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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}
}