Stress integration method for a nonlinear kinematic/isotropic hardening model and its characterization based on polycrystal plasticity

Sheet metal forming processes generally involve non-proportional strain paths including springback, leading to the Bauschinger effect, transient hardening, and permanent softening behavior, that can be possibly modeled by kinematic hardening laws. In this work, a stress integration procedure based on the backward-Euler method was newly derived for a nonlinear combined isotropic/kinematic hardening model based on the two-yield’s surfaces approach. The backward-Euler method can be combined with general non-quadratic anisotropic yield functions and thus it can predict accurately the behavior of aluminum alloy sheets for sheet metal forming processes. In order to characterize the material coefficients, including the Bauschinger ratio for the kinematic hardening model, one element tension–compression simulations were newly tried based on a polycrystal plasticity approach, which compensates extensive tension and compression experiments. The developed model was applied for a springback prediction of the NUMISHEET’93 2D draw bend benchmark example.     

Finite element modeling of tube hydroforming of polycrystalline aluminum alloy extrusions

Finite element modeling of tube hydroforming requires information about the anisotropy of the extruded aluminum tube. Unlike sheet metals, the complex geometry of extruded tubes makes it difficult, except in extrusion direction, to directly measure material properties. Therefore, polycrystalline models provide a good alternative for calculating the anisotropy of the tube in all directions and under various loading conditions. Using a rate-independent single crystal yield surface and rigid plasticity, a Taylor-type polycrystalline model was developed and implemented into ABAQUS/Explicit finite element (FE) code using VUMAT. The constitutive model was then used to calculate the crystallographic texture evolution during the hydroforming of an extruded aluminum tube. Initial crystallographic texture measured using orientation imaging microscopy (OIM) and uniaxial tensile test data obtained along the extrusion direction were input to this FEA model. In order to efficiently and practically simulate the tube hydroforming process using the polycrystalline model, sensitivity to the number of grain orientation, total simulation time, and number of finite elements were studied. Predicted results agreed very well with experimentally measured strain obtained from tube hydroforming process.     

Advances in experiments on metal sheets and tubes in support of constitutive modeling and forming simulations

This work is a review of experimental methods for observing and modeling the anisotropic plastic behavior of metal sheets and tubes under a variety of loading paths, such as biaxial compression tests; biaxial tension tests on metal sheets and tubes using closed-loop electrohydraulic testing machines; the abrupt strain path change method for detecting a yield vertex and subsequent yield loci without unloading; in-plane stress reversal tests on metal sheets; and multistage tension tests. Observed material responses are compared with the predictions of phenomenological plasticity models. Special attention is paid to the plastic deformation behavior of materials commonly used in industry, and to verifying the validity of conventional anisotropic yield criteria for those materials and associated flow rules at large plastic strains. The effects of using appropriate anisotropic yield criteria on the accuracy of simulations of forming defects, such as large springback and fracture, are also presented to highlight the importance of accurate material testing and modeling.     

A novel yield function for single crystals based on combined constraints optimization

A novel yield function representing the overall plastic deformation in a single crystal is developed using the concept of optimization. Based on the principle of maximum dissipation during a plastic deformation, the problem of single crystal plasticity is first considered as a constrained optimization problem in which constraints are yield functions for slip systems. To overcome the singularity that usually arises in solving the above problem, a mathematical technique is used to replace the above constrained optimization problem with an equivalent problem which has only one constraint. This single constraint optimization problem, the so-called combined constraints crystal plasticity (CCCP) model, is implemented into a finite element code and the results of modeling the uniaxial tensions of the single crystal copper along different crystallographic directions and also hydroforming of aluminum tubes proved the capability of the proposed CCCP model in accurately predicting the deformation in polycrystalline materials.     

A split Hopkinson bar technique for low-impedance materials

An experimental technique that modifies the conventional split Hopkinson pressure bar has been developed for measuring the compressive stress-strain responses of materials with low mechanical impedance and low compressive strengths such as elastomers at high strain rates. A high-strength aluminum alloy was used for the bar materials instead of steel, and the transmission bar was hollow. The lower Young's modulus of the aluminum alloy and the smaller cross-sectional area of the hollow bar increased the amplitude of the transmitted strain signal by an order of magnitude as compared to a conventional steel bar. In addition, a pulse shaper lengthened the rise time of the incident pulse to ensure stress equilibrium and homogeneous deformation in the low-impedance specimen. Experimental results show that the high strain rate, compressive stress-strain behavior of an elastomeric material can be determined accurately and reliably using this technique.     

Forming of aluminum alloys at elevated temperatures – Part 2: Numerical modeling and experimental verification

The temperature-dependent Barlat YLD96 anisotropic yield function developed previously [Forming of aluminum alloys at elevated temperatures – Part 1: Material characterization. Int. J. Plasticity, 2005a] was applied to the forming simulation of AA3003-H111 aluminum alloy sheets. The cutting-plane algorithm for the integration of a general class of elasto-plastic constitutive models was used to implement this yield function into the commercial FEM code LS-Dyna as a user material subroutine (UMAT). The temperature-dependent material model was used to simulate the coupled thermo-mechanical finite element analysis of the stamping of an aluminum sheet using a hemispherical punch under the pure stretch boundary condition. In order to evaluate the accuracy of the UMAT’s ability to predict both forming behavior and failure locations, simulation results were compared with experimental data performed at several elevated temperatures. Forming limit diagrams (FLDs) were developed for the AA3003-H111 at several elevated temperatures using the M-K model in order to predict the location of the failure in the numerical simulations. The favorable comparison found between the numerical and experimental data shows that a promising future exists for the development of more accurate temperature-dependent yield functions to apply to thermo-hydroforming process.     

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.     

The biaxial loading response of powder aluminum at elevated temperature

Nuclear fuel can be fabricated using powder-metallurgy processes by compacting uranium-oxide powder with aluminum powder to form a cermet and then extruding the cermet to form fuel tubes. This method of production allows greater control of uranium-oxide particle size and distribution in the tube, making the production of fuel with greater concentrations of uranium oxide possible, and thus decreasing the volume of radioactive waste remaining after the fuel is spent. As the concentration of uranium oxide increases, however, there is an increase in failures during extrusion. To address this problem, an experimental procedure was developed to examine the response of powder aluminum, a material with a structure similar to that of the cermet fuel, to biaxial loadings such as those experienced during extrusion. Biaxial loadings can be varied from pure shear to simple tension or compression, or to combinations of these loadings in a numerically controlled ‘tension-torsion’ testing machine. Data obtained using this system were used to develop a model for the post-yield behavior in extruded powder aluminum which includes information derived both from the macroscopic stress-strain behavior of 1100 aluminum and extruded powder aluminum and from the observed microscopic structure of the extruded powder aluminum. This paper describes the development of the experimental system and shows the different biaxial mechanical behavior of the two materials. Test fixtures were developed and software was written to control constant strain-rate tension, compression, torsion, combined tension-torsion, and combined compression-torsion tests performed using a computer-controlled MTS biaxial testing machine. Extruded powder aluminum and 1100 aluminum specimens were tested at 427°C, the powder-aluminum extrusion temperature, under those loading conditions. Each specimen was subjected to only one loading cycle. Data were recorded during loading only. Tested specimens were also sectioned and examined microscopically.     

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.     

Impact failure of granular materials – Non-equilibrium multiscale simulations and high-speed experiments

We present results of high-speed impact experiments on aluminum oxide (Al₂O₃) and silicon carbide (SiC) ceramics and propose a mesoscopic way to model the fracture behavior of these brittle materials based on discrete particles. The two-dimensional model used here has only three adjustable parameters, but is able of reproducing many salient features of the investigated ceramics under compressive, tensile and shock impact load. We discuss our particle model in detail and then consider strain and shear load simulations. In particular, we model explicitly the macroscopic experimental set-up of the edge-on impact experiment and show that the experimentally observed crack patterns can in principle be explained by the random distribution of particle overlaps and the thereby generated differences in the local strength of the material.     

Instability and failure of internally pressurized ductile metal cylinders

Forlong, ductile, thick-walled tubes under internal pressure instabilities and final failure modes are studied experimentally and theoretically. The test specimens are closed-end cylinders made of an aluminum alloy and of pure copper and the experiments have been carried out for a number of different initial external radius to internal radius ratios. The experiments show necking on one side of the tubes at a stage somewhat beyond the maximum internal pressure. All tubes, except for one aluminum alloy tube, failed by shear fracture under decreasing pressure. The aluminum alloy tubes exhibited localized shear deformations in the neck region prior to fracture and also occasionally surface wave instabilities. The numerical investigation is based on an elastic-plastic material model for a solid that develops a vertex on the yield surface, using representations of the uniaxial stress-strain curves found experimentally. In contrast to the simplest flow theory of plasticity this material model predicts shear band instabilities at a realistic level of strain. A rather sharp vertex is used in the material model for the aluminum alloy, while a more blunt vertex is used to characterize copper. The theoretically predicted bifurcation into a necking mode, the cross-sectional shape of the neck, and finally the initiation and growth of shear bands from the highly strained internal surface in the neck region are in good agreement with the experimental observations.     

Modeling the effects of material non-linearity using moving window micromechanics

In the analysis of materials with random heterogeneous microstructure the assumption is often made that material behavior can be represented by homogenized or effective properties. While this assumption yields accurate results for the bulk behavior of composite materials, it ignores the effects of the random microstructure. The spatial variations in these microstructures can focus, initiate and propagate localized non-linear behavior, subsequent damage and failure. In previous work a computational method, moving window micromechanics (MW), was used to capture microstructural detail and characterize the variability of the local and global elastic response. Digital images of material microstructure described the microstructure and a local micromechanical analysis was used to generate spatially varying material property fields. The strengths of this approach are that the material property fields can be consistently developed from digital images of real microstructures, they are easy to import into finite element models (FE) using regular grids, and their statistical characterizations can provide the basis for simulations further characterizing stochastic response. In this work, the moving window micromechanics technique was used to generate material property fields characterizing the non-linear behavior of random materials under plastic yielding; specifically yield stress and hardening slope, post yield. The complete set of material property fields were input into FE models of uniaxial loading. Global stress strain curves from the FE–MW model were compared to a more traditional micromechanics model, the generalized method of cells. Local plastic strain and local stress fields were produced which correlate well to the microstructure. The FE–MW method qualitatively captures the inelastic behavior, based on a non-linear flow rule, of the sample continuous fiber composites in transverse uniaxial loading.     

A three-dimensional model of anisotropic hardening in metals and its application to the analysis of sheet metal formability

The hardening model proposed by Z. Mróz based on the uniaxial fatigue behavior of many metals is adopted to derive an incremental constitutive equation for general three-dimensional problems. This constitutive law is then employed in the analysis of metal forming problems to assess the influence of loading cycles, of the types involved in standard forming processes, on the ultimate formability of sheet metals. The predicted forming limit curves differ quantitatively from results obtained via an isotropie hardening model and differ qualitatively from those obtained via a kinematic model. Also investigated are the effects of such loading cycles on material response to simple tensile loading, which is often used to characterize a material. Significant differences between the present model and the other two models considered are observed in such characterizers of simple tensile behavior as the stress-strain curve, the anisotropy parameter and the uniform elongation. These differences suggest a rather simple experiment to identify the proper material model to be used in analyses of problems which involve loading cycles. Comparisons with some experimental results reveal that the employment of an anisotropic hardening model, such as the generalized Mróz model derived herein, is indeed crucial in accurately predicting material response to complicated loading histories.     

A Constitutive Framework for Tubular Structures that Enables a Semi-inverse Solution to Extension and Inflation

Traditional constitutive frameworks for high-strain materials are ill-suited to solve extension and inflation, one of the simplest problems involving tubes, or more complicated problems. Moreover, it is experimentally necessary to minimize the covariance amongst constitutive response functions. We sought, hence, a constitutive framework that minimizes covariance and simplifies the balance equations for tubes, hoses, and arteries. Central to this theory are six objective scalars or strain attributes that decouple dilatation and distortion and succinctly define the strain. Because there is a one-to-one relationship between them and the components of the Right Cauchy–Green deformation tensor, these six strain attributes can be used to define the strain energy density function for hyperelastic materials. This approach yields mostly orthogonal response terms for high strain deformation (14 of the 15 inner products vanish). For infinitesimal deformation, the response terms are fully orthogonal. Further utility is demonstrated by showing how the governing equations are simplified for tubular structures and how response functions can be determined for the first time from the extension and inflation of thick-walled tubes composed of a homogeneous material with incompressible, hyperelastic behavior. This solution is applicable for materials with orthotropic behavior, and using the chain rule, this solution can be used for materials with isotropic behavior.     

PREDICTION FOR FORMING LIMIT OF AL2024T3 SHEET BASED ON DAMAGE THEORY USING FINITE ELEMENT METHOD

This paper presents the application of anisotropic damage theory to the study of forming limit diagram of A12024T3 aluminum alloy sheet. In the prediction of limiting strains of the aluminum sheet structure, a finite element cell model has been constructed. The cell model consists of two phases, the aluminum alloy matrix and the intermetallic cluster. The material behavior of the aluminum alloy matrix is described with a fully coupled elasto-plastic damage constitutive equation. The intermetallic cluster is assumed to be elastic and brittle. By varying the stretching ratio, the limiting strains of the sheet under biaxial stretching have been predicted by using the necking criterion proposed. The prediction is in good agreement with the experimental findings. Moreover, the finite element cell model can provide information for understanding the microscopic damage mechanism of the aluminum alloy. Over-estimation of the limit strains may result if the effect of material damage is ignored in the sheet metal forming study.     

爆炸载荷作用下铀气溶胶形成机理研究

针对铀材料在爆炸载荷作用下形成放射性气溶胶的过程,采用光滑粒子流体动力学方法开展了数值模拟和实验研究。通过将颗粒动力学和SPH方法结合,建立了炸药爆轰作用于铀金属壳的数值模拟模型,以铀材料比内能为气溶胶转化判据,获得了铀材料转化为气溶胶的物理过程,得到了在相同爆炸当量下,不同质量铀材料的气溶胶转化效率,并与实验结果进行了对比分析。结果显示,铀材料在爆炸载荷作用下,当其比内能达到1.9 MJ/kg时,即可认为完全转变为气溶胶,对于本文中的爆炸装置结构形式,当炸药质量为铀材料质量的6倍时,转化率超过90%。实验验证了数值模拟结果,表明该方法能够对铀材料的气溶胶转化过程进行准确描述。     

Forming of AA5182-O and AA5754-O at elevated temperatures using coupled thermo-mechanical finite element models

A temperature-dependent anisotropic material model was developed for two aluminum alloys AA5182-O and AA5754-O and their anisotropy parameters were established. A coupled thermo-mechanical finite element analysis of the forming process was then performed for the temperature range 25–260 °C (77–500 °F) at different strain rates. In the developed model, the anisotropy coefficients for Barlat’s YLD2000-2d anisotropic yield function [Barlat, F., Brem, J.C., Yoon, J.W., Chung, K., Dick, R.E., Lege, D.J., Pourboghrat, F., Choi, S.H., Chu, E., 2003. Plane stress yield function for aluminum alloy sheets – Part 1: Theory. Int. J. Plasticity 19, 1297–1319] in the plane-stress condition and the parameters for the isotropic strain hardening were established as a function of temperature. The temperature-dependent anisotropic yield function was then implemented into the commercial FEM code LS-DYNA as a user material subroutine (UMAT) using the cutting-plane algorithm for the integration of a general class of elastoplastic constitutive models [Abedrabbo, N., Pourboghrat, F., Carsley, J., 2006b. Forming of aluminum alloys at elevated temperatures – Part 2: Numerical modeling and experimental verification. Int. J. Plasticity 22 (2), 342–737]. The temperature-dependent material model was used to simulate the coupled thermo-mechanical finite element analysis of the stamping of an aluminum sheet using a hemispherical punch under the pure stretch boundary condition (no material draw-in was allowed). Simulation results were compared with experimental data at several elevated temperatures to evaluate the accuracy of the UMAT’s ability to predict both forming behavior and failure locations. Two failure criteria were used in the analysis; the M–K strain based forming limit diagrams (ε-FLD), and the stress based forming limit diagrams (σ-FLD). Both models were developed using Barlat’s YLD2000-2d anisotropic model for the two materials at several elevated temperatures. Also, as a design tool, the Genetic Algorithm optimization program HEEDS was linked with the developed thermo-mechanical models and used to numerically predict the “optimum” set of temperatures that would generate the maximum formability for the two materials in the pure stretch experiments. It was found that a higher temperature is not needed to form the part, but rather the punch should be maintained at the lowest temperature possible for maximum formability.     

Computational analysis of stress-based forming limit curves

This article, through computational analyses, examines the validity of using the stress-based and extended stress-based forming limit curves to predict the onset of necking during proportional loading of sheet metal. To this end, a model material consisting of a homogeneous zone and a zone that has voids (material inhomogeneity) is proposed and used to simulate necking under plane strain and uni-axial stress load paths. Results of the in-plane loading computations are used to construct a strain-based formability limit curve for the model material. This limit curve is transformed into principal stress space using the procedure due to Stoughton [Stoughton, T.B., 2000. A general forming limit criterion for sheet metal forming. International Journal of Mechanical Sciences 42, 1–27]. The stress-based limit curve is then transformed into equivalent stress and mean stress space to obtain an Extended Stress-Based Limit Curve (XSFLC). When subjected to three-dimensional loading, the model material is observed to display a variety of responses. From these responses, a criterion for the applicability of the XSFLC to predict the onset of necking in the model material when it is subjected to three-dimensional loading is obtained. In the context of straight tube hydroforming, to provide support for the use of the XSFLC, it is demonstrated that the criterion is satisfied.