Investigation of advanced strain-path dependent material models for sheet metal forming simulations

Sheet metal forming processes often involve complex loading sequences. To improve the prediction of some undesirable phenomena, such as springback, physical behavior models should be considered. This paper investigates springback behavior predicted by advanced elastoplastic hardening models which combine isotropic and kinematic hardening and take strain-path changes into account. A dislocation-based microstructural hardening model formulated from physical observations and the more classical cyclic model of Chaboche have been considered in this work. Numerical implementation was carried out in the ABAQUS software using a return mapping algorithm with a combined backward Euler and semi-analytical integration scheme of the constitutive equations. The capability of each model to reproduce transient hardening phenomena at abrupt strain-path changes has been shown via simulations of sequential rheological tests. A springback analysis of strip drawing tests was performed in order to emphasize the impact of several influential parameters, namely: process, numerical and behavior parameters. The effect of the two hardening models with respect to the process parameters has been specifically highlighted.     

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.     

A reliability study of springback on the sheet metal forming process under probabilistic variation of prestrain and blank holder force

This work deals with a reliability assessment of springback problem during the sheet metal forming process. The effects of operative parameters and material properties, blank holder force and plastic prestrain, on springback are investigated. A generic reliability approach was developed to control springback. Subsequently, the Monte Carlo simulation technique in conjunction with the Latin hypercube sampling method was adopted to study the probabilistic springback. Finite element method based on implicit/explicit algorithms was used to model the springback problem. The proposed constitutive law for sheet metal takes into account the adaptation of plastic parameters of the hardening law for each prestrain level considered. Rackwitz-Fiessler algorithm is used to find reliability properties from response surfaces of chosen springback geometrical parameters. The obtained results were analyzed using a multi-state limit reliability functions based on geometry compensations.     

Path-dependence of the forming limit stresses in a sheet metal

The effect of changing strain paths on the forming limit stresses of sheet metals is investigated using the Marciniak–Kuczyński model and a phenomenological plasticity model with non-normality effects [Kuroda, M., Tvergaard, V., 2001. A phenomenological plasticity model with non-normality effects representing observations in crystal plasticity. J. Mech. Phys. Solids 49, 1239–1263]. Forming limits are simulated for linear stress paths and two types of combined loading: a combined loading consisting of two linear stress paths in which unloading is included between the first and second loadings (combined loading A), and combined loading in which the strain path is abruptly changed without unloading (combined loading B). The forming limit stresses calculated for combined loading A agree well with those calculated for the linear stress paths, while the forming limit curves in strain space depend strongly on the strain paths. The forming limit stresses calculated for the combined loading B do not, however, coincide with those calculated for the linear stress paths. The strain-path dependence of the forming limit stress is discussed in detail by observing the strain localization process.     

A new method for circular grid analysis in the sheet metal forming test

Computer vision systems are employed to determine the major and minor lengths of deformed elliptic grids while determining a sheet metal's workability. The existing method identifies the ellipse using the least squares analysis. It suffers two drawbacks: assumptions in direct conflict with the observed real-world processes and an undesirable property of orientation dependence. For the remedy, this paper presents a new method that, in addition to achieving the desired property of orientation invariance, discards assumptions that conflict with real-world processes. The proposed method is implemented and tested using simulated and real-world data. Results are reported and compared with those obtained by the existing method.     

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.     

Model identification and FE simulations: Effect of different yield loci and hardening laws in sheet forming

The bi-axial experimental equipment [Flores, P., Rondia, E., Habraken, A.M., 2005a. Development of an experimental equipment for the identification of constitutive laws (Special Issue). International Journal of Forming Processes] developed by Flores enables to perform Bauschinger shear tests and successive or simultaneous simple shear tests and plane strain tests. Flores investigates the material behavior with the help of classical tensile tests and the ones performed in his bi-axial machine in order to identify the yield locus and the hardening model. With tests performed on one steel grade, the methods applied to identify classical yield surfaces such as [Hill, R., 1948. A theory of the yielding and plastic flow of anisotropic materials. Proceedings of the Royal Society of London A 193, 281–297; Hosford, W.F., 1979. On yield loci of anisotropic cubic metals. In: Proceedings of the 7th North American Metalworking Conf. (NMRC), SME, Dearborn, MI, pp. 191–197] ones as well as isotropic Swift type hardening, kinematic Armstrong–Frederick or Teodosiu and Hu hardening models are explained. Comparison with the Taylor–Bishop–Hill yield locus is also provided. The effect of both yield locus and hardening model choices is presented for two applications: plane strain tensile test and Single Point Incremental Forming (SPIF).     

薄板冲压成型中板料起皱的临界应力分析和预测

针对薄板冲压成型中起皱这一常见的材料失效形式，运用板料压缩失稳理论，提出虚拟刚度变量的概念和板料产生起皱的临界应力计算方法，并借助于计算机仿真技术和有限元计算方法，搜寻并计算得到反映板料各处发生起皱难易程度的临界因子，生成起皱云图来观察材料各部分的稳定状态，预测可能出现起皱的部位，为修改冲压工艺和修模提供依据，通过分析起皱云图得出的结论与实际情况非常接近。     

Initiation and growth of wrinkling due to nonuniform tension in sheet metal forming

An experimental investigation was conducted on the initiation and growth of wrinkling due to nonuniform tension using the Yoshida buckling test. The initiation of wrinkling was detected by strain gages mounted on both surfaces of the samples in the loading and transverse directions. The bifurcation of aluminum auto body sheets appeared to be smooth and much less abrupt than that observed in a steel sheet. A special fixture was designed to, perhaps for the first time, continuously measure the in situ growth of the buckle heights so that the rates of buckle growth were monitored as functions of strain and stress in the loading direction. In contrast to what is commonly believed, it was found that the buckle height is not predominantly determined by the material yield strength, and lower averager value does not increase the rate of buckle growth. Crystallographic texture components and pole figures of the test materials were also measured, and the relationship of plastic anisotropy with wrinkling behavior was investigated by experiments with specimens aligned in the rolling direction, the transverse direction and 45-deg to the rolling direction of the sheet materials.     

Analysis of sheet metal formability through isotropic and kinematic hardening models

The present paper aims at analysing the sheet metal formability through several isotropic and kinematic hardening models. Specifically, a special attention is paid to the physically-based hardening model of Teodosiu and Hu (1995), which accounts for the anisotropic work-hardening induced by the microstructural evolution at large strains, as well as to some more conventional hardening models, including the isotropic Swift strain-hardening power law, and the Voce saturation strain-hardening law, combined with a non-linear kinematic hardening described by the Armstrong–Frederick law. The onset of localized necking is simulated by an advanced sheet metal forming limit model which connects, through the Marciniak–Kuczinsky analysis, the hardening models with the anisotropic yield criterion Yld2000-2d (Barlat et al., 2003). Both linear and complex strain paths are taken into account. The selected material is a DC06 steel sheet. The validity of each model is assessed by comparing the predicted forming limits with experimental results carefully obtained on this steel. The origin of discrepancy in the predicted results using different hardening models is thoroughly analyzed.     

On the implementation of anisotropic yield functions into finite strain problems of sheet metal forming

In this article the implementation of anisotropic yield functions into finite element investigations of orthotropic sheets with planar anisotropy is discussed within a plane-stress context. Special attention is focused on the proper treatment of the orientation of the anisotropic axes during deformation into the finite-strain range. As an example problem the hydrostatic bulging of a membrane is considered in conjunction with a recently proposed anisotropic yield function. It is shown that the aspects of the plane-stress assumption, which do not come into consideration in isotropic analyses, can play an important role on the accuracy of the solution when the rotation of the orthotropic axes enters the computation directly due to the presence of material anisotropy. When the material anisotropy is considered and when the deformation of the workpiece is not limited to the plane of the undeformed sheet (such as cup drawing, hydrostatic bulging, etc.), the numerical experiments indicate that the only correct formulation is the one based on numerically imposing the requirement that for the plane-stress application, the in-plane material axes have to remain in the plane of the sheet during the deformation.     

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.     

Marciniak–Kuczynski type modelling of the effect of Through-Thickness Shear on the forming limits of sheet metal

The Marciniak–Kuczynski (MK) forming limit model is extended in order to predict localized necking in sheet metal forming operations in which Through-Thickness Shear (TTS), also known as out-of-plane shear, occurs. An example of such a forming operation is Single Point Incremental Forming. The Forming Limit Diagram (FLD) of a purely plastic, isotropic hardening material with von Mises yield locus is discussed, for monotonic deformation paths that include TTS. If TTS is present in the plane containing the critical groove direction in the MK model, it is seen that formability is increased for all in-plane strain modes, except equibiaxial stretching. The increase in formability due to TTS is explained through a detailed study of some selected deformation modes. The underlying mechanism is a change of the stress mode in the groove that results in a delay of the onset of localized necking.     

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.     

Continuum thermodynamic formulation of models for electromagnetic thermoinelastic solids with application in electromagnetic metal forming

The purpose of this work is the formulation and application of a continuum thermodynamic approach to the phenomenological modeling of a class of engineering materials which can be dynamically formed using strong magnetic fields. This is carried out in the framework of a thermodynamic, internal-variable-based formulation in which the deformation, temperature and magnetic fields are in general coupled. This coupling takes the form of the Lorentz force as an additional supply of momentum, and the electromotive power as an additional supply of energy, in the material. In the current approach, the basic thermomechanical field relations for mass, momentum and moment of momentum are obtained from the total energy balance via invariance, and completed by Maxwells field equations. The constitutive formulation is based on the exploitation of the Müller-Liu entropy principle, here for the case of isotropic thermoelastic, viscoplastic material behaviour. The resulting reduced constitutive and field relations and restrictions are then applied to the modeling and simulation of high-speed electromagnetic forming of metal tubes and sheet metal. In this context, scaling arguments show that, over the relevant length- and timescales of engineering interest, the evolution of the magnetic field is diffusive in nature, and thermal conduction is negligible. Comparison of the simulation and experimental results for the final sheet metal form shows very good agreement.Received: 16 March 2004, Accepted: 6 May 2004, Published online: 17 September 2004PACS: 46.05. + b, 46.25.Hf, 46.35 + z Correspondence to: B. Svendsen     

基于概率和非概率混合模型的结构鲁棒设计方法

讨论了同时存在概率不确定性量和非概率不确定性量时可行鲁棒性和目标函数鲁棒性的实现策略,提出了基于概率和非概率混合模型的结构鲁棒设计方法。基本做法是首先视非概率型不确定性量为参变量,按照传统概率统计的方法计算约束函数和目标函数的均值和标准方差,然后再考虑非概率型不确定性量的波动变化对约束函数和目标函数统计特征量的影响,以修正常规可行鲁棒性和目标函数鲁棒性的数学模型。所提方法应用于一个10杆桁架结构的最轻质量设计和节点位移鲁棒设计,获得了对不确定性量波动变化不敏感的设计方案。     

Analytical and numerical analysis of sheet metal instability using a stress based criterion

Strain based Keeler–Goodwin diagrams are widely used in forming processes to predict onset of local necking. Plastic instability is determined once the forming limit strain is exceeded. Use of these diagrams requires proportional strain paths, which is not necessarily the case in sheet metal forming operations. In many forming processes, the strain path changes during deformation. This may change the forming limit curve significantly. In the paper, a stress based forming limit criterion is adopted to deal with strain path non-linearities. Comparisons with earlier published work on forming limits are made through analytical considerations. Furthermore, the criterion is implemented into the finite element code LS-DYNA and verified numerically against results from large scale bulge tests.     

基于ESGA遗传算法的水射流自驱旋转喷头优化设计

超高压水射流自驱旋转型喷头是目前广泛应用于船壁除锈的一种装置,其布局方式直接影响船壁除锈的效率和质量,目前喷头布局多依赖工程经验,缺少准确的理论分析和优化技术支持。针对水射流自驱旋转型喷头的布局优化问题,在传统遗传算法（genetic algorithm,GA）的基础上,提出一种基于“锦标赛选择”的精英策略遗传算法（elitist strategy genetic algorithm,ESGA）,该算法通过采用种群进化过程中精英个体直接保留到下一代的进化策略,从而有效提高算法的全局收敛能力和算法的鲁棒性。结合旋转喷头扫掠冲击性能和轨迹特征,以喷头移动路径垂直打击面上的能量分布均匀度为衡量标准,建立超高压水射流自驱旋转型喷头的螺旋扫掠冲击离散化时间优化模型,并分别利用两种遗传算法对其进行优化改进。对一字形水射流自驱旋转型喷头的布局优化研究发现,经ESGA算法优化的旋转喷头,其扫掠冲击能量分布均匀度较原喷头布局提升了47.2%,其收敛精度也高于GA算法。经对ESGA算法优化后的喷头实验验证发现,ESGA优化方案较原设计方案除锈效率提高了42.0%。改进的ESGA优化算法可行性强,能够在收敛...