Modeling the Bauschinger effect for sheet metals,part I: theory

It is essential to model the Bauschinger effect correctly for sheet metal forming process simulation and subsequent springback prediction when material points are subjected to cyclic loading conditions. The combined nonlinear hardening model for time independent cyclic plasticity, proposed by Chaboche and co-workers, is examined and a simple modification is suggested for the isotropic part of the hardening rule to utilize the conventional tensile test data directly. This modification is useful for the materials whose reverse loading curves saturate to the monotonic loading curve. In addition, an anisotropic nonlinear kinematic hardening model (ANK model) is proposed in an attempt to represent the Bauschinger effect more realistically. Possible offset in flow stress is modeled by treating the back stress evolution during reverse loading differently from the initial loading. This strategy coupled with the modified isotropic hardening rule seems to provide a way to model the Bauschinger effect consistently over multiple cycles. Two types of auto-body alloys are examined in this paper. Associated material parameters are determined by employing available tension-compression test data and multi-cycle bend test data. A developed finite element formulation is applied to analyze simple validation type of problems. The cyclic stress–strain curves generated from the proposed ANK model match remarkably well with measured data.     

Continuous, large strain, tension/compression testing of sheet material

Modeling sheet metal forming operations requires understanding of the plastic behavior of sheet alloys along non-proportional strain paths. Measurement of hardening under reversed uniaxial loading is of particular interest because of its simplicity of interpretation and its application to material elements drawn over a die radius. However, the compressive strain range attainable with conventional tests of this type is severely limited by buckling. A new method has been developed and optimized employing a simple device, a special specimen geometry, and corrections for friction and off-axis loading. Continuous strain reversal tests have been carried out to compressive strains greater than 0.20 following the guidelines provided for optimizing the test. The breadth of application of the technique has been demonstrated by preliminary tests to reveal the nature of the Bauschinger effect, room-temperature creep, and anelasticity after strain reversals in commercial sheet alloys.     

一种基于电磁霍普金森杆的材料动态包辛格效应测试装置及方法

金属材料在复杂载荷条件下的动态力学行为研究一直备受关注,但受限于实验设备,金属材料的动态包辛格效应响应一直都难以获得。为了探究金属材料的包辛格效应与应变率效应之间的关系,本文中提出一种基于电磁霍普金森杆(electromagnetic split Hopkinson bar,ESHB) 的非同步加载实验技术,为测试金属材料在高应变率加载下的包辛格效应提供了一种有效的实验方法。本文中,首先介绍了非同步加载装置的主要特点,即可以用两列由脉冲发生器产生的应力波对受载试样进行连续的一次动态拉-压循环加载,且加载过程保证了应力波的一致性。分析了应力波对试样加载过程中的波传播历程,确保了加载过程的连续性。随后介绍了动态加载过程,数据处理方法和波形分离手段,并对动态加载过程进行应力平衡性分析,论证了实验装置的可靠性。最后采用该方法测试了5%预应变下6061铝合金动态压缩-动态拉伸的包辛格效应,并与准静态下的实验结果进行对比。实验结果表明,该材料单轴压缩没有明显的应变率效应,但其包辛格效应具有应变率依赖性,高应变率下材料的包辛格应力影响因子由0.07增大至0.17,具有显著的提升,这对传统意义上铝合金材料应变率不敏感的结论提出了挑战。     

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.     

单轴载荷下X80钢的包申格效应研究

本文通过单轴拉伸和压缩试验研究了X80管线钢的包申格效应(BE)。采用正向与反向加载方法研究材料变形历史特性。测定了X80钢的简单拉伸试验曲线,其应力-应变关系表明,该材料具有理想弹塑性特点。为了得到X80钢的BE,在不同预变形下对几个试件分别进行加载,并当给定的预应变值分别达到0.63%,0.67%,0.95%,1.27%和1.55%时就卸载。随后再进行反向加载实验,并记录应力应变曲线。该钢材反向加载时出现加工硬化,且屈服强度比正向加载时要低。正反向加载之间的屈服强度差值随着预应变增加而增大;当预应变超过0.95%时,反向屈服强度达到恒量。实验表明,X80钢的反向加载特性可用Remberg-Osgood关系拟合。最后给出了屈服强度降和预塑性应变之间的经验公式。     

On the fracture toughness of ferroelastic materials

The toughness enhancement due to domain switching near a steadily growing crack in a ferroelastic material is analyzed. The constitutive response of the material is taken to be characteristic of a polycrystalline sample assembled from randomly oriented tetragonal single crystal grains. The constitutive law accounts for the strain saturation, asymmetry in tension versus compression, Bauschinger effects, reverse switching, and strain reorientation that can occur in these materials due to the non-proportional loading that arises near a propagating crack. Crack growth is assumed to proceed at a critical level of the crack tip energy release rate. Detailed finite element calculations are carried out to determine the stress and strain fields near the growing tip, and the ratio of the far field applied energy release rate to the crack tip energy release rate. The results of the finite element calculations are then compared to analytical models that assume the linear isotropic K-field solution holds for either the near tip stress or strain field. Ultimately, the model is able to account for the experimentally observed toughness enhancement in ferroelastic ceramics.     

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.     

Three-dimensional constitutive model for shape memory alloys based on microplane model

A new model for the behavior of polycrystalline shape memory alloys (SMA), based on a statically constrained microplane theory, is proposed. The new model can predict three-dimensional response by superposing the effects of inelastic deformations computed on several planes of different orientation, thus reproducing closely the actual physical behavior of the material. Due to the structure of the microplane algorithm, only a one-dimensional constitutive law is necessary on each plane. In this paper, a simple constitutive law and a robust kinetic expression are used as the local constitutive law on the microplane level. The results for SMA response on the macroscale are promising: simple one-dimensional response is easily reproduced, as are more complex features such as stress-strain subloops and tension-compression asymmetry. A key feature of the new model is its ability to accurately represent the deviation from normality exhibited by SMAs under nonproportional loading paths.     

显式方法精确模拟形状记忆合金循环荷载下的变形行为

本文提出全新的有限弹塑性J2流方程,用来显式、精确地模拟SMAs（形状记忆合金）材料在循环加载-卸载条件下从塑性逐渐转变为伪弹性的变形行为．首先,改进流动法,使得本构方程耦合屈服中心的移动和屈服面的增大,并改进背应力演化方程,使模型可以产生强烈的包辛格效应,从理论上具备模拟SMAs独特变形行为的能力;其次,构造全过程下的统一硬化函数显式表达式,代入本构方程后能得到符合要求的形函数;再次,利用选定的数据点构造统一光滑的上屈服函数,再利用上下屈服应力之间的一种线性关系,推导得到下屈服阶段的形函数;最后,只需要给定一个参数就可以得到单个循环结果,利用拉格朗日插值方法构建参数随循环次数变化的函数,就可以模拟任意循环荷载下的变形行为．通过模型结果和实验数据对比证明新方法的有效性．     

Multiple-slip work-hardening model in crystals with application to torsion-tension behaviors of aluminium tubes

Torsion-tension behaviors of aluminium tubes are simulated numerically using the finite-element polycrystal model. As a multiple-slip work-hardening model in crystals, the backlash model and the maximum forest dislocation model are proposed to account for Bauschinger effect in reverse loading and cross effect (latent hardening) in non-proportional loading, respectively. The simulations with the new microscopic constitutive law predict well Bauschinger curves, cyclic loading curves and cross loading curves.     

Spring-back evaluation of automotive sheets based on isotropic-kinematic hardening laws and non-quadratic anisotropic yield functions: Part II: characterization of material properties

In order to improve the prediction capability of spring-back in the computational analysis of automotive sheet forming processes, the modified Chaboche type combined isotropic-kinematic hardening law was formulated to account for the Bauschinger and transient behavior in Part I. As for the yield stress function, the non-quadratic anisotropic yield potential, Yld2000-2d, was utilized under the plane stress condition. Experimental procedures to obtain the material parameters of the combined hardening law and the yield potential are presented here in Part II for three automotive sheets: AA5754-O, AA6111-T4 and DP-Steel. The modified Chaboche model was confirmed to well represent the measured hardening behavior including the Bauschinger and transient behavior. While the theoretical and numerical formulations of the constitutive law are discussed in Part I, experimental verifications for spring-back of formed parts are further discussed in Part III.     

DYNAMIC TENSILE TESTING OF SHEET MATERIAL USING THE SPLIT-HOPKINSON BAR TECHNIQUE

We have described an experimental method based on the SHPB technique which allows dynamic tensile testing of 1.0-mm-thick sheet material. The test method employs a framing camera to make strain measurements based on direct observation of the deforming test sample. Stress in the sample is determined using traditional SHPB wave analysis. This information is used to construct engineering stress-strain behavior. The stress-strain behavior determined using the test method is shown to be reasonably accurate for annealed tantalum and less accurate for annealed copper. We believe that this phenomenon is related to the constitutive behavior of the test material. Although the stress-strain behavior extracted from the test is in some cases suspect, the test technique is shown to provide highly reproducible results and thus can be employed to examine effects of microstructural features, alloying elements, etc., on dynamic deformation and fracture of ductile materials.     

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.     

Spring-back evaluation of automotive sheets based on isotropic-kinematic hardening laws and non-quadratic anisotropic yield functions: Part I: theory and formulation

In order to improve the prediction capability of spring-back in automotive sheet forming processes, the modified Chaboche type combined isotropic-kinematic hardening law was formulated based on the modified equivalent plastic work principle to account for the Bauschinger effect and transient behavior. As for the yield stress function, the non-quadratic anisotropic yield potential, Yld2000-2d, was utilized under the plane stress condition. Besides the theoretical aspect of the constitutive law including the general plastic work principle for monotonously proportional loading, the method to determine hardening parameters as well as numerical formulations to update stresses were developed based on the incremental deformation theory and the consistency requirement as summarized in Part I, while the characterization of material properties and verifications with experiments are discussed in Part II and III, respectively.     

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．     

Prise en compte de l'effet Bauschinger dans l'acier X2CrNiMo17-12-2 par deux lois de comportement

Various constitutive laws from thermodynamical formulation take into account a Bauschinger effect. Nevertheless this effect exhibits different aspects according to different materials. This work analyses how two of these laws represent the Bauschinger effect which is observed in an AISI 316L austenitic stainless steel during uniaixial tension-compression loading.     

Evaluation of the VDA 238–100 Tight Radius Bend Test for Plane Strain Fracture Characterization of Automotive Sheet Metals

Accurate characterization of the fracture limit in plane strain tension of automotive sheet metals is critical for the design and crash performance of structural components. Plane strain bending using the VDA 238–100 V-bend test has potential for proportional fracture characterization by avoiding a tensile instability. The VDA 238–100 V-bend test was evaluated using DIC strain measurement to characterize the plane strain fracture limit under proportional plane stress loading and to evaluate the effect of the VDA pre-straining methodology for ductile alloys upon the material response. The load-based failure criterion of the V-bend test was evaluated with DIC to monitor the development of surface cracking. The influence of the non-linear strain path imposed by the pre-straining procedure for ductile materials was then evaluated for three automotive alloys: an advanced high strength dual phase steel, DP1180, a rare-earth magnesium, ZEK100, and an AA5182 aluminum. A fracture criterion based on the load threshold was reasonable for the three alloys considered. Pre-straining in uniaxial tension prior to plane strain bending affected each alloy differently. The DP1180 was not affected by the non-linear strain path whereas the cumulative equivalent strain for the AA5182 and ZEK100 increased by strains of 0.07 and 0.05 strain, respectively. The non-linear strain path within the VDA pre-straining methodology creates ambiguity in comparing the fracture limits of different materials. The plane strain fracture limit for proportional loading can be readily obtained in the V-bend test with DIC strain measurement.

     

The inelastic behavior of metals subject to loading reversal

One of the consequences of memory effects in the plastic deformation of metals is the Bauschinger effect (Civilingenieur 27 (1881) 289–348), which manifests itself as a difference in the values of the yield stress in tension and compression for a material that has undergone plastic deformation. The Bauschinger effect has been modeled with the kinematic hardening rules e.g., Ziegler (Quart. Appl. Math. 17 (1959) 55) and Chaboche (Int. J. Plasticity 2 (1986) 149). These models, though, are not able to reproduce the stress-strain response accurately at points of loading reversal: it has been observed (Acta Metall. 34 (1986) 1553; Mater. Sci. Engineering A113 (1989) 441) that, for some materials, the stress has a plateau after the loading is reversed. This is not reflected by the kinematic hardening rule nor by its modifications. In this paper we will develop a general three dimensional model that is able to reproduce the stress–strain response at loading reversals and can be applied also to more general changes of loading direction. The central idea of our model is to link the hardening behavior of the material to thermodynamical quantities such as the stored energy due to cold work and the rate of dissipation. The predictions of the theory show good agreement with the stress–strain curve and also with the manner in which the stored energy varies with the inelastic strain, as obtained from experiments (Progress in Materials Science (1973) Vol. 17. Pergamon, Oxford; Trans. Met. Soc. AIME 224 (1962) 719).     

数据驱动梯度结构材料弹塑性本构

梯度结构材料因其优异的力学性能被广泛应用于工程结构中.论文整合塑性理论和人工神经网络技术,发展了一种构建梯度结构材料弹塑性本构模型的新方法.该方法基于梯度结构材料不同位置的微结构,构建不同代表性体积单元,进而生成应力应变数据,应用生成的数据训练人工神经网络,建立基于神经网络的材料本构模型.应用该方法,论文开展了针对实际...