Overview on the Prediction Models for Sheet Metal Forming Failure:Necking and Ductile Fracture

The formability of the material determines the amount of available deformation before failure and thus is important for the production of various structural components in industries. The workability of materials is commonly evaluated by different forms of failure models during sheet metal forming(SMF) processes. In order to provide a whole picture about the prediction models for SMF failure, necking-related formability and ductile fracture-related formability studies in SMF processes are systematically summarized, the applicability and limitation of each model are highlighted, and the link between forming limit diagram and ductile fracture criterion is pointed out. Conclusions about some critical issues on failure in SMF are made.     

Out-of-plane Testing Procedure for Inverse Identification Purpose: Application in Sheet Metal Plasticity

Many recent works in inverse identification of constitutive parameters have pointed to the need of tests which exhibit heterogeneous strain paths. The present study details a new testing procedure based on out-of-plane motion capture by Stereo-Image Correlation (SIC). With the original test proposed hereby, a unique sample is deformed on a tensile machine along two perpendicular tensile directions, two perpendicular shear directions and one expansion area. The choice of the sample shape is discussed along with the stereo imaging device, 3D reconstruction and measurement uncertainties. The test sample is made from a sheet of commercially pure titanium. A Finite-Element updating inverse method is applied in order to identify six parameters of an anisotropic plastic constitutive model. Results show that this new testing procedure allows every constitutive parameter of the model to be identified from one and only one test.     

Inferring Post-Necking Strain Hardening Behavior of Sheets by a Combination of Continuous Bending Under Tension Testing and Finite Element Modeling

Experimental Mechanics - This paper presents a combined experimental and simulation approach to identify post-necking hardening behavior of ductile sheet metal. The method is based on matching a...     

韧性金属Kaiser效应方向独立性的实验研究

Kaiser效应是声发射技术实际应用的理论基础。本文以韧性金属材料Q345不同方向拉伸实验为例,探究力的方向对韧性金属Kaiser效应的影响。实验结果表明,韧性金属材料在某一方向加载时,表现出了Kaiser效应;当改变加载方向时,呈现出与第一次加载方向类似的声发射特性,说明声发射现象对其他加载方向上所承受的最大载荷不具有记忆的能力,而仅与该方向承载历史有关,即韧性金属Kaiser效应与力的方向性间具有独立性。同时,利用细观损伤理论对这一现象产生的机理进行了定性的解释。     

FAST ACCURATE PREDICTION OF BLANK SHAPE IN SHEET METAL FORMING

By using the Finite Element Inverse Approach based on the Hill quadratic anisotrop-ically yield criterion and the quadrilateral element, a fast analyzing software-FASTAMP for the sheet metal forming is developed. The blank shapes of three typical stampings are simulated and compared with numerical results given by the AUTOFORM software and experimental results, respectively. The comparison shows that the FASTAMP can predict blank shape and strain distribution of the stamping more precisely and quickly than those given by the traditional methods and the AUTOFORM.     

Anisotropic Hardening of Sheet Metals at Elevated Temperature: Tension-Compressions Test Development and Validation

New test equipment has been developed to measure the in-plane cyclic behavior of sheet metals at elevated temperatures. The tester has clamping dies with adjustable side force to prevent the sheet specimens from buckling during compressive loading. In addition to the room temperature experiment, cartridge type heaters are inserted in the clamping dies so that the specimen can be heated up to 400 °C during the cyclic tests. For the strain measurement, a non-contact type laser extensometer is used. In order to validate the newly developed test device, the tension-compression (and compression-tension) tests under pre-strains and various temperatures have been performed. As model materials, the aluminum alloy sheet which exhibits a large Bauschinger effect and the magnesium alloy sheet which exhibits different amounts of asymmetry under cyclic loading are used. The developed device can be well-suited to measure the cyclic material behavior, especially the anisotropic and asymmetric hardening of light-weight materials.     

Large Strain Shear Compression Test of Sheet Metal Specimens

A hybrid experimental-computational procedure to establish accurate true stress-plastic strain curve of sheet metal specimen covering the large plastic strain region using shear compression test data is described. A new shear compression jig assembly with a machined gage slot inclined at 35° to the horizontal plane of the assembly is designed and fabricated. The novel design of the shear compression jig assembly fulfills the requirement to maintain a uniform volume of yielded material with characteristic maximum plastic strain level across the gage region of the Shear Compression Metal Sheet (SCMS) specimen. The approach relies on a one-to-one correlation between measured global load–displacement response of the shear compression jig assembly with SCMS specimen to the local stress-plastic strain behavior of the material. Such correlations have been demonstrated using finite element (FE) simulation of the shear compression test. Coefficients of the proposed correlations and their dependency on relative plastic modulus were determined. The procedure has been established for materials with relative plastic modulus in the range 5?×?10^?4?<?(E _p /E)?<?0.01. It can be readily extended to materials with relative plastic modulus values beyond the range considered in this study. Nonlinear characteristic hardening of the material could be established through piecewise linear consideration of the measured load–displacement curve. Validity of the procedure is established by close comparison of measured and FE-predicted load–displacement curve when the provisional hardening curve is employed as input material data in the simulation. The procedure has successfully been demonstrated in establishing the true stress-plastic strain curve of a demonstrator 0.0627C steel SCMS specimen to a plastic strain level of 49.2 pct.     

金属板料拉延二次成形的有限元法模拟

建立了二次拉延成形加工的有限元分析计算模型;采用一次成形-回弹计算-二次成形的连续计算过程模拟了实际加工过程;有限元计算采用动力显式计算程序MSC/DYTRAN;用主从面（master surface-slave surface)模型定义板料和模具的接触,摩擦力用库仑定律计算;利用动力松弛法对成形过程中的回弹进行了计算。模拟结果和实际零件比较,证明模型合理,自满稳定,结果可靠,具有良好的应用价值。     

测定薄板疲劳裂纹扩展门槛值的升降法

测定疲劳裂纹扩展门槛值传统方法的整个过程只测出裂纹扩展门槛值的一个观测值,而由于材料不均匀等客观因素的限制,传统试验法的结果具有一定的随机性.本文利用升降法的原理,提出一种测定疲劳裂纹扩展门槛值的升降法:预制裂纹并逐级降载使裂纹扩展速率接近门槛值速率,设定应力强度因子的级差,按照设定级差逐级降载,直至裂纹扩展速率低于门槛值速率,然后开始升载,直至裂纹扩展速率高于门槛值速率,再开始降载,如此重复进行即可以在疲劳裂纹扩展门槛值附近测得多对相反的数据点.运用小子样升降法数据处理方法,就可得到疲劳裂纹扩展门槛值的均值和方差.最后通过某型铝合金薄板疲劳裂纹扩展门槛值的测定试验验证了此方法的可行性.     

Multi-Axial Deformation Setup for Microscopic Testing of Sheet Metal to Fracture

While the industrial interest in sheet metal with improved specific-properties led to the design of new alloys with complex microstructures, predicting their safe forming limits and understanding their microstructural deformation mechanisms remain as significant challenges largely due to the inadequacy of the existing experimental tools. The investigation of the strain-path dependent failure mechanisms requires miniaturized testing equipment, which can be placed in a scanning electron microscope for in situ experiments. So far, such tests could only be carried out for a single strain path (uniaxial tension). In this work, in order to fill this gap, a miniaturized Marciniak test setup is designed, built and tested. With this setup real-time, multi-axial tests of industrial sheet metal can be carried out to the point of fracture within a scanning electron microscope. Proof-of-principle experiments demonstrate that a realm of information can be obtained, crucial for the understanding of the mechanical behavior of new alloys.     

一种用于金属薄板轴向拉压疲劳试验的防弯夹具

在金属薄板的轴向疲劳S-N曲线测试中,研究将一种侧向防弯曲夹具应用于存在压向载荷的试验。通过粘贴应变片方法测量试样的表面应力,对试样的受力情况做了定量的分析。测量结果表明试样安装防弯曲夹具后,基本消除了由压缩失稳产生的弯曲应力。且通过对不同拧紧方式的测量,表明一定的夹紧力下不对试验力产生影响。试验夹具设计成对试样中心轴线的支撑而让边缘疲劳敏感部位处在非接触状态,试样断口表明疲劳起源在这些并没有与试样接解的部位。用钛和铝两种材料的薄板在不同试验机上进行了不同寿命和频率的试验,试验结果与正应力比试验同时给出以对比,各种研究表明本试验有效解决了薄板疲劳受压时的失稳问题。     

塑性各向异性板料本构关系及冲压成形的数值模拟

推导了具有一般屈服函数形式的弹塑性速率型本构关系;给出了用于板料成形的Hill塑性各向异性屈服模型下本构关系的具体形式;用有限元动力显式计算程序MSC/DYTRAN模拟了金属板料的冲压成形;通过算例分析,考察了塑性各向异性对凸耳形成和大小以及对成形模拟结果准确性的影响;数值结果和实验结果表明：各向（厚向）异性本构模型比各向同性本构模型更真实地反映了板料的成形性。     

板料三维成形过程的有限元数值模拟

基于有限变形理论建立了三维金属板料成形过程的刚塑性有限元数学模拟,该数学模型采用物质坐标系中的Ｕｐｄａｔｅ－Ｌａｇｒａｎｇｅ描述,等向强化假设,考虑了板料的厚向异性,对于金属板料与模具有摩擦采用近似的库仑摩擦定律以改善计算的收敛性。为简经计算采用薄膜单元,并根据此模型编制程序。     

室温下镁合金板循环塑性随动强化本构模型研究

本文在具有各向异性屈服强度和拉压不对称的CPB06屈服准则的基础上,建立了基于随动强化的循环塑性本构模型．通过引入滑移、孪晶以及去孪等不同变形模式下的背应力演化方程,对室温下镁合金板材异常循环硬化行为进行了模拟．选取了AZ31B-O和AZ31B两种镁合金板材,通过拉伸-压缩-拉伸(T-C-T)和压缩-拉伸(C-T)等不同加载路径下的部分实验曲线确定模型的参数,采用三次插值多项式建立了背应力参数与上一变形模式中累积的等效塑性应变（即预应变）之间的函数关系．使用本模型对剩下的实验曲线进行了预测,发现预测结果与实验结果有良好的一致性,说明了当前模型的正确性．     

电摩擦现象--电场对金属/陶瓷摩擦行为的影响

探讨了利用调节外加电场改变金属／陶瓷摩擦副摩擦行为的可行性及通过在线反馈控制外加电压的大小实现摩擦系数主动的控制的可能性。试验发现,在硬脂酸锌乳化液润滑条件下,施加数十伏的外加直流电压,由三氧化二铝、石英玻璃等陶瓷材料与钢、黄铜、不锈钢等构成的滑动摩擦副的摩擦系数发生显著变化,变化幅度与所加电压的大小、极性以及金属材料的种类有关。初步分析表明,发生这种电摩擦现象的原因在于摩擦副表面特别是金属表面吸     

无铆连接模具参数对异种金属板料接头成形的影响

为了研究无铆连接模具参数对304不锈钢和AL6061板料接头成形的影响,基于DEFORM-2D建立了有限元模型,分析了凹模深度、凹槽深度和凸模直径三个主要模具参数对接头成形的影响.研究结果表明,凹模深度越大,越有利于下板料变形,反之,则有利于上板料变形.当凹模直径一定时,凹槽深度和凸模直径过小不利于形成互锁,而凹槽深度不宜过大,避免出现充不满现象,凸模直径过大导致接头颈厚值过小.通过正交试验发现,对接头成形的影响程度从大到小依次为凸模直径、凹槽深度和凹模深度,确定了最优模具参数,并通过无铆连接实验验证了正交试验的可靠性.此外,通过剪切实验获得了接头最大剪切失效载荷为1.8 kN.     

延性材料的损伤断裂

以细观统计损伤理论为基础 ,对材料受冲击载荷作用下初期损伤的成核成长效应进行了定量计算。得到了不同动载荷作用下从损伤成核到成长阶段转换的特征时间 ,并把它应用于Johnson提出的延性材料的损伤断裂模型 ,减小了原模型中的模型参数初始损伤度的随意性 ,增加了Johnson模型的确定性与可预测性。用改进后的模型计算不同冲击速度下OFHC铜的损伤断裂 ,计算结果与实测结果吻合较好。     

金属往复滑动摩擦噪声源的识别

对金属往复滑动摩擦噪声进行了声学和动力学测量 ,通过对声压级和加速度进行时间历程波形分析、功率谱分析 ,确认摩擦噪声是由参加相对滑动的摩擦副的 1个或 2个部件的振动辐射所产生 ,摩擦噪声的声源体为参加摩擦运动的振动部件     

Hardening of an elastoplastic body

The purpose of the experimental investigations whose results are described here is to study plastic states in which loading occurs in some directions and unloading in others, and also to verify the applicability of the plastic strain schemes proposed in [1,2] for these states. The existence of an angular point on the loading surface is detected. The influence of the loading path on the development of this point is investigated. A load of biaxial tension type was produced in a 45KhN steel-pipe specimen subjected to internal pressure and an axial force. The ratio between the principal stresses hence varied, but the principal directions of the stress tensor remained fixed in the body of the specimen.Translated from Zhurnal Prikladnoi Mekhaniki i Tekhnicheskoi Fiziki, No. 3, pp. 144–148, May–June, 1976.The author is grateful to E. I. Shemyakin for supervising the research, and to V. M. Zhigalkin, G. F. Bobrov, and N. S. Adigamov for taking part in performing the tests.     

Erosion of Ductile and Brittle Materials

The fundamental mechanisms of erosion by solid particle impact were investigated in both brittle and ductile materials. A review of the literature of erosion theoretical models indicated various different models. The most important ones were used to reproduce experimental tests concerning the erosion by solid particle impingement using gas jets. If supported by an appropriate tuning of certain parameters, they perform well. Since a continuous tuning of these parameters is required, experiment based theoretical models seem to be inappropriate in the development of advanced materials for high temperature applications. Consequently, we have developed a new approach based on the finite element method. Since it only requires the knowledge of the main mechanical properties as a function of the temperature, it seems suitable for the erosion rate evaluation in a wide range of applications. Early assessment results, compared to experimental erosion tests conducted at room temperature, showed good predictive capabilities which are even better than theoretical models.