各向异性本构关系在板料成形数值模拟中的应用

对几种能表达面内各向异性的屈服准则Hill、Barlat-Lian、Barlat进行了比较。以弹性变形服从各向同性广义虎克定律的情况下，给出了基于张量算法推导的弹塑性本构关系的一般表达式，并由此导出了相应屈服准则的弹塑性本构关系的显式表达。借助ABAQUS软件本构模块用户子程序接口，分别实现了这些屈服准则在ABAQUS的嵌入。以模拟方形盒的拉延过程为例，分析了不同的屈服准则在板料成形过程数值模拟中的应用。模拟结果表明，基于弹塑性本构关系一般表达所列出的相应屈服准则的显式表达式是正确的；在采用壳元来模拟板料成形时，采用Barlat准则的模拟结果和采用Barlat-Lian准则的结果差别不大。     

织构可调塑性本构模型标定及其应用

提出了利用率相关晶体塑性模型标定织相可调本构模型的求解步骤,得出了一组依赖于晶粒间相互作用假设而独立于具体板材织构的本构相关系数.以此为基础再结合板材织构系数所得出的本构模型系数可避免出现屈服面非外凸的情形.利用所提求解步骤对在不同热处理条件下产生不同织构的AL5052铝合金板的深拉成形过程进行了有限元模拟.结果再现了典型织构在板材成形过程中所出现的塑性各向异性,从而表明求解步骤的可行性.     

基于非关联流动规律的Gotoh屈服准则的参数确定方法

屈服准则对板料成形过程的理论解析、工艺优化和有限元模拟有着重要的影响. 通过提高屈服准则的各向异性表征能力, 可以确保成形过程的可靠性及实际预测的准确性. 本文基于非关联流动法则, 给出了Gotoh屈服准则一套全新的参数求解方法. 在结合常用屈服准则并考虑流动规律的基础上, 分别以5754O铝合金、DP980先进高强钢和SAPH440结构钢作为研究对象, 进行了不同加载路径下各向异性变形行为的预测. 根据Gotoh屈服准则推导的屈服函数、塑性势函数以及基于关联流动的理论函数计算出屈服应力和各向异性指数$r$值随加载角度的分布趋势, 进而针对平面应力状态的屈服轨迹展开分析, 验证了不同屈服准则和流动规律对各向异性屈服行为的预测精度. 理论与实验数据对比结果表明: 不同屈服准则针对同种板料在流动规律一致的情形下其表征各向异性的能力有显著差异; 相同屈服准则基于不同流动规律其表征能力也具有明显差别. 基于非关联流动的屈服准则能极大地提高精度, 各向异性表征能力显著加强. 相关结果能够为各向异性屈服准则在塑性成形领域的实际应用方案提供重要参考.      

基于非关联流动规律的Gotoh屈服准则的参数确定方法

屈服准则对板料成形过程的理论解析、工艺优化和有限元模拟有着重要的影响.通过提高屈服准则的各向异性表征能力,可以确保成形过程的可靠性及实际预测的准确性.本文基于非关联流动法则,给出了Gotoh屈服准则一套全新的参数求解方法.在结合常用屈服准则并考虑流动规律的基础上,分别以5754O铝合金、DP980先进高强钢和SAPH440结构钢作为研究对象,进行了不同加载路径下各向异性变形行为的预测.根据Gotoh屈服准则推导的屈服函数、塑性势函数以及基于关联流动的理论函数计算出屈服应力和各向异性指数r值随加载角度的分布趋势,进而针对平面应力状态的屈服轨迹展开分析,验证了不同屈服准则和流动规律对各向异性屈服行为的预测精度.理论与实验数据对比结果表明:不同屈服准则针对同种板料在流动规律一致的情形下其表征各向异性的能力有显著差异;相同屈服准则基于不同流动规律其表征能力也具有明显差别.基于非关联流动的屈服准则能极大地提高精度,各向异性表征能力显著加强.相关结果能够为各向异性屈服准则在塑性成形领域的实际应用方案提供重要参考.     

考虑运动硬化的DD3镍基合金力学行为研究

详细介绍了镍基合金的晶体塑性本构模型,在Asaro大变形晶体塑性框架下,详细介绍了镍基合金的晶体塑性本构模型,在Asaro大变形晶体塑性框架下,引入了运动硬化规律,考虑了温度和应变率对晶体塑性变形的影响,通过针对每个滑移系考虑屈服准则和流动规律建立了晶体塑性模型. 对积分过程进行了推导,通过编写ABAQUS材料用户子程序(UMAT), 实现本构模型的有限元积分算法. 在此基础上模拟了DD3镍基单晶合金在单轴拉伸和循环载荷下的响应,并与实验数据进行了对比. 利用该模型可以很好地模拟镍基单晶所具有的各向异性特性,体现了镍基单晶在循环载荷作用下的拉-压不对称性.      

各向异性屈服准则的发展及实验验证综述

鉴于材料的屈服行为对板料成形的重要性, 人们对各向异性屈服准则进行了长期研究. 本文对各向异性屈服准则的发展进行了较为全面的回顾, 对Hill系列、Hosford系列和Drucker系列3类屈服准则分别进行归纳. 重点介绍不同类型屈服准则的适用范围及缺陷, 总结目前国内外所采用的不同的实验验证方法, 最后指出各向异性屈服准则在数值模拟中应用的难点及今后的研究方向.      

金属成形过程中的塑性失稳

本文评述了金属成形过程中塑性失稳现象(剪切带、颈缩、皱曲)研究的最新进展和仍存在的问题,着重讨论了塑性失稳预报和本构关系选择的密切关系,指出了塑性失稳预报结果取决于所选择的本构关系。还讨论了材料各向异性、应变率敏感性、不均匀性及其幅度、惯性等因素对塑性失稳的影响。除此之外,对作为分析塑性失稳的基本理论工具——Hill分叉准则亦作了简要讨论。      

准脆性材料的弹塑性各向异性损伤耦合本构模型研究

针对准脆性材料的非线性特征：强度软化和刚度退化、单边效应、侧限强化和拉压软化、不可恢复变形、剪胀及非弹性体胀,在热动力学框架内,建立了准脆性材料的弹塑性与各向异性损伤耦合的本构关系。对准脆性材料的变形机理和损伤诱发的各向异性进行了诠释,并给出了损伤构形和有效构形中各物理量之间的关系。在有效应力空间内,建立了塑性屈服准则、拉压不同的塑性随动强化法则和各向同性强化法则。在损伤构形中,采用应变能释放率,建立了拉压损伤准则、拉压不同的损伤随动强化法则和各向同性强化法则。基于塑性屈服准则和损伤准则,构建了塑性势泛函和损伤势泛函,并由正交性法则,给出了塑性和损伤强化效应内变量的演化规律,同时,联立塑性屈服面和损伤加载面,给出了塑性流动和损伤演化内变量的演化法则。将损伤力学和塑性力学结合起来,建立了应变驱动的应力-应变增量本构关系,给出了本构数值积分的要点。以单轴加载-卸载往复试验识别和校准了本构材料常数,并对单轴单调试验、单轴加载-卸载往复试验、二轴受压、二轴拉压试验和三轴受压试验进行了预测,并与试验结果作了比较,结果表明,所建本构模型对准脆性材料的非线性材料性能有良好的预测能力。     

考虑细观变形特征的镁合金宏观本构模型及数值模拟

为了能有效描述镁合金宏观各向异性塑性行为,考虑了滑移、孪生、去孪生三种细观变形模式的特点,给出了相应的硬化函数;根据VonMises屈服准则,发展了一种镁合金宏观本构模型及其迭代算法。模型将变形模式的开启与晶粒取向相关联,同时针对镁合金孪生变形时引起的晶粒重新定向问题,描述了一种晶向偏转的方法。在此基础上编写了ABAQUS/UMAT材料用户子程序;利用开发的本构模型,开展了单轴拉伸、单轴压缩、单轴循环拉压加载条件下镁合金塑性行为的数值模拟,并对随机织构下的镁合金板材轧制过程进行了有限元仿真实验。模拟结果表明:单轴拉伸、单轴压缩和循环加载情形下的镁合金宏观硬化行为与实验结果基本吻合;轧制后镁合金板材表现出了应力-应变不均匀特性,多晶织构演化结果与实验结果基本一致。说明文中所提出的宏观本构模型、晶向偏转模型能够有效描述镁合金的宏观塑性行为和织构演化。     

超高强度钢AF1410塑性流动特性及其本构关系

在本文中,为揭示超高强度钢AF1410的塑性流动性,并研究其塑性流动本构关系,利用CSS4410电子万能试验机和改进的Hopkinson拉压杆技术,对AF1410钢在温度从100K到600K,应变率从0.001/s到2000/s,塑性应变超过20%的塑性流动特性进行了试验研究。结果表明,拉伸加载下AF1410钢屈服强度低于压缩屈服强度,且随应变率增加,拉压屈服强度差值越来越大;该材料塑性流动应力对应变率敏感性低,而对温度较为敏感;随应变率的提高,该材料拉伸失效应变减小,但温度对失效应变无明显影响。最后基于位错的运动学关系,借助试验数据,获得了AF1410钢的塑性流动物理概念本构模型,并通过与经典J-C模型的结果对比对该物理概念本构模型进行了评估分析,表明该物理概念本构模型在较宽温度和应变率范围能较好的预测AF1410钢的塑性流动应力。     

Finite element modeling of plastic anisotropy induced by texture and strain-path change

Consideration of plastic anisotropy is essential in accurate simulations of metal forming processes. In this study, finite element (FE) simulations have been performed to predict the plastic anisotropy of sheet metals using a texture- and microstructure-based constitutive model. The effect of crystallographic texture is incorporated through the use of an anisotropic plastic potential in strain-rate space, which gives the shape of the yield locus. The effect of dislocation is captured by use of a hardening model with four internal variables, which characterize the position and the size of the yield locus. Two applications are presented to evaluate the accuracy and the efficiency of the model: a cup drawing test and a two-stage pseudo-orthogonal sequential test (biaxial stretching in hydraulic bulging followed by uniaxial tension), using an interstitial-free steel sheet. The experimental results of earing behavior in the cup drawing test, maximum pressure and strain distribution in bulging, and transient hardening in the sequential test are compared against the FE predictions. It is shown that the current model is capable of predicting the plastic anisotropy induced by both the texture and the strain-path change. The relative significance of texture and strain-path change in the predictions is discussed.     

PREDICTION OF EARING IN TEXTURED ALUMINIUM SHEETS BASED ON CRYSTAL PLASTICITY

The phenomenon of earing is investigated in the present study based on the theory of crystal plasticity with the dynamic explicit finite element program developed. Firstly texture analysis is carried out of rolled aluminium alloy Al5052 by means of X-ray technique. Then from the texture coefficients an analytical expression for the orientation distribution function (ODF) is derived making use of the computer algebraic language Mathematica4.0, which makes it easier to discretize the ODF into a series of Eulerian angles representing the distribution of lattices and further the preferred orientation (texture) of crystals of the original sheets. For the polycrystal model, the material is described using crystal plasticity where each material point in grains with each grain modelled as an FCC crystal with 12 distinct slip systems. The modified Taylor theory of crystal plasticity is used and only the initial texture is taken into consideration during large plastic deformation. Numerical simulation of earing has been performed for an aluminium sheet with texture and one with crystals exhibiting random distribution to demonstrate the effect of texture of materials on their plastic anisotropy and formability. Project supported by the National Natural Science Foundation of China (No. 59875025).     

An extended Marciniak-Kuczynski model for anisotropic sheet subjected to monotonic strain paths with through-thickness shear

Some metal sheet forming processes may induce an amount of plastic shear over the sheet thickness. This paper investigates how formability of anisotropic sheet metal is affected by such through-thickness shear (TTS). The Marciniak-Kuczynski (MK) model framework, a commonly used analytical tool to predict the limit of sheet formability due to the onset of localized necking, is extended in this paper in order to explicitly account for TTS in anisotropic metal sheets. It is a continuation of previous work by the present authors (Eyckens et al., 2009), in which TTS is incorporated for isotropic sheet. This is achieved by the introduction of additional force equilibrium and geometric compatibility equations that govern the connection between matrix and groove in the MK model. Furthermore, in order to integrate plastic anisotropy, a material reference frame available in recent literature is incorporated, as well as a particular model for anisotropic yielding that relies on virtual testing of anisotropic properties (Facet plastic potential), since out-of-plane anisotropy related to TTS cannot be measured experimentally.It is found that formability may be increased by TTS, depending on the direction onto which it is imposed by the forming process. TTS is thus a relevant aspect of the formability in, for instance, sheet forming processes in which sliding contact with friction between sheets and forming tools occur.     

NUMERICAL SIMULATION OF NON-PLANAR PLASTIC ANISOTROPY OF COLD ROLLING POLYCRYSTALLINE MATERIALS

The plastic anisotropy of sheet metal is usually caused by preferred orientation of grains, developed by mechanical deformation and thermal treatment. In the present study, a Taylor-like polycrystal model suggested by Asaro and Needleman is applied to investigate the evolution of the anisotropic behavior of a face centered cubic (FCC) polycrystalline metal, which is considered having {111} (110) slip systems, by stretching it along an arbitrary direction after it has undergonea plane-strata compression that rationally simulates the cold rolling process of FCC polycrystalline pure aluminium. By using the Taylor-like polycrystal model, pole figures are obtained to describe the texture development of polycrystalline aggregate after plane-strain compression, and then the plastic anisotropy of polycrystalline aggregate is evaluated by stretching the polycrystalline aggregate in different direction in term of yield stress. According to the results, the contours of longitudinal flow stress in three-dimensional orientation space are given and analyzed. Experiment results similar to the prediction of planar anisotropy can be found inthe literature written by Takahashi et al. that in directly show the correctness of the prediction of non-planar plastic anisotropy by this analysis.     

Texture development and plastic anisotropy of B.C.C. strain hardening sheet metals

A Taylor-like polycrystal model is adopted here to investigate the plastic behavior of body centered cubic (b.c.c.) sheet metals under plane-strain compression and the subsequent in-plane biaxial stretching conditions. The <111> pencil glide system is chosen for the slip mechanism for b.c.c. sheet metals. The {110} <111> and {112} <111> slip systems are also considered. Plane-strain compression is used to simulate the cold rolling processes of a low-carbon steel sheet. Based on the polycrystal model, pole figures for the sheet metal after plane-strain compression are obtained and compared with the corresponding experimental results. Also, the simulated plane-strain stress—strain relations are compared with the corresponding experimental results. For the sheet metal subjected to the subsequent in-plane biaxial stretching and shear, plastic potential surfaces are determined at a given small amount of plastic work. With the assumption of the equivalence of the plastic potential and the yield function with normality flow, the yield surfaces based on the simulations for the sheet metal are compared with those based on several phenomenological planar anisotropic yield criteria. The effects of the slip system and the magnitude of plastic work on the shape and size of the yield surfaces are shown. The plastic anisotropy of the sheet metal is investigated in terms of the uniaxial yield stresses in different planar orientations and the corresponding values of the anisotropy parameter R, defined as the ratio of the width plastic strain rate to the through-thickness plastic strain rate under in-plane uniaxial tensile loading. The uniaxial yield stresses and the values of R at different planar orientations from the polycrystal model can be fitted well by a yield function recently proposed by Barlat et al. (1997b).     

On the use of a reduced enhanced solid-shell (RESS) element for sheet forming simulations

A recently proposed reduced enhanced solid-shell (RESS) element [Alves de Sousa, R.J., Cardoso, R.P.R., Fontes Valente, R.A., Yoon, J.W., Grácio, J.J., Natal Jorge, R.M., 2005. A new one-point quadrature enhanced assumed strain (EAS) solid-shell element with multiple integration points along thickness: Part I – Geometrically Linear Applications. International Journal for Numerical Methods in Engineering 62, 952–977; Alves de Sousa, R.J., Cardoso, R.P.R., Fontes Valente, R.A., Yoon, J.W., Grácio, J.J., Natal Jorge, R.M., 2006. A new one-point quadrature enhanced assumed strain (EAS) solid-shell element with multiple integration points along thickness: Part II – Nonlinear Applications. International Journal for Numerical Methods in Engineering, 67, 160–188.] is based on the enhanced assumed strain (EAS) method with a one-point quadrature numerical integration scheme. In this work, the RESS element is applied to large-deformation elasto-plastic thin-shell applications, including contact and plastic anisotropy. One of the main advantages of the RESS is its minimum number of enhancing parameters (only one), which when associated with an in-plane reduced integration scheme, circumvents efficiently well-known locking phenomena, leading to a computationally efficient performance when compared to conventional 3D solid elements. It is also worth noting that the element accounts for an arbitrary number of integration points through thickness direction within a single element layer. This capability has proven to be efficient, for instance, for accurately describing springback phenomenon in sheet forming simulations. A physical stabilization procedure is employed in order to correct the element’s rank deficiency. A general elasto-plastic model is also incorporated for the constitutive modelling of sheet forming operations with plastic anisotropy. Several examples including contact, anisotropic plasticity and springback effects are carried out and the results are compared with experimental data.     

The effect of plastic anisotropy on compressive instability in sheet metal forming

The wrinkling behavior of a thin sheet with perfect geometry is associated with compressive instability. The compressive instability is influenced by many factors such as stress state, mechanical properties of the sheet material, geometry of the body, contact conditions and plastic anisotropy. The analysis of compressive instability in a plastically deforming body is difficult considering all the factors because the effects of the factors are very complex and the instability behavior may show a wide variation for a small deviation of the factors. In this study, the bifurcation theory is introduced for the finite element analysis of puckering initiation and growth of a thin sheet with perfect geometry. All the above mentioned factors are conveniently considered by the finite-element method. The instability limit is found by the incremental analysis and the post-bifurcation behavior is analyzed by introducing the branching scheme proposed by Riks. The finite-element formulation is based on the incremental deformation theory and elastic–plastic material modeling. The finite-element analysis is carried out using the continuum-based resultant shell elements considering the anisotropy of the sheet metal. In order to investigate the effect of plastic anisotropy on the compressive instability, a square plate that is subjected to compression in one direction and tension in the other direction is analyzed by the above-mentioned finite-element analysis. The critical stress ratios above which buckling does not take place are found for various plastic anisotropic modeling methods and discussed. Finally, the effect of plastic anisotropy on the puckering behavior in the spherical cup deep drawing process is investigated. From the results of the finite-element analysis, it is shown that puckering behavior of sheet metal is largely affected by plastic anisotropy.