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Title: Edge Fracture Prediction ofTraditional and Advanced Trimming Processes for AA6111-T4 Sheets

This work examines the traditional and advanced trimming of AA6111-T4 aluminum sheets with finite element simulations. The Rice-Tracy damage model is used for the simulation with damage parameters estimated from experimental observation of grain aspect ratio near the fracture surface of trimmed parts. Fine meshes at the shearing zone, adaptive meshing, and adaptive contact techniques are used to accurately capture the contact interactions between the sharp corner of the trimming tools and the blank to be trimmed. To the knowledge of the authors, these are the first trimming simulations that can predict the effects of shearing clearance on burr heights with quantitative accuracy for AA6111-T4 aluminum sheets. In addition, the models have also accurately reproduced the crack initiation site as well as burr and sliver formation mechanisms observed experimentally.
Authors:
; ; ;
Publication Date:
OSTI Identifier:
1132664
Report Number(s):
PNNL-SA-93147
VT0505000
DOE Contract Number:
AC05-76RL01830
Resource Type:
Journal Article
Resource Relation:
Journal Name: Journal of Manufacturing Science and Engineering, 136(2):Article No. 021016
Research Org:
Pacific Northwest National Laboratory (PNNL), Richland, WA (US)
Sponsoring Org:
USDOE
Country of Publication:
United States
Language:
English
Subject:
Aluminum Alloys; Finite Element Method; Cutting; Formability; Edge Damage; Adaptive Contact.