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.     

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.     

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.     

韧性材料颈缩主应力面上应变分布假定的研究

为了深入研究韧性材料主应力面的应变分布情况,讨论Bridgman关于主应力面上应变均布假定的精度．本文首先结合断口学基本理论与在室温条件下拉伸断裂的Q235钢、40Cr钢和45#钢断口电子显微镜扫描结果,从微观角度分析其韧窝分布后发现应变均布假定存在一定的误差;然后基于体积守恒和Aramis三维应变观测系统测得的试验结果,将计算值和试验值进行对比分析发现,三种材料中除含碳量较高的45#钢外,应变均布假定并不适用于分析颈缩主应力面上应变分布．本文的研究成果可为进一步研究韧性材料颈缩大塑性阶段的应力、应变本构关系提供一定的参考．     

高强钢及软钢断裂失效行为表征与仿真预测

针对汽车碰撞、结构强度等分析中无法准确模拟高强钢及软钢的断裂失效,研究了高强钢及软钢的断裂失效特性以及其仿真预测方法．以宝钢高强钢HC340/590DP及软钢DC05为研究对象,首先通过不同应变率的拉伸试验和不同应力状态的断裂失效试验,来表征两种钢材的弹塑性及断裂失效行为．并从试验数据中得到LS-DYNA中的Damage Initiation and Evolution Criteria (DIEC)失效模型所需参数,建立失效模型,通过子系统试验及仿真计算对DIEC失效模型进行验证．结果表明基于准确的材料试验数据,正向建立的DIEC失效模型可以准确预测HC340/590D及DC05的断裂失效行为．本研究方法可推广到其他高强钢和软钢的断裂失效仿真预测中．     

Fracture Prediction for an Advanced High-Strength Steel Sheet Using the Fully Coupled Elastoplastic Damage Model with Stress-State Dependence

In this study,the numerical simulations of sheet metal forming processes are performed based on a fully coupled elastoplastic damage model.The effects of stress...     

New Correlative Models to Improve Prediction of Fracture Permeability and Inertial Resistance Coefficient

Presence of fracture roughness and occurrence of nonlinear flow complicate fluid flow through rock fractures. This paper presents a qualitative and quantitative study on the effects of fracture wall surface roughness on flow behavior using direct flow simulation on artificial fractures. Previous studies have highlighted the importance of roughness on linear and nonlinear flow through rock fractures. Therefore, considering fracture roughness to propose models for the linear and nonlinear flow parameters seems to be necessary. In the current report, lattice Boltzmann method is used to numerically simulate fluid flow through different fracture realizations. Flow simulations are conducted over a wide range of pressure gradients through each fracture. It is observed that creeping flow at lower pressure gradients can be described using Darcy’s law, while transition to inertial flow occurs at higher pressure gradients. By detecting the onset of inertial flow and regression analysis on the simulation results with Forchheimer equation, inertial resistance coefficients are determined for each fracture. Fracture permeability values are also determined from Darcy flow as well. According to simulation results through different fractures, two parametric expressions are proposed for permeability and inertial resistance coefficient. The proposed models are validated using 3D numerical simulations and experimental results. The results obtained from these two proposed models are further compared with those obtained from the conventional models. The calculated average absolute relative errors and correlation coefficients indicate that the proposed models, despite their simplicity, present acceptable outcomes; the models are also more accurate compared to the available methods in the literature.     

Mechanical Testing of Polymers in Pressurized Hydrogen: Tension,Creep and Ductile Fracture

The paper aims at characterizing some key features of the mechanical behavior of two semi-crystalline polymers in weakly pressurized hydrogen. The opportunity to use hydrogen as an alternative energy strengthens the need for reliable data on possible coupling effects between gas diffusion and mechanical properties, especially for safe design purpose. However, such effects have not been really quantified in polymers. In the present study, a hydraulic testing machine has been fitted with a pressure hydrogen chamber, and three major aspects of the mechanical behavior have been investigated in polyethylene and polyamide 11: monotonic tension, long-term creep (based on a time-temperature superposition principle) and ductile fracture (evaluated from an essential work of fracture method). Suitable protocols have been defined to take into account specificity like temperature and pressure history dependence and gas saturation kinetics of the sample.     

Experimental and Numerical Analysis of an In-Plane Shear Specimen Designed for Ductile Fracture Studies

An in-plane shear specimen made of dual phase steel designed for ductile fracture studies is presented and then analyzed experimentally and numerically. In the experiment, digital image correlation (DIC) technique is utilized to measure the deformation of the specimen. Based on the implicit nonlinear FE solver Abaqus/Standard, numerical analysis of the specimen is performed by using plane stress and solid elements respectively. The elongation of the specimen’s gauge length and the shear strain distribution within the shear zone are compared between the experimental and numerical results and a general good agreement is obtained. Thereafter, based on calculated results, the stress state of the shear zone is investigated in detail. It is shown that the shear stress is dominant within the shear zone despite of the emergence of normal stresses. The deformation is concentrated in the shear zone, where the incipient fracture is most likely to occur. The stress triaxiality and the Lode parameter at the fracture initiation are found to be maintained at a relatively low level, which implies that the stress state achieved by the specimen is close to pure shear. The present study demonstrates that the proposed in-plane shear specimen is suitable for investigation of the fracture behavior of high strength materials under shear stress states.     

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.     

几种金属材料断裂形式变化规律的试验分析

本文研究了几种金属材料在常规破坏试验过程中的断裂现象，分析了不同材料不同复合比下断裂力学试验结果，结果表明，材料在不同受力形式下，随应力状态参数兄从大向小改变，材料断裂机理从以孔洞扩张、聚合为主导，向局部剪切带产生、发展为主导转化，材料断裂形式、断裂条件也随着发生变化，通过试验结果与应力场分析，讨论了不同应力状态参数下，金属材料韧性断裂形式的变化规律。     

On the Cover: Analysis of Damage and Failure in Anisotropic Ductile Metals Based on Biaxial Experiments with the H-Specimen

Experimental Mechanics -     

Analysis of Damage and Failure in Anisotropic Ductile Metals Based on Biaxial Experiments with the H-Specimen

Background

Dependence of strength and failure behavior of anisotropic ductile metals on loading direction and on stress state has been indicated by many experiments. To realistically predict safety and lifetime of structures these effects must be taken into account in material models and numerical analysis.

Objective

The influence of stress state and loading direction on damage and failure behavior of the anisotropic aluminum alloy EN AW-2017A is investigated.

Methods

New biaxial experiments and numerical simulations have been performed with the H-specimen under different load ratios. Digital image correlation shows evolution of strain fields and scanning electron microscopy is used to visualize failure modes on fracture surfaces. Corresponding numerical studies predict stress states to explain damage and fracture processes on the micro-scale.

Results

The stress state, the load ratio and the loading direction with respect to the principal axes of anisotropy affect the width and orientation of localized strain fields and the formation of damage mechanisms and fracture modes at the micro-level.

Conclusions

The enhanced experimental program with biaxial tests considering different loading directions and load ratios is suggested for characterization of anisotropic metals.

     

电子封装技术中金属基板结构的热失效行为研究

本文将电子散斑干涉与有限元数值计算相结合，对金属基板结构的热失效行为进行了研究。获得了低维氧化物绝缘薄膜的热失效温度，以及失效过程中基板表面的变形分布；测定了25μm厚度绝缘氧化薄膜的热膨胀系数，室温下弹性模量和失效应力等三个重要的材料常数；结合实验所测定的材料常数和研究的基板结构及性能，用有限元数值方法，模拟计算了绝缘氧化薄膜在不同缺陷形状时的失效过程。并给出了不同温度下绝缘氧化薄膜的最大应力集中值。     

水力压裂解析模型裂缝扩展参数敏感性分析

水力压裂形成复杂裂缝网络是致密储层油气开采的重要技术,掌握水压裂缝扩展机理是控制压裂行为和优化压裂效果的关键.水压裂缝动态扩展行为涉及储层岩体、注入压裂液、压裂实施工艺等方面,其中水力压裂扩展时间、压裂液流体动力粘度系数、压裂液流体注入流速、储层岩石剪切模量成为决定裂缝扩展长度和裂缝开度的重要因素.本研究采用KGD、PKN两类等高解析模型对主控因素的参数敏感性进行分析,直观、快速、可靠地获得水压裂缝扩展长度、张开度动态演化行为的量化数值.研究发现,压裂持续开展过程中水压裂缝扩展长度呈线性增长、开度逐渐趋于稳定,高流体动力粘度导致裂缝难扩展、形成较大裂缝开度,通过增加压裂液流体注入流速可同时增加裂缝扩展长度和开度,较高的岩石剪切模量将降低水压裂缝的开度.通过对比两类解析模型在不同参数下的水压裂缝扩展结果,分析压裂参数与裂缝扩展的相关性和敏感系数,讨论水力压裂解析模型的裂缝扩展参数敏感性.     

纯弯曲梁的应变损伤失效分析和预测

提出了纯弯曲梁的应变损伤失效分析方法,与Kachanov的材料受载横截面减少定义拉伸损伤变量类似,以梁的弯曲惯性矩阵减少定义弯曲损伤变量。推导了梁的弯曲应变损伤基本方程,其中的材料常数可由Kachanov拉伸损伤模型的材料常数确定。并且提出了便于工程应用的应变失效预测方程。     

Comparison of Two Unsteady Intermittency Models for Bypass Transition Prediction on a Turbine Blade Profile

The present paper evaluates two unsteady transition modelling approaches: the prescribed unsteady intermittency method PUIM, developed at Cambridge University and the dynamic unsteady intermittency method developed at Ghent University. The methods are validated against experimental data for the N3-60 steam turbine stator profile for steady and for unsteady inlet flow conditions. The characteristic features of the test case are moderately high Reynolds number and high inlet turbulence intensity, which causes bypass transition. The tested models rely both on the intermittency parameter and are unsteady approaches. In the prescribed method, the time-dependent intermittency distribution is obtained from integral relations. In the dynamic method, the intermittency distribution follows from time-dependent differential equations. For unsteady computations, self-similar wake profiles are prescribed at the inlet of the computational domain. Joint validation of the prescribed and the dynamic unsteady intermittency models against experimental data shows that both methods are able to reproduce the global features of the periodical evolution of the boundary layer under the influence of a periodically impinging wake. The overall quality of the dynamic method is better than that of the prescribed method.     

基于临界距离点法的混凝土Ⅰ型断裂韧度的预测

混凝土的断裂韧度是极为重要的断裂力学材料参数,本文利用临界距离理论(TCD)中的点法和混凝土标准断裂梁试样裂缝尖端应力场的近似解,提出了一种对混凝土断裂问题按临界距离的点法进行分析的方法.基于已有文献的试验材料及其实验结果,分析了这种断裂研究分析方法的可行性.将临界距离点法与双K断裂准则应用于几何相似的混凝土梁的断裂韧性和断裂过程区分析,验证了TCD点法的可靠性.实验表明:临界距离理论的点法能够获得比双K断裂准则相对安全的失稳断裂韧度,利用临界距离法还可得到相应断裂过程区长度的极限估算值.     

Nonclassical Problems of Fracture/Failure Mechanics: on the Occasion of the 50th Anniversary of the Research (Review)

International Applied Mechanics - The principal results of research on some nonclassical problems of fracture/failure mechanics have been analyzed. These results have been obtained by the author...     

基于应力三轴度和罗德参数的6061和7075铝合金材料断裂失效分析

分别对6061铝合金和7075铝合金材料的缺口圆棒试件和凹槽平板试件进行准静态拉伸试验,并采用ABAQUS软件对拉伸过程进行数值模拟。模拟结果与试验测试结果吻合很好,验证了有限元模型的合理性和可靠性。通过有限元模拟,分别给出了不同试件的应力三轴度和罗德参数随等效塑性应变的变化曲线以及两种材料的失效轨迹,并对它们进行了分析讨论。结果表明:形状相同、材料性质不同的试件,应力三轴度的演化规律不同;材料的失效应变受应力三轴度和罗德参数的影响,并且不同性质的材料对罗德参数的敏感性不同。