Dual-phase steel sheets under cyclic tension–compression to large strains: Experiments and crystal plasticity modeling

In this work, we develop a physically-based crystal plasticity model for the prediction of cyclic tension–compression deformation of multi-phase materials, specifically dual-phase (DP) steels. The model is elasto–plastic in nature and integrates a hardening law based on statistically stored dislocation density, localized hardening due to geometrically necessary dislocations (GNDs), slip-system-level kinematic backstresses, and annihilation of dislocations. The model further features a two level homogenization scheme where the first level is the overall response of a two-phase polycrystalline aggregate and the second level is the homogenized response of the martensite polycrystalline regions. The model is applied to simulate a cyclic tension–compression–tension deformation behavior of DP590 steel sheets. From experiments, we observe that the material exhibits a typical decreasing hardening rate during forward loading, followed by a linear and then a non-linear unloading upon the load reversal, the Bauschinger effect, and changes in hardening rate during strain reversals. To predict these effects, we identify the model parameters using a portion of the measured data and validate and verify them using the remaining data. The developed model is capable of predicting all the particular features of the cyclic deformation of DP590 steel, with great accuracy. From the predictions, we infer and discuss the effects of GNDs, the backstresses, dislocation annihilation, and the two-level homogenization scheme on capturing the cyclic deformation behavior of the material.     

一般加载规律的弹塑性本构关系

将有关文献给出一般加载规律一维全量理论的简单模型推广到一般加载规律的一维增量理论,进而推广到一般加载规律的多维增量理论,在此基础上,建立了推导一般加载规律的多维增量理论的本构关系的一种途径。应用这种途径,从应力空间的加载函数和应变空间的加载函数出发,推导了等向强化材料和被加热的等向强化材料的一般加载规律的弹塑性本构关系的两种表示形式。理论和实例均表明,这种途径对等向强化材料、随动强化材料和理想弹塑性材料均适用。     

Research note on a reexamination of neutral loading experiments

In the examination of the published results from neutral loading experiments, the question as to whether plastic deformation occurs is found to depend on both the material and initial loading strain. Provided that initial loading is elastic, then a subsequent stress path that follows the boundary of the initial yield surface for a hardening material is truly neutral with a wholly elastic response. However, when initial loading is elastic-plastic, then further plastic deformation is produced from a subsequent stress path that follows an isotropic expansion of the initial yield surface. These results enable the appropriateness of the kinematic hardening rule and more recent developments in plasticity theory to be appraised. Neutral loading of a non-hardening material produces plastic flow. Whether the absence of hardening is inherent or induced by plastic prestrain, it is shown that the Prandtl-Reuss theory then represents the observed behavior. In general, the purely elastic and nonhardening solutions provide respectively lower and upper bounds on the deformation.     

Plastic analysis of thin plates with anisotropic hardening

In this paper we discuss the adoption of the anisotropic hardening model due to the existence of Bauschinger effect when thin plate is applied by repeated loading. The loading condition of thin plates for linear kinematic hardening has been deduced in terms of generalized forces and generalized plastic deformation. And it can be extended to nonlinear kinematic hardening and mixed hardening. Finally as an example the numerical results are obtained for a circular plate.     

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.     

Modeling multi-axial deformation of planar anisotropic elasto-plastic materials,part I: Theory

In sheet metal forming processes local material points can experience multi-axial and multi-path loadings. Under such loading conditions, conventional phenomenological material formulations are not capable to predict the deformation behavior within satisfying accuracy. While micro-mechanical models have significantly improved the understanding of the deformation processes under such conditions, these models require large sets of material data to describe the micromechanical evolution and quite enormous computation expenses for industrial applications. To reduce the drawbacks of phenomenological material models under the multi-path loadings a new anisotropic elasto-plastic material formulation is suggested. The model enables the anisotropic yield surface to grow (isotropic hardening), translate (kinematic hardening) and rotate (rotation of the anisotropy axes) with respect to the deformation, while the shape of the yield surface remains essentially unchanged.Essentially, the model is formulated on the basis of an Armstrong–Frederick type kinematic hardening, the plastic spin theory for the reorientation of the symmetry axes of the anisotropic yield function, and additional terms coupling these expressions. The capability of the model is illustrated with multi-path loading simulations in ‘tension-shear’ and ‘reverse-shear’ to assess its performance with ‘cross’ hardening and ‘Bauschinger’ effects.     

A cyclic plasticity model for single crystals

The Armstrong–Frederick type kinematic hardening rule was invoked to capture the Bauschinger effect of the cyclic plastic deformation of a single crystal. The yield criterion and flow rule were built on individual slip systems. Material memory was introduced to describe strain range dependent cyclic hardening. The experimental results of copper single crystals were used to evaluate the cyclic plasticity model. It was found that the model was able to accurately describe the cyclic plastic deformation and properly reflect the dislocation substructure evolution. The well-known three distinctive regimes in the cyclic stress–strain curve of the copper single crystals oriented for single slip can be reproduced by using the model. The model can predict the enhanced hardening for crystals oriented for multislip, showing the model's ability to describe anisotropic cyclic plasticity. For a given loading history, the model was able to capture not only the saturated stress–strain response but also the detailed transient stress–strain evolution. The model was used to predict the cyclic plasticity under a high–low loading sequence. Both the stress–strain responses and the microstructural evolution can be appropriately described through the slip system activation.     

Plastic deformation modelling of tempered martensite steel block structure by a nonlocal crystal plasticity model

The plastic deformations of tempered martensite steel representative volume elements with different martensite block structures have been investigated by using a nonlocal crystal plasticity model which considers isotropic and kinematic hardening produced by plastic strain gradients. It was found that pronounced strain gradients occur in the grain boundary region even under homogeneous loading. The isotropic hardening of strain gradients strongly influences the global stress–strain diagram while the kinematic hardening of strain gradients influences the local deformation behaviour. It is found that the additional strain gradient hardening is not only dependent on the block width but also on the misorientations or the deformation incompatibilities in adjacent blocks.     

On shakedown theory for elastic-plastic materials and extensions

The idea that an elastic-plastic structure under given loading history may shake down to some purely elastic state (and hence to a safe state) after a finite amount of initial plastic deformation, can apply to many sophisticated material models with possible allowable changes of additional material characteristics, as has been done in the literature. Despite some claims to the contrary, it is shown; however, that the shakedown theorems in a Melan-Koiter path-independent sense have been extended successfully only for certain elastic-plastic hardening materials of practical significance. Shakedown of kinematic hardening material is determined by the ultimate and initial yield stresses, not the generally plastic deformation history-dependent hardening curve between. The initial yield stress is no longer the convenient one (corresponding to the plastic deformation at the level of 0.2%) as in usual elastic-plastic analysis but to be related to the shakedown safety requirement of the structure and should be as small as the fatigue limit for arbitrary high-cycle loading. Though the ultimate yield strength is well defined in the standard monotonic loading experiment, it also should be reduced to the so-called “high-cycle ratchetting” stress for the path-independent shakedown analysis. A reduced simple form of the shakedown kinematic theorem without time integrals is conjectured for general practical uses. Application of the theorem is illustrated by examples for a hollow cylinder, sphere, and a clamped disk, under variable (including quasiperiodic dynamic) pressure.     

Constitutive relations for isotropic or kinematic hardening at finite elastic–plastic deformations

The rate-type constitutive relations of rate-independent metals with isotropic or kinematic hardening at finite elastic–plastic deformations were presented through a phenomenological approach. This approach includes the decomposition of finite deformation into elastic and plastic parts, which is different from both the elastic–plastic additive decomposition of deformation rate and Lee’s elastic–plastic multiplicative decomposition of deformation gradient. The objectivity of the constitutive relations was dealt with in integrating the constitutive equations. A new objective derivative of back stress was proposed for kinematic hardening. In addition, the loading criteria were discussed. Finally, the stress for simple shear elastic–plastic deformation was worked out.     

Elastic–plastic behavior of steel sheets under in-plane cyclic tension–compression at large strain

Elastic–plastic behavior of two types of steel sheets for press-forming (an aluminum-killed mild steel and a dual-phase high strength steel of 590 MPa ultimate tensile strength) under in-plane cyclic tension–compression at large strain (up to 25% strain for mild steel and 13% for high strength steel) have been investigated. From the experiments, it was found that the cyclic hardening is strongly influenced by cyclic strain range and mean strain. Transient softening and workhardening stagnation due to the Bauschinger effect, as well as the decrease in Young's moduli with increasing prestrain, were also observed during stress reversals. Some important points in constitutive modeling for such large-strain cyclic elasto-plasticity are discussed by comparing the stress–strain responses calculated by typical constitutive models of mixed isotropic–kinematic hardening with the corresponding experimental observations.     

Application of corotational rates of the logarithmic strain in constitutive modeling of hardening materials at finite deformations

In this paper a finite deformation constitutive model for rigid plastic hardening materials based on the logarithmic strain tensor is introduced. The flow rule of this constitutive model relates the corotational rate of the logarithmic strain tensor to the difference of the deviatoric Cauchy stress and the back stress tensors. The evolution equation for the kinematic hardening of this model relates the corotational rate of the back stress tensor to the corotational rate of the logarithmic strain tensor. Using Jaumann, Green–Naghdi, Eulerian and logarithmic corotational rates in the proposed constitutive model, stress–strain responses and subsequent yield surfaces are determined for rigid plastic kinematic and isotropic hardening materials in the simple shear problem at finite deformations.     

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.     

THE ELASTO-PLASTIC STRAIN ANALYSIS OF NOTCHED PLATE UNDER CYCLIC LOADING—AN APPLICATION OF PLASTIC ANISOTROPIC HARDENING THEORY

In order to predict the life of engineering structures, it is necessary to investigate the strain distribution in notched members. In general, the Bauschinger Effect of materials under cyclic loading is not negligible, and so the anisotropic hardening model has been suggested. From the comparison between the calculated and experimental results in this paper, we can see that even the linear kinematic hardening model is quite suitable for strain analysis under cyclic loading.     

Stress–strain curve and stored energy during uniaxial deformation of polycrystals

The subject of this paper is an attempt to obtain information about the energy stored during plastic deformation from experimentally measured stress–strain curve.Theoretical analysis of the stress–strain curve for elastic-perfectly plastic polycrystalline material has shown that only the part of stored energy can be calculated from the stress–strain curve. This part is the energy stored during non-homogeneous plastic deformation.The results of such calculation have been compared with the total stored energy determined experimentally. It has been shown that part of total stored energy related to non-homogeneous plastic deformation of investigated materials is much lower than that corresponding to homogeneous one.     

An evaluation of a combined isotropic-kinematic hardening model for representation of complex strain-path changes in dual-phase steel

This paper aims at evaluating an elastoplastic constitutive model which accounts for combined isotropic-kinematic hardening for complex strain-path changes in a dual-phase steel, DP800. The capability of the model to reproduce the transient hardening phenomena under two-stage non-proportional loading has been assessed through numerical simulations of sequential uniaxial tension and notched tension/shear tests. Finite element simulations with shell elements were performed using the explicit non-linear FE code LS-DYNA. Numerical predictions of the stress–strain response were compared to the corresponding experimental data. The results from the experiments demonstrated that prior plastic deformation has certainly influenced the subsequent work-hardening behaviour of the material under biaxial or shear deformation modes. Furthermore, the numerical simulations from the two-stage uniaxial tension–notched tension and uniaxial tension–shear tests predicted the general trends of the experimental results such as transitory hardening and overall work hardening. However, some discrepancies were found in accurately describing the transient hardening behaviour subsequent to strain path changes between the experiments and numerical simulations.     

Stress integration method for a nonlinear kinematic/isotropic hardening model and its characterization based on polycrystal plasticity

Sheet metal forming processes generally involve non-proportional strain paths including springback, leading to the Bauschinger effect, transient hardening, and permanent softening behavior, that can be possibly modeled by kinematic hardening laws. In this work, a stress integration procedure based on the backward-Euler method was newly derived for a nonlinear combined isotropic/kinematic hardening model based on the two-yield’s surfaces approach. The backward-Euler method can be combined with general non-quadratic anisotropic yield functions and thus it can predict accurately the behavior of aluminum alloy sheets for sheet metal forming processes. In order to characterize the material coefficients, including the Bauschinger ratio for the kinematic hardening model, one element tension–compression simulations were newly tried based on a polycrystal plasticity approach, which compensates extensive tension and compression experiments. The developed model was applied for a springback prediction of the NUMISHEET’93 2D draw bend benchmark example.     

Constitutive modeling of cyclic plasticity deformation of a pure polycrystalline copper

Cyclic plasticity experiments were conducted on a pure polycrystalline copper and the material was found to display significant cyclic hardening and nonproportional hardening. An effort was made to describe the cyclic plasticity behavior of the material. The model is based on the framework using a yield surface together with the Armstrong–Frederick type kinematic hardening rule. No isotropic hardening is considered and the yield stress is assumed to be a constant. The backstress is decomposed into additive parts with each part following the Armstrong–Frederick type hardening rule. A memory surface in the plastic strain space is used to account for the strain range effect. The Tanaka fourth order tensor is used to characterize nonproportional loading. A set of material parameters in the hardening rules are related to the strain memory surface size and they are used to capture the strain range effect and the dependence of cyclic hardening and nonproportional hardening on the loading magnitude. The constitutive model can describe well the transient behavior during cyclic hardening and nonproportional hardening of the polycrystalline copper. Modeling of long-term ratcheting deformation is a difficult task and further investigations are required.