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).     

Assessment of crystal plasticity based calculation of the lattice spin of polycrystalline metals for FE implementation

When texture is incorporated in the finite element simulation of a metal forming process, much computer time can be saved by replacing continuous texture and corresponding yield locus updates by intermittent updates after strain intervals of e.g. 20%. The hypothesis that the evolution of the anisotropic properties of a polycrystalline material during such finite interval of plastic deformation can be modelled by just rotating the initial texture instead of continuously updating it by means of a polycrystal deformation model is tested in this work. Two spins for rotating the frame have been assessed: the classical rigid body spin and a crystal plasticity based “Mandel spin” (calculated from the rotated initial texture) which is the average of the spins of all the crystal lattices of the polycrystal. Each of these methods was used to study the evolution of the yield locus and the r-value distribution during the 20% strain interval. The results were compared to those obtained by simulating the texture evolution continuously using a polycrystal deformation model. When the texture was not updated during deformation, it was found that for most initial textures the Mandel spin does not perform better than the rigid body spin, except for some special initial textures for which the Mandel spin is much better. The latter ones are textures which are almost stable for the corresponding strain mode. When the texture was updated after each strain interval of e.g. 20% the Mandel spin performed much better than the rigid body spin.     

Convex plastic potentials of fourth and sixth rank for anisotropic materials

It is briefly reminded how the theory of dual plastic potentials has been used in the past to generate analytical expressions for plastic potentials of anisotropic polycrystalline materials with a known crystallographic texture. Such constitutive models are fairly general, and the identification of their parameters can readily be done on the basis of data obtained from a texture measurement. As a result, they are suitable for engineering applications such as elastic–plastic finite element models for forming processes. However, the yield loci generated in this way are not automatically convex. Therefore, a new variant of the method has now been developed, which preserves the advantages of the old method, but for which convexity can at least been tested by means of a mathematical criterion. In addition, it has turned out to be possible to slightly modify plastic potentials which do not satisfy the criterion, in order to achieve convexity. An example of a plastic potential modified in this way is discussed. After modification, it was still a good analytical approximation of the plastic potential directly derived from the Taylor–Bishop–Hill theory on the basis of the crystallographic texture of the material.     

Modeling of deformation induced anisotropy in free-end torsion

The main purpose of this work is to develop a phenomenological model, which accounts for the evolution of the elastic and plastic properties of fcc polycrystals due to a crystallographic texture development and predicts the axial effects in torsion experiments. The anisotropic portion of the effective elasticity tensor is modeled by a growth law. The flow rule depends on the anisotropic part of the elasticity tensor. The normalized anisotropic part of the effective elasticity tensor is equal to the 4th-order coefficient of a tensorial Fourier expansion of the crystal orientation distribution function. Hence, the evolution of elastic and viscoplastic properties is modeled by an evolution equation for the 4th-order moment tensor of the orientation distribution function of an aggregate of cubic crystals. It is shown that the model is able to predict the plastic anisotropy that leads to the monotonic and cyclic Swift effect. The predictions are compared to those of the Taylor–Lin polycrystal model and to experimental data. In contrast to other phenomenological models proposed in the literature, the present model predicts the axial effects even if the initial state of the material is isotropic.     

Postbifurcation behavior of wrinkles in square metal sheets under Yoshida Test

The stretching of a square sheet along one of its diagonals, called “Yoshida Test”, has been developed to simulate the wrinkling behavior in press forming of steel sheets into autobody panels. The finite deformation, onset of wrinkling, and growth of wrinkles in such a specimen are investigated. Hill's yield criterion for sheet materials having the normal anisotropy and Hill's quasistatic bifurcation criterion are employed. The growth of wrinkles in the finite deformation process is incrementally and numerically determined by a thin shell finite element in a convected coordinate system. The Lagrangian formulation of the thin shell finite element is based on Hill's variational principle for elastic-plastic solids, a modification of Love-Kirchhoff postulates and a quasiconforming element technique. The shell element fulfills the interelement C¹ continuity condition in a variational sense. Reasonable agreements between the present numerical results and available analytical and experimental results are shown.     

Rate-independent crystalline and polycrystalline plasticity,application to FCC materials

This paper deals with the simulation of the mechanical response and texture evolution of cubic crystals and polycrystals for a rate-independent elastic–plastic constitutive law. No viscous effects are considered. An algorithm is introduced to treat the difficult case of multi-surface plasticity. This algorithm allows the computation of the mechanical response of a single crystal. The corresponding yield surface is made of the intersection of several hyper-planes in the stress space. The problem of the multiplicity of the slip systems is solved thanks to a pseudo-inversion method. Self and latent hardening are taken into account. In order to compute the response of a polycrystal, a Taylor homogenization scheme is used. The stress–strain response of single crystals and polycrystals is computed for various loading cases. The texture evolution predicted for compression, plane strain compression and simple shear are compared with the results given by a visco-plastic polycrystalline model.     

A method of generating analytical yield surfaces of crystalline materials

An analytical representation of the yield loci of single crystals obeying the Schmid law is examined. It involves an exponent n. The study is conducted first in the fcc case, but it can be extended to more complex modes of slip. A method of predicting the plastic behaviour of polycrystals from the knowledge of their texture is then derived. It leads to completely analytical formulae and is compatible with the assumption of uniform stress. In case n = 2, it is equivalent to Hill's 1948 yield criterion but experiments show that the values of the best-fitting n are higher than 2. These larger values account for phenomena which cannot be predicted by the quadratic criterion, such as ‘anomalous behaviour’. Further reflection leads us to propose an alternative method of averaging, characterized by the introduction of a second exponent m. The effect of m is to realize a fair balance between the contributions of the various crystallographic components to the global mechanical behaviour. The comparison with experimental data from two aluminium sheets shows that it leads to an improvement in the predictions of the values of the strain rate ratio.     

Multiscale modeling of plasticity based on embedding the viscoplastic self-consistent formulation in implicit finite elements

This paper is concerned with the multiscale simulation of plastic deformation of metallic specimens using physically-based models that take into account their polycrystalline microstructure and the directionality of deformation mechanisms acting at single-crystal level. A polycrystal model based on self-consistent homogenization of single-crystal viscoplastic behavior is used to provide a texture-sensitive constitutive response of each material point, within a boundary problem solved with finite elements (FE) at the macroscale. The resulting constitutive behavior is that of an elasto-viscoplastic material, implemented in the implicit FE code ABAQUS. The widely-used viscoplastic selfconsistent (VPSC) formulation for polycrystal deformation has been implemented inside a user-defined material (UMAT) subroutine, providing the relationship between stress and plastic strain-rate response. Each integration point of the FE model is considered as a polycrystal with a given initial texture that evolves with deformation. The viscoplastic compliance tensor computed internally in the polycrystal model is in turn used for the minimization of a suitable-designed residual, as well as in the construction of the elasto-viscoplastic tangent stiffness matrix required by the implicit FE scheme.Uniaxial tension and simple shear of an FCC polycrystal have been used to benchmark the accuracy of the proposed implicit scheme and the correct treatment of rotations for prediction of texture evolution. In addition, two applications are presented to illustrate the potential of the multiscale strategy: a simulation of rolling of an FCC plate, in which the model predicts the development of different textures through the thickness of the plate; and the deformation under 4-point bending of textured HCP bars, in which the model captures the dimensional changes associated with different orientations of the dominant texture component with respect to the bending plane.     

Polycrystal constraint and grain subdivision

Typically, intergranular constraint relations of various sorts are introduced to improve the accuracy of prediction of texture evolution and macroscale stress–strain behavior of metallic polycrystals within the context of simple polycrystal averaging schemes. This paper examines the capability of a 3-D polycrystal plasticity theory (Kocks, U.F., Kallend, J.S., Wank, H.-R., Rollett, A.D. and Wright, S.I. (1994), popLA, Preferred Orientation Package—Los Alamos. LANL LA-CC-89-18), based on the Taylor assumption of uniform deformation among grains, to predict texture evolution and stress–strain behavior for complex finite deformation loading paths of OFHC Cu. Compression, shear and sequences of deformation path are considered. It is shown that the evolution of texture is too rapid and that the intensity of peaks is more pronounced than for experimentally measured pole figures. Comparisons of both stress–strain behavior and texture evolution are made with experiments, with and without the inclusion of latent hardening effects. It is argued that grain subdivision processes accommodate intergranular kinematical constraints, leading to the notion of a generalized Taylor constraint that considers the distribution of subgrain orientations. The subdivision process is assumed to follow the experimentally observed refinement of low energy dislocation structures associated with geometrically necessary dislocations. A modification of the kinematical structure of crystal plasticity is proposed based on generation of geometrically necessary dislocations that accommodate a fraction of the plastic stretch and rotation at the scale of a grain.     

Green's Function for Orthorhombic Aggregates of Weakly Anisotropic Cubic Crystals

Herein a closed but approximate formula of the Green's function is obtained for orthorhombic aggregates of cubic crystallites. This formula, which includes three material constants and three texture coefficients, accounts for the effects of the orientation distribution function (ODF) up to terms linear in the texture coefficients. Thus it is expected that our formula would be applicable to aggregates with weak texture or to materials such as aluminum whose single crystal has weak anisotropy. The approximate formula remains valid and assumes a simpler form when the polycrystal reduces to a weakly anisotropic cubic crystal. Two examples are presented to compare predictions from our formula with those from Nishioka and Lothe's formula and from Synge's contour integral through numerical integration.     

结晶型高分子材料的平面取向演化与塑性响应

建立了描述结晶型高分子材料的平面取向演化及其塑性响应的解析框架。文中针对材料中分子链不可伸长的特点，修正了Ｔａｙｌｏｒ假定。引入连续的取向分布函数，并将它展开成不可约的张量形式表示，通过建立并求解展开系数的演化方程，最终获得问题的解。文中模拟了单轴拉伸和简单剪切时链轴朝拉伸方向偏转的过程，描述了应力的上扬硬化现象．     

Anisotropic yield functions with plastic-strain-induced anisotropy

In most anisotropic yield functions, the stress exponent, M, associated with the shape of the yield surface is usually independent of plastic-strain accumulation. This does not allow for different work-hardening characteristics under various strain states, as has been observed in aluminum alloys. Assuming coefficients characterizing anisotropy do not change with plastic deformation, the M value should vary with plastic strain, relaxing the isotropic hardening assumption. To verify this, plane-strain tests along with numerical analysis were carried out with 2008-T4 aluminium and 70/30 brass. The effective stress and effective plastic-strain curve assuming plane strain and plane stress was fit to the corresponding stress-strain data obtained in uniaxial tension. This was done by allowing M value to vary with effective plastic-strain. Hill's 1979 (case iv),Hosford's 1979 and Barlat's 1991 (6 component) yield functions were evaluated. Results showed that, with all the yield functions tested, the aluminum exhibited substantial variation of M value especially at larger strains while the brass showed minor change. Relevant numerical analysis indicated that, even though all the yield functions showed noticeable changes of M as strain increases in order for the plane-strain curve to match with the uniaxial curve, this variation of M will not affect much to the prediction with Hosford's and Barlat's yield functions, of which the typically valid M is much higher than that of Hill's. FEM simulation of plane-strain sheet forming with 2008-T4 aluminium alloy verified that implementation of varying M-value with Hill's yield function led to better agreement with experimental measurements, while the variation of M with Barlat's yield function exhibited little influence on the strain prediction.     

Modeling texture evolution in equal channel angular extrusion using crystal plasticity finite element models

A new approach to modeling crystallographic texture evolution in Equal Channel Angular Extrusion (ECAE) is presented in this paper. The proposed approach utilizes an elastic–viscoplastic single crystal constitutive model implemented in a finite element framework. A representative volume element of the polycrystal is subjected to boundary conditions that simulate the approximate deformation history experienced by different regions of the sample (at different through-thickness depths) in both Route A and Route C processing. The proposed approach aims to capture the influence of the complex interactions that ensue among the constituent individual crystals of a polycrystal in controlling the texture evolution in the sample, while capturing the boundary conditions inherent to ECAE deformation. The predictions from the proposed approach are compared against previously reported experimental measurements in ECAE of copper. It is observed that the proposed approach provides significantly better agreement with the measurements when compared against previously reported model predictions.     

Failure prediction in anisotropic sheet metals under forming operations with consideration of rotating principal stretch directions

An approximate macroscopic yield criterion for anisotropic porous sheet metals is adopted to develop a failure prediction methodology that can be used to investigate the failure of sheet metals under forming operations. Hill's quadratic anisotropic yield criterion is used to describe the matrix normal anisotropy and planar isotropy. The approximate macroscopic anisotropic yield criterion is a function of the anisotropy parameter R, defined as the ratio of the transverse plastic strain rate to the through-thickness plastic strain rate under in-plane uniaxial loading conditions. The Marciniak–Kuczynski approach is employed here to predict failure/plastic localization by assuming a slightly higher void volume fraction inside randomly oriented imperfection bands in a material element of interest. The effects of the anisotropy parameter R, the material/geometric inhomogeneities, and the potential surface curvature on failure/plastic localization are first investigated. Then, a non-proportional deformation history including relative rotation of principal stretch directions is identified in a critical element of a mild steel sheet under a fender forming operation given as a benchmark problem in the 1993 NUMISHEET conference. Based on the failure prediction methodology, the failure of the critical sheet element is investigated under the non-proportional deformation history. The results show that the gradual rotation of principal stretch directions lowers the failure strains of the critical element under the given non-proportional deformation history.     

Predictions of forming limit diagrams using a rate-dependent polycrystal self-consistent plasticity model

In the sheet-metal forming industry, forming-limit strains have been a useful tool for quantifying metals formability. However, the experimental measurement of these strains is a difficult, time consuming and expensive process. It would be useful if strains calculated with a theoretical model could replace many of the experimental measurements. In this research, we analyze forming-limit strains of metals using a rate-dependent plasticity, polycrystal, self-consistent (VPSC) model in conjunction with the Marciniak–Kuczynski (M–K) approach. Previous researchers have studied forming limit diagrams (FLDs) based on the full-constraints Taylor model. This is the first time, to the authors’ knowledge, that the self-consistent approach has been introduced to simulate the polycrystal FLD behavior. Numerous microstructural factors characterizing the material have a strong influence on the FLD, so our model includes the effects of slip hardening, strain-rate sensitivity, anisotropy and initial texture. Finally, the calculation of the FLD with a more realistic scale transition successfully predicts some of the experimental tendencies that the Taylor model cannot reproduce for aluminum alloys AA6116-T4 and AA5182-O.     

Texture predictions using a polycrystal plasticity model incorporating neighbor interactions

A viscoplastic model is presented for distributing the deformation applied to a polycrystal in a non-uniform fashion among the constituent crystals. Interactions with surrounding crystals are incorporated in the calculation of the deformation rate of each crystal through an appropriately defined local neighborhood. A compliance tensor is computed for each crystal based on a viscoplastic constitutive relation for deformation by crystallographic slip. The compliance of the crystal relative to that of its neighborhood provides a means for partitioning the macroscopic deformation rate among the crystals. The deviation of the crystal deformation rate from the macroscopic value is suitably scaled to obtain the crystal spin. Polycrystal simulations of crystallographic texture development using this model are compared to the results of similar calculations using the Taylor model, to finite element simulations of a model polycrystal, and to experimental data. The model incorporating neighbor interactions is shown to result in improved texture predictions, in terms of both the intensity levels and the locations of certain texture components.