高强度钢板热成形本构理论与实验分析

热成形(热冲压)过程中硼钢的热、力、相变耦合关系是研究热成形理论的基础, 同时也是决定热成形工艺及数值模拟准确性的关键因素. 对热成形硼钢进行高温拉伸及淬火实验: 硼钢板材试样在奥氏体化(950℃)后保温一定时间, 然后在连续冷却的同时施加拉伸力, 记录此过程中力、位移、膨胀量及温度的变化. 通过对不同冷却速率及不同拉伸力情况下上述物理量的变化规律及微观组织性能的分析, 研究硼钢相变过程中的热、力、相变耦合关系. 建立了硼钢相变过程中的热、力、相变耦合模型. 通过引入混合定律对热成形过程中的多相材料热力学参数和力学性能进行等效分析; 对热成形应变组成及其形成机理进行了分析, 引入了相变体积应力及相变塑性应力等新概念. 硼钢高温流动应力采用修改的Norton-Hoff形式, 并通过实验确定了流动应力的材料常数. 在此基础上将热、力、相变耦合关系引入热成形本构方程中, 分别建立了高强度钢板热成形的全量形式及增量形式本构方程. 对U形零部件热成形过程进行了数值模拟, 并与实验结果进行比较, 结果证明建立的本构理论的有效性.      

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。     

变形-损伤耦合的起塑性恒压轴对称充模胀形的有限元模拟

采用大变形刚粘塑性有限元法模拟超塑性恒压轴对称充模胀形过程、分析了模具几何参数及材料参数对胀形过程中材料的流变行为、胀形制许厚度分布和成形时间的影响规律。给出了质点的流动轨迹、不同时刻制件的剖面形状及应力、应变分布；基于修正的Gurson粘塑性势推导了内部空洞体积分数累积增大模型并据此进行了变形-损伤耦合计算．     

变形—损伤耦合的超塑性恒压轴对称充模胀形的有限元模拟

采用大变形刚粘塑性有限元法模拟超塑性恒压轴对称充模胀形过程，分析了模具几何参数及材料参数对胀形过程中材料的流变行为、胀形制件厚度分布和成形时间的影响规律，给出了质点的流动轨迹，不同时刻制件的剖面形状及应力、应变分布；基于修正的Ｇｕｒｓｏｎ粘塑性势推导了内部空洞体积分数累积增大模型并据此进行了变形－损伤耦合计算。     

引入工艺因素的汽车车身部件碰撞仿真分析

采用自主开发的高效快速的逆成形有限元分析方法和网格映射技术,并与碰撞仿真技术相结合,提出了引入工艺因素、又保证设计周期、提高碰撞仿真精度的汽车车身及部件"精细"仿真分析方法.以某轿车中的主要碰撞承载和吸能部件左前纵梁为例,采用一步逆算有限元法和LS-DYNA软件对其进行基于引入工艺因素的碰撞仿真分析.结果表明:为了提高碰撞分析的精度,在汽车车身碰撞仿真中需要采用考虑冲压成形效应的碰撞分析方法,其中影响程度最大的因素是等效塑性应变.     

高温下编织复合材料热相关参数识别方法研究

为了获取高温下编织复合材料的准确弹性参数与热膨胀系数,提出一种基于均匀化理论的热相关参数识别方法. 首先,在编织复合材料单胞有限元模型基础上,基于均匀化理论和热弹性理论,施加周期性位移边界条件和温度边界条件,预测编织复合材 料的热弹性相关参数. 然后,考虑到等效过程中编织复合材料应力分布不均匀等因素引起的误差,将复合材料精细模型的热模态数据作为补 充信息,识别编织复合材料热相关参数,对预测的材料参数进行校准. 本文在二维编织结构单胞模型基础上,开展等效预测和识别方法研 究,验证所提出方法的有效性和准确性. 对比等效和识别后热模态的误差,结果表明:本文提出的基于等效预测的参数识别方法,能够 准确识别高温下编织复合材料宏观热相关参数.      

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.     

微凸体碰撞对接触应力应变的影响

基于有限元法建立了单对半球状微凸体的接触、碰撞模型,研究了碰撞对微凸体在完全弹性、弹塑性和完全塑性三种接触状态下的Mises应力分布和等效塑性应变(PEEQ)的影响.结果表明:接触变形状态不同时,微凸体的Mises应力分布在碰撞过程具有不同的变化过程,但碰撞结束后,Mises应力值都降低,仅在完全塑性接触时,个别节点的Mises应力峰值大于屈服极限.碰撞使微凸体的等效塑性应变迅速增加到峰值,并保持到碰撞结束,与接触变形状态无关.完全弹性、弹塑性接触状态和完全塑性接触状态下,微凸体等效塑性应变的峰值分别位于接触中心区域和应变峰值环,这意味着裂纹可能产生的部位也不同.     

高温下编织复合材料热相关参数识别方法研究

为了获取高温下编织复合材料的准确弹性参数与热膨胀系数,提出一种基于均匀化理论的热相关参数识别方法.首先,在编织复合材料单胞有限元模型基础上,基于均匀化理论和热弹性理论,施加周期性位移边界条件和温度边界条件,预测编织复合材料的热弹性相关参数.然后,考虑到等效过程中编织复合材料应力分布不均匀等因素引起的误差,将复合材料精细模型的热模态数据作为补充信息,识别编织复合材料热相关参数,对预测的材料参数进行校准.本文在二维编织结构单胞模型基础上,开展等效预测和识别方法研究,验证所提出方法的有效性和准确性.对比等效和识别后热模态的误差,结果表明:本文提出的基于等效预测的参数识别方法,能够准确识别高温下编织复合材料宏观热相关参数.     

第Ⅱ类尺寸效应影响下金属薄板液压胀形本构模型研究

尺寸效应是微成形研究中的热点和难点之一.目前采用经典塑性理论仍不能对金属薄板液压胀形中尺寸效应对应力变化现象的影响进行较好的解释.为了深入分析该问题,结合应变梯度塑性理论,建立了第Ⅱ类尺寸效应影响下金属薄板液压胀形本构模型.基于该模型,分析了板料厚度变化以及胀形凹模直径变化对液压胀形过程流动应力变化的影响.研究结果表明应用该本构模型能较好地解释金属薄板液压胀形中尺寸效应对应力变化的影响,验证了该本构模型的正确性.     

NUMERICAL PREDICTIONS AND EXPERIMENTAL VALIDATIONS OF DUCTILE DAMAGE EVOLUTION IN SHEET METAL FORMING PROCESSES

Prediction of forming limit in sheet metal forming is among the most important challenges confronting researchers. In this paper, a fully coupled elastic-plastic-damage model has been developed and implemented into an explicit code. Due to the adoption of the plane stress and finite strain theories, model can predict deformation and damage of parts quickly and accurately. Also, damage initiation, propagation, and fracture in some operations are predicted and validated with experiments. It is concluded that finite strain combined with continuum damage mechanics can be used as a quick tool to predict ductile damage, fracture, and forming limits in sheet metal forming processes.     

The shear fracture of dual-phase steel

Unexpected fractures at high-curvature die radii in sheet forming operations limit the adoption of advanced high strength steels (AHSS) that otherwise offer remarkable combinations of high strength and tensile ductility. Identified as “shear fractures” or “shear failures,” these often show little sign of through-thickness localization and are not predicted by standard industrial simulations and forming limit diagrams. To understand the origins of shear failure and improve its prediction, a new displacement-controlled draw-bending test was developed, carried out, and simulated using a coupled thermo-mechanical finite element model. The model incorporates 3D solid elements and a novel constitutive law taking into account the effects of strain, strain rate, and temperature on flow stress. The simulation results were compared with companion draw-bend tests for three grades of dual-phase (DP) steel over a range of process conditions. Shear failures were accurately predicted without resorting to damage mechanics, but less satisfactorily for DP 980 steel. Deformation-induced heating has a dominant effect on the occurrence of shear failure in these alloys because of the large energy dissipated and the sensitivity of strain hardening to temperature increases of the order of 75 °C. Isothermal simulations greatly overestimated the formability and the critical bending ratio for shear failures, thus accounting for the dominant effect leading to the inability of current industrial methods to predict forming performance accurately. Use of shell elements (similar to industrial practice) contributes to the prediction error, and fracture (as opposed to strain localization) contributes for higher-strength alloys, particularly for transverse direction tests. The results illustrate the pitfall of using low-rate, isothermal, small-curvature forming limit measurements and simulations to predict the failure of high-rate, quasi-adiabatic, large-curvature industrial forming operations of AHSS.     

Predicting ductile fracture of low carbon steel sheets: Stress-based versus mixed stress/strain-based Mohr–Coulomb model

Two distinct implementations of the Mohr–Coulomb failure model are used in conjunction with a non-associated quadratic plasticity model to describe the onset of fracture in low carbon steel sheets. The stress-based version corresponds to the original Mohr–Coulomb model in stress space. For the mixed stress/strain-based version, the Mohr–Coulomb failure criterion is first transformed into the space of stress triaxiality, Lode angle parameter and equivalent plastic strain and then used as stress-state dependent weighting function in a damage indicator model. Basic fracture experiments including tensile specimens of different notch radii and a punch test are performed to calibrate the material parameters of the respective models. Subsequently, the models are used to predict the crack initiation in a Hasek test and during the stamping of an anticlastic structure. Unlike for the calibration experiments, the loading history during stamping is highly non-linear. Both models can be calibrated with similar accuracy, but the strain-based model predicts the instant of onset of fracture with greater accuracy in the stamping experiment which is an advantage of the empirical damage accumulation rule.     

S30408低温棘轮效应本构描述

S30408奥氏体不锈钢因其优异的力学性能和耐低温性能而被广泛用于制作LNG等低温罐车罐体的内容器。此类罐体的内容器在其支撑部位不但承受内压引起的恒定应力还会承受惯性载荷引起的交变应力,容易发生渐进的塑性应变累积即棘轮效应。但目前还缺乏有效预测S30408低温棘轮效应的本构描述。利用几种较为先进的本构模型对低温S30408奥氏体不锈钢棘轮应变进行模拟,发现这些本构模型存在循环初期过低预测和循环后期过高预测的缺点,并且这种过高预测会随着循环圈数的增加而增大。基于Ohno - Wang II模型,关联形变马氏体含量与各向同性强化与随动强化,并给出马氏体极限含量dL的演化规律,进而提出一种含马氏体相变的循环塑性本构模型。与其它模型相比,该模型能有效改善在循环初期预测值过低和后期预测值过高的情况,同时能够较好地预测循环加载过程中形变马氏体的含量。     

S30408低温棘轮效应本构描述

S30408奥氏体不锈钢因其优异的力学性能和耐低温性能而被广泛用于制作LNG等低温罐车罐体的内容器.此类罐体的内容器在其支撑部位不但承受内压引起的恒定应力还会承受惯性载荷引起的交变应力,容易发生渐进的塑性应变累积即棘轮效应.但目前还缺乏有效预测S30408低温棘轮效应的本构描述.利用几种较为先进的本构模型对低温S30408奥氏体不锈钢棘轮应变进行模拟,发现这些本构模型存在循环初期过低预测和循环后期过高预测的缺点,并且这种过高预测会随着循环圈数的增加而增大.基于Ohno-Wang Ⅱ模型,关联形变马氏体含量与各向同性强化和随动强化,并给出马氏体含量d ξ的演化规律,进而提出一种含马氏体相变的循环塑性本构模型.与其它模型相比,该模型能有效改善在循环初期预测值过低和后期预测值过高的情况,同时能够较好地预测循环加载过程中形变马氏体的含量.     

预估在非比例加载下薄金属板成型极限的损伤基力学模型

探讨了用损伤基力学模型研究应变路径对薄金属板塑性失稳的影响,这种力学模型考虑了材料损伤作用．基于这种模型,在等效应变空问建立了考虑损伤的塑性失稳判据,并用以预估在比例或非比例加载下薄金属板成型极限曲线(FLC)．借助这种理论模型和方法,预估薄金属板的理论成型极限曲线与Graf和Hosford的实验结果一致。     

Finite element and experimental method for analyzing the effects of martensite morphologies on the formability of DP steels

Abstract

In this article, we investigated the effect of martensite morphology on the mechanical properties and formability of dual phase steels. At first, three heat treatment cycles were subjected to a low-carbon steel to produce ferrite–martensite microstructure with martensite morphology of blocky-shaped, continuous, and fibrous. Tensile tests were then carried out so as to study mechanical properties, particularly the strength and strain hardening behavior of dual phase steels. In order to study the formability of dual phase samples, Forming Limit Diagram was obtained experimentally and numerically. Experimental forming limit diagram was obtained using Nakazima forming test, while Finite Element Method was utilized to numerically predict the forming limit diagram. The results indicated that the dual phase samples with fibrous martensite morphology had the highest tensile properties and strain rate hardening out of the three different microstructures. Blocky-shaped martensite morphology, on the other hand, had the worst mechanical properties. The study of the strain hardening behavior of dual phase sample by Kocks–Mecking-type plots, evinced two stages of strain hardening for all specimens with different microstructures: stages III and IV. The forming limit diagram of dual phase steels also proved that samples with fibrous martensite morphology had the best formability compared to other two microstructures. The simulated forming limit diagram manifested that there is a good agreement between experimental results and those obtained by FEM.     

Characterization of story-level seismic damage using an energy-based damage model

An energy-based damage model currently used for seismic analysis of structures is modified to ensure a positive value in the damage index at all levels of inelastic response. At the ultimate limit state, the modified model gives the same plastic strain energy capacity as the previous damage model. Testing of small-scale cantilever specimens showed different strength deterioration parameters for coldrolled and hot-rolled steel and composite systems of double cantilevers. The strength deterioration parameter for the composite system is smaller than that of the individual cantilevers. Various weighted-average rules for combining local member damage indices into story-level damage indices are compared with measured story-level damage indices. Based on testing of small-scale steel cantilevers, the current combination rules predict the story-level damage reasonably well near the ultimate limit state but tend to underestimate the story-level damage in the less severely damaged states. A combination rule based on best fitting of the experimental data obtained in this study is presented.