Finite element simulation of sheet forming based on a planar anisotropic strain-rate potential

Many finite element (FEM) formulations have been based on stress potentials defined in the stress field. Nevertheless, there are formulations where potentials defined in the strain-rate field are especially convenient to implement. These include rigid-plastic formulations based on minimum plastic work paths, which can be used for process design as well as for process analysis. Based on a strain-rate potential recently proposed for anisotropic materials exhibiting orthotropic symmetry, a formulation for sheet forming process analysis has been developed using a Cartesian coordinate system in this paper. An efficient formulation to account for material rotation is also included. Earing predictions made for a cup drawing test of a 2090-T3 aluminum-lithium alloy sheet showed good agreement with experiments. However, some discrepancies were observed between predicted and experimental thickness strain and cup height directional trends. The cause of the discrepancies was discussed using a simple analysis based on Lankford (or plastic strain ratio, r) values.     

A finite element formulation based on non-associated plasticity for sheet metal forming

In the present paper, a finite element formulation based on non-associated plasticity is developed. In the constitutive formulation, isotropic hardening is assumed and an evolution equation for the hardening parameter consistent with the principle of plastic work equivalence is introduced. The yield function and plastic potential function are considered as two different functions with functional form as the yield function of Hill [Hill, R., 1948. Theory of yielding and plastic flow of anisotropic metals. Proc. Roy. Soc. A 193, 281–297] or Karafillis–Boyce associated model [Karafillis, A.P. Boyce, M., 1993. A general anisotropic yield criterion using bounds and a transformation weighting tensor. J. Mech. Phys. Solids 41, 1859–1886]. Algorithmic formulations of constitutive models that utilize associated or non-associated flow rule coupled with Hill or Karafillis–Boyce stress functions are derived by application of implicit return mapping procedure. Capabilities in predicting planar anisotropy of the Hill and Karafillis–Boyce stress functions are investigated considering material data of Al2008-T4 and Al2090-T3 sheet samples. The accuracy of the derived stress integration procedures is investigated by calculating iso-error maps.     

Spring-back evaluation of automotive sheets based on isotropic-kinematic hardening laws and non-quadratic anisotropic yield functions: Part II: characterization of material properties

In order to improve the prediction capability of spring-back in the computational analysis of automotive sheet forming processes, the modified Chaboche type combined isotropic-kinematic hardening law was formulated to account for the Bauschinger and transient behavior in Part I. As for the yield stress function, the non-quadratic anisotropic yield potential, Yld2000-2d, was utilized under the plane stress condition. Experimental procedures to obtain the material parameters of the combined hardening law and the yield potential are presented here in Part II for three automotive sheets: AA5754-O, AA6111-T4 and DP-Steel. The modified Chaboche model was confirmed to well represent the measured hardening behavior including the Bauschinger and transient behavior. While the theoretical and numerical formulations of the constitutive law are discussed in Part I, experimental verifications for spring-back of formed parts are further discussed in Part III.     

On the use of homogeneous polynomials to develop anisotropic yield functions with applications to sheet forming

This paper investigates the capabilities of several non-quadratic polynomial yield functions to model the plastic anisotropy of orthotropic sheet metal (plane stress). Fourth, sixth and eighth-order homogeneous polynomials are considered. For the computation of the coefficients of the fourth-order polynomial an improved set of analytic formulas is proposed. For sixth and eighth-order polynomials the identification uses optimization. Simple constraints on the optimization process are shown to lead to real-valued convex functions. A general method to extend the above plane stress criteria to full 3D stress states is also suggested. Besides their simplicity in formulation, it is found that polynomial yield functions are capable to model a wide range of anisotropic plastic properties (e.g., the Numisheet’93 mild steel, AA2008-T4, AA2090-T3). The yield functions have then been implemented into a commercial finite element code as constitutive subroutines. The deep drawing of square (Numisheet’93) and cylindrical (AA2090-T3) cups have been simulated. In both cases excellent agreement with experimental data is obtained. In particular, it is shown that non-quadratic polynomial yield functions can simulate cylindrical cups with six or eight ears. We close with a discussion on earing and further examples.     

Spring-back evaluation of automotive sheets based on isotropic-kinematic hardening laws and non-quadratic anisotropic yield functions: Part I: theory and formulation

In order to improve the prediction capability of spring-back in automotive sheet forming processes, the modified Chaboche type combined isotropic-kinematic hardening law was formulated based on the modified equivalent plastic work principle to account for the Bauschinger effect and transient behavior. As for the yield stress function, the non-quadratic anisotropic yield potential, Yld2000-2d, was utilized under the plane stress condition. Besides the theoretical aspect of the constitutive law including the general plastic work principle for monotonously proportional loading, the method to determine hardening parameters as well as numerical formulations to update stresses were developed based on the incremental deformation theory and the consistency requirement as summarized in Part I, while the characterization of material properties and verifications with experiments are discussed in Part II and III, respectively.     

Anisotropic strain hardening behavior in simple shear for cube textured aluminum alloy sheets

Finite element (FE) simulations of the simple shear test were conducted for 1050-O and 6022-T4 aluminum alloy sheet samples. Simulations were conducted with two different constitutive equations to account for plastic anisotropy: Either a recently proposed anisotropic yield function combined with an isotropic strain hardening law or a crystal plasticity model. The FE computed shear stress–shear strain curves were compared to the experimental curves measured for the two materials in previous works. Both phenomenological and polycrystal approaches led to results consistent with the experiments. These comparisons lead to a discussion concerning the assessment of anisotropic hardening in the simple shear test.     

增量型各向异性损伤理论与数值分析

考虑到目前各向异性损伤理论存在一些不足,该文在增量型各向异性损伤理论的框架下,引入二阶对称张量,构造四阶对称有效损伤张量,建立了有效应力方程．类似于塑性流动分析方法,定义了增量弹性应力．应变关系．利用von Mises塑性屈服准则,并考虑各向异性损伤效应,推导出四阶对称的弹．塑性变形损伤刚度张量,其对称性反映了材料的固有特性．根据物体的变形和现时损伤状态,构造了材料损伤演化方程,方程中各项具有明确的物理意义．通过对A12024-T3金属薄板单向拉伸的有限元分析,确定了损伤演化参数,验证了损伤演化方程的正确性．此外还对含孔口薄板做有限元模拟,讨论了反力—位移曲线的变化规律以及它所揭示变形性质,给出了损伤场的分布规律。     

A non-associated constitutive model with mixed iso-kinematic hardening for finite element simulation of sheet metal forming

In this paper an anisotropic material model based on non-associated flow rule and mixed isotropic–kinematic hardening was developed and implemented into a user-defined material (UMAT) subroutine for the commercial finite element code ABAQUS. Both yield function and plastic potential were defined in the form of Hill’s [Hill, R., 1948. A theory of the yielding and plastic flow of anisotropic metals. Proc. R. Soc. Lond. A 193, 281–297] quadratic anisotropic function, where the coefficients for the yield function were determined from the yield stresses in different material orientations, and those of the plastic potential were determined from the r-values in different directions. Isotropic hardening follows a nonlinear behavior, generally in the power law form for most grades of steel and the exponential law form for aluminum alloys. Also, a kinematic hardening law was implemented to account for cyclic loading effects. The evolution of the backstress tensor was modeled based on the nonlinear kinematic hardening theory (Armstrong–Frederick formulation). Computational plasticity equations were then formulated by using a return-mapping algorithm to integrate the stress over each time increment. Either explicit or implicit time integration schemes can be used for this model. Finally, the implemented material model was utilized to simulate two sheet metal forming processes: the cup drawing of AA2090-T3, and the springback of the channel drawing of two sheet materials (DP600 and AA6022-T43). Experimental cyclic shear tests were carried out in order to determine the cyclic stress–strain behavior and the Bauschinger ratio. The in-plane anisotropy (r-value and yield stress directionalities) of these sheet materials was also compared with the results of numerical simulations using the non-associated model. These results showed that this non-associated, mixed hardening model significantly improves the prediction of earing in the cup drawing process and the prediction of springback in the sidewall of drawn channel sections, even when a simple quadratic constitutive model is used.     

Analytical derivation of earing in circular cup drawing based on simple tension properties

In the circular cylindrical cup drawing process of sheet materials, an earing profile develops, incurred by the planar anisotropic properties of sheets. Therefore, proper analysis of earing in cup drawing is important to evaluate anisotropic properties and also to control the development of earing. Even though anisotropic properties are commonly measured in the simple tension test, deformation in circular cylindrical cup drawing is in a near plane strain mode (at the flange) so that numerical simulations utilizing yield functions are common practices to analyze earing. In this work, simplified analytical derivation of earing development in circular cylindrical cup drawing is proposed, based on two simple tension anisotropic properties: the yield stress and the r-value. Good performance of the analytical derivation was verified for AA2090-T3, which has strong anisotropy and six ears in cup drawing. Since the current approach directly utilizes measured simple tension data without involving any yield functions, computational cost is significantly lower. Besides, the current derivation can handle any set of detailed anisotropic measurements in the simple tension test, unlike numerical approaches involving yield functions, which need the development of sophisticated yield functions in the first place.     

A plane stress anisotropic plastic flow theory for orthotropic sheet metals

A phenomenological theory is presented for describing the anisotropic plastic flow of orthotropic polycrystalline aluminum sheet metals under plane stress. The theory uses a stress exponent, a rate-dependent effective flow strength function, and five anisotropic material functions to specify a flow potential, an associated flow rule of plastic strain rates, a flow rule of plastic spin, and an evolution law of isotropic hardening of a sheet metal. Each of the five anisotropic material functions may be represented by a truncated Fourier series based on the orthotropic symmetry of the sheet metal and their Fourier coefficients can be determined using experimental data obtained from uniaxial tension and equal biaxial tension tests. Depending on the number of uniaxial tension tests conducted, three models with various degrees of planar anisotropy are constructed based on the proposed plasticity theory for power-law strain hardening sheet metals. These models are applied successfully to describe the anisotropic plastic flow behavior of 10 commercial aluminum alloy sheet metals reported in the literature.     

Prediction of six or eight ears in a drawn cup based on a new anisotropic yield function

In this work, the recently proposed anisotropic yield function, Yld2004-18p [Barlat, F., Aretz, H., Yoon, J.W., Karabin, M.E., Brem, J.C., Dick, R.E., 2005. Linear transformation based anisotropic yield function, Int. J. Plasticity 21, 1009], is implemented in a finite element (FE) code for application to the cup drawing simulation of a circular blank sheet. A short review of the Yld2004-18p relevant features is provided and the stress integration scheme for its implementation in FE codes is described. The simulation of the drawing process is conducted for an aluminum alloy sheet sample (AA2090-T3). The predicted and experimental cup height profiles (earing profiles) with six ears are shown to be in excellent agreement. Additional simulations on a ficticious material are performed in order to show that the yield function Yld2004-18p can lead to the prediction of cups with eight ears. In order to achieve these results, a sufficient number of input data are required to calculate the yield function coefficients. Finally, a simplified analytical approach that relates the earing profile to the r-value directionality is also presented in this paper. It is shown that this approach can be very useful as a first approximation of the earing profile of drawn cups.     

Prediction of localized thinning in sheet metal using a general anisotropic yield criterion

The forming limit diagram (FLD) is a useful concept for characterizing the formability of sheet metal. The ability to accurately predict the FLD for a given material has been shown to depend on the shape of the selected yield function. In addition, both experimental and numerical results have shown that the level of the FLD is strongly strain path dependent. In this work, a combination of Marciniak–Kuczynski (M–K) analysis and a general anisotropic yield criterion developed by Karafillis and Boyce (Karafillis, A.P., Boyce, M.C., 1993. A general anisotropic yield criterion using bounds and transformation weighting tensor. J. Mech. Phys. Solids 41, 1859) is used to predict localized thinning of sheet metal alloys for linear and nonlinear strain paths. A new method for determining the constants in the yield criterion is proposed. The optimal values are obtained by fitting the initial yield stresses and calculated FLD under linear strain paths with the experimental measurement. Using this approach, accurate yield functions can be defined for both Al2008-T4 and Al6111-T4. Comparisons of computed FLDs with the experimental data of Graf and Hosford (Graf, A., Hosford, W.F., 1993b. Effect of changing strain paths on forming limit diagrams of Al 2008-T4. Metall. Trans. A. 24, 2503; Graf, A., Hosford, W.F., 1994. The influence of strain path changes on forming limit diagrams of Al 6111-T4. Int. J. Mech. Sci. 36, 897) show good agreements.     

A physically motivated anisotropic tensorial representation of damage with separate functions for void nucleation,growth, and coalescence

A phenomenological anisotropic damage progression formulation for porous ductile metals with second phases is described through mechanisms of void nucleation, growth and coalescence. The model is motivated from fracture mechanisms and microscale physical observations. To describe the creation of new pores, the decohesion at the particle–matrix interface and the fragmentation of second phase particles, the void-crack nucleation equation is related to several microstructural parameters (fracture toughness, length scale parameter, particle size, volume and fraction of second phase), the plastic strain level, and the stress state. Nucleation is represented by a general symmetric second rank tensor, and its components are proportional to the absolute value of the plastic strain rate components. Based on the Rice and Tracey model, void growth is a scalar function of the trace of damage tensor and the positive triaxiality. Like nucleation, coalescence is a second rank tensor governed by the plastic strain rate tensor and the stress state. The coalescence threshold is related to the void length scale for void impingement and void sheet mechanisms. The coupling of damage with the Bammann–Chiesa–Johnson (BCJ) plasticity model is written in the thermodynamic framework and derives from the concept of effective stress assuming the hypothesis of energy equivalence. A full-implicit algorithm is used for the stress integration and the determination of the consistent tangent operator. Finally, macroscale correlations to cast A356 AL alloy and wrought 6061-T6 AL alloy experimental data are completed with predictive void-crack evolution to illustrate the applicability of the anisotropic damage model.     

Prediction of forming limit curves using an anisotropic yield function with prestrain induced backstress

The Forming Limit Diagram (FLD), a plot of the maximum major principal strains that can be sustained by sheet materials prior to the onset of localized necking, is a useful concept for characterizing the formability of sheet metal. Both experimental and numerical results in the literature have shown that the level of the FLD is strongly strain path dependent and the prediction of FLD depends on the shape of the initial yield function and its evolution. In this work, to improve the accuracy of FLD prediction under nonlinear strain paths for a given material, the evolution of the yield function is proposed in terms of the changes of its center and its curvature. The center of the subsequent yield surface after preloading and unloading will be determined via a backstress tensor, and the curvature change will be reflected by changing the exponent in the yield function. Both parameters are functions of the effective plastic strain and will be determined using the forming limit strains obtained from two nonlinear tests. Using this approach, a combination of Marciniak–Kuczynski (M–K) analysis (Marciniak, Z., Kuczynski, K. 1967. Limit strains in the processes of stretch-forming sheet metal. Int. J. Mech. Sci. 9, 609.) and a general anisotropic yield criterion developed by Karafillis and Boyce (Karafillis, A.P., Boyce, M.C. 1993. A general anisotropic yield criterion using bounds and transformation weighting tensor, J. Mech. Phys. Solids, 41, 1859) is used to predict nonlinear FLDs of both Al2008-T4 and Al6111-T4. Excellent agreements were obtained between computed FLDs with the experimental data of Graf and Hosford (Graf, A., Hosford, W.F. 1993a. Calculations of forming limit diagrams for changing strain paths. Metall. Trans. A. 24, 2497; Graf, A., Hosford, W.F. 1993b. Effect of changing strain paths on forming limit diagrams of Al 2008-T4. Metall. Trans. A. 24, 2503; Graf, A., Hosford, W.F. 1994. The influence of strain path changes on forming limit diagrams of Al 6111-T4. Int. J. Mech. Sci. 36, 897). This prediction capability provides a powerful tool in the design and optimization process of 3D sheet metal forming where strain path changes are inevitable.     

用损伤理论方法预测铝合金薄板成型极限

应用各向异性损伤理论研究2024-T3铝合金薄板的成形极限,通过构造有限元单胞模型预测薄板结构的极限应变.单胞模型由两相材料组成:铝合金基体和金属强化物.基体采用全耦合弹塑性-损伤本构方程描述,而金属强化物则视为弹脆性材料.采用所提出的缩颈准则,得到了双轴拉伸状态下铝合金薄板的极限应变,和实验结果比较两者吻合较好.研究结果揭示有限元单胞模型可以提供铝合金的细观损伤机理信息,当忽略材料的损伤影响,采用金属薄板成型理论的研究结果将过高估计薄板的极限应变.     

A hybrid membrane/shell method for calculating springback of anisotropic sheet metals undergoing axisymmetric loading

To reduce the computation cost of finite element analyses aiding die design for sheet metal stamping, a hybrid membrane/shell method was developed to determine the springback of anisotropic sheet metal undergoing axisymmetric loading. The hybrid membrane/shell method uses a membrane model to analyze the stamping operation. The bending/unbending strains and stresses varying through thickness are calculated analytically from the incremental shape determined by the membrane analysis. These bending strains and stresses and the final membrane shape are used with a shell finite element model to unload the sheet and calculate springback. The accuracy of the springback prediction with the hybrid method was verified against the springback of 2036-T4 aluminum and a DQAK steel sheet drawn into a cup. It was found that, in comparison with a full shell model, a minimum of 50% CPU time saving and a comparable accuracy was achieved when the hybrid method was used to predict springback.     

Experimental and numerical study on formability of friction stir welded TWB sheets based on hemispherical dome stretch tests

In order to investigate formability performance and also to obtain guidelines for the stamping process design of friction stir welded TWB (tailor welded blank) sheets, the hemispherical dome stretching test was experimentally performed and the results of the base and friction stir welded samples were compared. Also, in order to better understand the experimental results, numerical analysis was performed. In this work, five automotive sheets, 6111-T4, 5083-H18, 5083-O aluminum alloy, dual-phase steel (DP590) and AZ31 magnesium alloy sheets were considered by (friction stir) welding the same materials. To represent mechanical properties for the numerical analysis, the non-quadratic orthotropic yield function, Yld2000-2d, was utilized for the aluminum alloy and DP590 sheets, while the Cazacu anisotropic/asymmetric yield function was applied for the AZ31 sheet considering different hardening behavior in tension and compression.     

两种各向异性材料界面共线裂纹的反平面问题

本文研究两种各向异性材料界面共线裂纹的反平面剪切问题。利用复变函数方法，提出了一般问题公式和某些实际重要问题的封闭形式解。考察了裂纹尖端附近的应力分布并给出了应力强度因子公式。从本文解签的特殊情形，可以直接导出两种各向同性材料界面裂纹，均匀各向异性材料共线裂纹以及均匀各向同性材料共线裂纹的相应问题公式，其中包括已有的经典结果。