Investigation of the Capabilities of Yield Functions on Describing the Deformation Behavior of 5754O Aluminum Alloy Sheet Under Combined Loading Paths

The combined loading tests of 5754 O aluminum alloy sheet are used to verify the yield function. Three yield functions are implemented into the commercial finite element model(FEM) code ABAQUS as a user material subroutine UMAT for the FEM simulation of the combined loading tests. The comparison of the simulating and experimental results shows that the modified Yld2000-2d yield function can describe the mechanical behavior of5754 O aluminum alloy sheet under combined loading paths reasonably while other three yield functions do not.The performance of the modified Yld2000-2d yield function on describing the mechanical behavior under combined loading paths is analyzed in detail. It is concluded that the modified Yld2000-2d yield function can be adopted to describe the deformation behavior of 5754 O aluminum alloy sheet for industrial applications.

Application and comparison of different anisotropic yield criteria in the formability analysis of aluminum sheet

The application of four widely used anisotropic yield criteria,namely,Hill'48,Hill'90,Barlat'89,and Yld2000,on the formability analysis of an automobile aluminum sheet is investigated. The applicability and reliability of these four yield criteria are identified on the basis of uniaxial tensile and stamping tests of an aluminum covering panel by embedding the specimen in the corresponding finite element models. Results show that the strain distribution and safety margin of the aluminum sheet after stamping can be predicted with a high accuracy by applying Yld2000 compared to those subjected to the three other yield criteria. The significant effects of the anisotropic plastic characteristics of the aluminum sheet on stamping are discussed by applying the advanced simulation technology.

Quasi-static-dynamic formability of AA5052-O sheet under uniaxial and plane-strain tension

An experimental study on the quasi-static-dynamic formability specified in electromagnetically assisted sheet metal stamping(EMAS)was presented.A series of uniaxial and plane-strain tensile experiments were carried out on AA5052-O sheet by using a combined quasi-static stretching and pulsed electromagnetic forming(EMF)method.Failure strains representing formability beyond conventional quasi-static forming limits are observed under both uniaxial tensile and plane-strain states.The total forming limits of the as-received aluminum alloy undergoing both low and high quasi-static pre-straining are almost similar in quasi-static-dynamic deformation.Ultimate total formability seems to depend largely on the high-velocity loading conditions.Thus, it appears that for quasi-static-dynamic deformation,the quasi-static pre-straining of material is not of primary importance to the additionally useful formability.These observations will enable to develop forming operations that take advantage of this improvement in formability,and will also enable the use of a quasi-static preform fairly close to the quasi-static forming limits without weakening its total formability for design of an EMAS process in shaping large aluminum shell parts like auto body panels.

Numerical Quantification Model and Experiment of External Force on Roller Hemming of Curved Edge Aluminium Alloy with Adhesive

Accurate quantification of external force is the key to improve the high-precision hemming of autobody closure panels.However,the mechanism of external force on forming quality of complex contour sheet metal with adhesive is not clear subjected to geometric curvature and materials.In the present study,taking the curved edge aluminum sheet as the research object,SPH(smooth particle hydrodynamics)is introduced to simulate the viscous adhesive,and the SPH-FEM(Finite element method)coupling model of adhesive and panels considering the viscosity-pressure effect is established.The numerical simulation of the roller hemming process is carried out,then the validity and reliability of the proposed method are verified by measuring the external force in real time using triaxial force sensor.The multi-step forming process and the effect of external force on the roll in/out,surface wave and plastic strain of aluminum alloy sheet under the viscosity-pressure effect are studied,and the relationship between process parameters and external force is discussed.Results show that the coupling SPH-FEM model can well reflect the hemming process of curved edge structure.The normal force is about 2–3 times of the tangential force in the pre and final hemming process.Compared with the case without adhesive,the surface wave of flange part of the hemming with adhesive is slightly larger.The normal force and the tangential force increase about 90 N and 30 N respectively,when the height increases by 1 mm.It provides an important basis for the accurate control of hemming trajectory and the improvement of manufacturing quality of autobody closure panels.

Hot Granules Medium Pressure Forming Process of AA7075 Conical Parts

High strength aluminum alloy plate has a low elongation at room temperature, which leads to the forming of its components need a high temperature. Liquid or gas is used as the pressure-transfer medium in the existing flexible mould forming process, the heat resistance of the medium and pressurizing device makes the application of aluminum alloy plate thermoforming restricted. To solve this problem, the existing medium is replaced by the heat-resisting solid granules and the general pressure equipments are applied. Based on the pressure-transfer performance test of the solid granules medium, the feasibility that the assumption of the extended Drucker-Prager linear model can be used in the finite element analysis is proved. The constitutive equation, the yield function and the theoretical forming limit diagram（FLD） of AA7075 sheet are established. Through the finite element numerical simulation of hot granules medium pressure forming（HGMF） process, not only the influence laws of the process parameters, such as forming temperature, the blank-holder gap and the diameter of the slab, on sheet metal forming performance are discussed, but also the broken area of the forming process is analyzed and predicted, which are coincided with the technological test. The conical part whose half cone angle is 15° and relative height H/d0 is 0.57, is formed in one process at 250℃. The HGMF process solves the problems of loading and seal in the existing flexible mould forming process and provides a novel technology for thermoforming of light alloy plate, such as magnesium alloy, aluminium alloy and titanium alloy.

Stress-strain analysis on AA7075 cylindrical parts during hot granule medium pressure forming

Hot granule medium pressure forming(HGMF) is a technology in which heat-resistant granules are used to replace liquids or gases in existing flexible-die forming technology as pressure-transfer medium. Considering the characteristic of granule medium that seals and loads easily, the technology provides a new method to realize the hot deep-drawing forming on high strength aluminum alloy sheet. Based on the pressure-transfer performance test of granule medium and the material performance test of AA7075-T6 sheet, plastic mechanics analysis is conducted for the areas, such as the flange area, force-transfer area and free deforming area, of cylindrical parts deep-drawn by HGMF technology, and the function relation of forming pressure is obtained under the condition of nonuniform distribution of internal pressure. The comparison between theoretical result and experimental data shows that larger deviation occurs in the middle and later period of forming process, and the maximum theoretical forming force is less than the experimental value by 24.6%. The variation tendency of the theoretical thickness curve is close to the practical situation, and the theoretical value basically agrees well with experimental value in the flange area and the top area of spherical cap which is in the free deforming area.

Formability of AA 2219-O sheet under quasi-static,electromagnetic dynamic,and mechanical dynamic tensile loadings

The mechanism by which electromagnetic forming(EMF)enhances the formability of metals is unclear owing to the coupling effect of multi-physics fields.In the present work,the associated formability improvement mechanisms were qualitatively categorized and illustrated.This was realized by comparing the formability of fully annealed 2219 aluminum alloy(AA 2219-O)sheet under quasi-static(QS),electromagnetic dynamic(EM),and mechanical dynamic(MD)tensile loadings.It was found that the forming limit of AA 2219-O sheet under EM tensile loading was significantly(45.4%)higher than that under QS tensile loading,and was marginally(3.7%–4.3%)higher than that under MD tensile loading.In addition,the forming limit of AA 2219-O sheet demonstrated a negative dependency on the strain rate within the range of the dynamic tensile tests conducted.The deformation conditions common to EM and MD tensile loadings were responsible for the significant formability improvement compared with QS tensile loading.In particular,the inertial effect was dominant.The different deformation conditions that distinguish EM tensile loading from MD tensile loading resulted in the marginal improvement in formability.This was caused by the absence of a sustaining contact force at the later deformation stage and the lower strain rate.The body force exerted little influence on the formability improvement,and the thermal effect under the two dynamic tensile loadings was negligible.

Influence of uniaxial tensile pre-strain on forming limit curve by using biaxial tensile test

This paper focused on the effect of pre-strain on forming limit curves(FLC)of 5754-O aluminum alloy sheet through utilizing biaxial tensile approach.Based on Swift model and Yld2000-2 d yield criterion,the dimensions of cruciform specimen was optimized through applying finite element method for increasing the strain at specimen center.After that,with the recommended specimen size,the cruciform specimen was tested under various stroke ratios to experimentally characterize the limit strains under different pre-strain levels.Subsequently,the biaxial tensile tests were simulated by Abaqus to obtain the limit strains and validate the material models.It can be observed in both experiments and simulations that the pre-strained uniaxial tension followed by plane tension or equi-biaxial tension can improve the formability of sheet metals.Besides,the strain path change affects the trend of first derivative of strain rate difference between neighboring points with respect to time.An early increase occurred and then fell back to the stable value,the steady evolution continued until to a new increase reaching the critical value.The M–K prediction approach was simulated to verify the influence of pre-strain on FLC.It can be found that the early increase peaks of the major strain incremental ratio rose with the amplitude of pre-strain.Finally,the phenomenon of pseudolocalization caused by the strain path change was explained through evolution of stress state inside the groove.