication Date:
OSTI Identifier:
21057330
Resource Type:
Journal Article
Resource Relation:
Journal Name: AIP Conference Proceedings; Journal Volume: 908; Journal Issue: 1; Conference: NUMIFORM '07: 9. international conference on numerical methods in industrial forming processes, Porto (Portugal), 17-21 Jun 2007; Other Information: DOI: 10.1063/1.2740796; (c) 2007 American Institute of Physics; Country of input: International Atomic Energy Agency (IAEA)
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; ALLOYS; ANISOTROPY; BOUNDARY-VALUE PROBLEMS; COMPUTERIZED SIMULATION; CRACK PROPAGATION; CUTTING; DRAWING; DUCTILITY; FINITE ELEMENT METHOD; FRACTURES; FRICTION; HARDENING; IMPLEMENTATION; ITERATIVE METHODS; METALS; PLASTICITY; SHEETS

Citation Formats

Saanouni, Khemais, and Badreddine, Houssem. Damage Prediction in Sheet Metal Forming. United States: N. p., 2007. Web. doi:10.1063/1.2740796.
Saanouni, Khemais, & Badreddine, Houssem. Damage Prediction in Sheet Metal Forming. United States. doi:10.1063/1.2740796.
Saanouni, Khemais, and Badreddine, Houssem. Thu . "Damage Prediction in Sheet Metal Forming". United States. doi:10.1063/1.2740796.
@article{osti_21057330,
title = {Damage Prediction in Sheet Metal Forming},
author = {Saanouni, Khemais and Badreddine, Houssem},
abstractNote = {Ductile (or plastic) damage often occurs during sheet metal forming processes due to the large plastic flow localization. Accordingly, it is crucial for numerical tools, used in the simulation of that processes, to use fully coupled constitutive equations accounting for both hardening and damage. This can be used in both cases, namely to overcome the damage initiation during some sheet metal forming processes as deep drawing, ... or to enhance the damage initiation and growth as in sheet metal cutting. In this paper, a fully coupled constitutive equations accounting for combined isotropic and kinematic hardening as well as the ductile damage is implemented into the general purpose Finite Element code for metal forming simulation. First, the fully coupled anisotropic constitutive equations in the framework of Continuum Damage Mechanics are presented. Attention is paid to the strong coupling between the main mechanical fields as elasto-viscoplasticity, mixed hardening, ductile isotropic damage and contact with friction. The anisotropy of the plastic flow is taken into account using various kinds of quadratic or non quadratic yield criteria in the framework of non associative finite plasticity theory with two types of normality rules. The associated numerical aspects concerning both the local integration of the coupled constitutive equations as well as the (global) equilibrium integration schemes are presented. The local integration is outlined thanks to the Newton iterative scheme applied to a reduced system of 2 equations. For the global resolution of the initial and boundary value problem, the classical dynamic explicit (DE) scheme with an adaptive time step control is used. The numerical implementation of the damage is made in such a manner that calculations can be executed with or without damage effect, i.e. fully coupled or uncoupled calculations. For the 2D processes an advanced adaptive meshing procedure is used in order to enhance the numerical solution and to kill the fully damaged elements in order to describe the macroscopic crack propagation. Various 2D and 3D examples are given in order to show the capability of the methodology to predict the damage initiation and growth during various sheet metal forming processes.},
doi = {10.1063/1.2740796},
journal = {AIP Conference Proceedings},
number = 1,
volume = 908,
place = {United States},
year = {Thu May 17 00:00:00 EDT 2007},
month = {Thu May 17 00:00:00 EDT 2007}
}
  • The formability in sheet metal forming processes is mainly conditioned by ductile fracture resulting from geometric instabilities due to necking and strain localization. The macroscopic collapse associated with ductile failure is a result of internal degradation described throughout metallographic observations by the nucleation, growth and coalescence of voids and micro-cracks. Damage influences and is influenced by plastic deformation and therefore these two dissipative phenomena should be coupled at the constitutive level. In this contribution, Lemaitre's ductile damage model is coupled with Hill's orthotropic plasticity criterion. The coupling between damaging and material behavior is accounted for within the framework of Continuummore » Damage Mechanics (CDM). The resulting constitutive equations are implemented in the Abaqus/Explicit code, for the prediction of fracture onset in sheet metal forming processes. The damage evolution law takes into account the important effect of micro-crack closure, which dramatically decreases the rate of damage growth under compressive paths.« less
  • The experimental research on the formability of metal sheets has shown that there is a significant dispersion of the limit strains in an area delimited by two curves: a lower curve (LFLC) and an upper one (UFLC). The region between the two curves defines the so-called Forming Limit Band (FLB). So far, this forming band has only been determined experimentally. In this paper the authors suggested a method to predict the Forming Limit Band. The proposed method is illustrated on the AA6111-T43 aluminium alloy.
  • In terms of the intensive similarity between the sheet metal forming-springback process and that of the annealing of metals, it is suggested that the simulation of the sheet metal forming process is performed with the Nonlinear FEM and the springback prediction is implemented by solving the large-scale combinational optimum problem established on the base of the energy descending and balancing in deformed part. The BFGS-SA hybrid SA approach is proposed to solve this problem and improve the computing efficiency of the traditional SA and its capability of obtaining the global optimum solution. At the same time, the correlative annealing strategiesmore » for the SA algorithm are determined in here. By comparing the calculation results of sample part with those of experiment measurement at the specified sections, the rationality of the schedule of springback prediction used and the validity of the BFGS-SA algorithm proposed are verified.« less
  • In this study, a modified Johnson-Cook (J-C) model and an innovated method to determine (J-C) material parameters are proposed to predict more correctly stress-strain curve for tensile tests in elevated temperatures. A MATLAB tool is used to determine material parameters by fitting a curve to follow Ludwick's hardening law at various elevated temperatures. Those hardening law parameters are then utilized to determine modified (J-C) model material parameters. The modified (J-C) model shows the better prediction compared to the conventional one. As the first verification, an FEM tensile test simulation based on the isotropic hardening model for boron sheet steel atmore » elevated temperatures was carried out via a user-material subroutine, using an explicit finite element code, and compared with the measurements. The temperature decrease of all elements due to the air cooling process was then calculated when considering the modified (J-C) model and coded to VUMAT subroutine for tensile test simulation of cooling process. The modified (J-C) model showed the good agreement between the simulation results and the corresponding experiments. The second investigation was applied for V-bending spring-back prediction of magnesium alloy sheets at elevated temperatures. Here, the combination of proposed J-C model with modified hardening law considering the unusual plastic behaviour for magnesium alloy sheet was adopted for FEM simulation of V-bending spring-back prediction and shown the good comparability with corresponding experiments.« less
  • It is well established that ductile fracture occurs by nucleation, growth and coalescence of voids generally associated with particles. However, volume damage is present in the material at the first stage of the plastic deformation and, therefore, has an influence on the plastic behavior of the material. Metallographical observations and relative density change measurements show that there exist two main damage mechanisms: either decohesion at the particle-matrix interface or failure of the particles. In both cases, an analysis of the evolution of damage is performed and a model is proposed. A general law of void growth according to the strainmore » and strain path is then established for both damage mechanisms.« less