The forming limit diagram plays an important role in predicting the forming limit of sheet metals.Previous studies have shown that,the method to construct the forming limit diagram based on instability theory of the o...The forming limit diagram plays an important role in predicting the forming limit of sheet metals.Previous studies have shown that,the method to construct the forming limit diagram based on instability theory of the original shear failure criterion is efective and simple.The original shear instability criterion can accurately predict the left area of the forming limit diagram but not the right area.In this study,in order to improve the accuracy of the original shear failure criterion,a modifed shear failure criterion was proposed based on in-depth analysis of the original shear failure criterion.The detailed improvement strategies of the shear failure criterion and the complete calculation process are given.Based on the modifed shear failure criterion and diferent constitutive equations,the theoretical forming limit of TRIP780 steel and 5754O aluminum alloy sheet metals are calculated.By comparing the theoretical and experimental results,it is shown that proposed modifed shear failure criterion can predict the right area of forming limit more reasonably than the original shear failure criterion.The efect of the pre-strain and constitutive equation on the forming limits are also analyzed in depth.The modifed shear failure criterion proposed in this study provides an alternative and reliable method to predict forming limit of sheet metals.展开更多
In this work, forming limit diagram for aluminum alloy 3105 is performed experimentally and forming limit based on stress (FLSD) calculated from strains that resulted from experimental procedure. In addition, numerica...In this work, forming limit diagram for aluminum alloy 3105 is performed experimentally and forming limit based on stress (FLSD) calculated from strains that resulted from experimental procedure. In addition, numerical prediction by ductile fracture criteria using simulation is considered and it is shown that they are well suited with the experimental results. The strain paths from finite element simulations are found fairly acceptable to represent both sides of the FLD.展开更多
The stress-based forming limit diagram(FLSD) established with limit stress is independent of the strain paths. Compared with traditional strain-based forming limit diagram(FLD),it is more convenient and practical to u...The stress-based forming limit diagram(FLSD) established with limit stress is independent of the strain paths. Compared with traditional strain-based forming limit diagram(FLD),it is more convenient and practical to use as the criterion of forming limit under complex strain paths. The forming limit of 3A21 aluminum alloy sheet was tested and its forming limit diagram(FLD) was determined. Then the FLSD of 3A21 was constituted by transformation formulas between limit strain and limit stress. This FLSD was used in conjunction with LS-DYNA finite element simulations to predict the onset of fracture and limit forming pressure in tube hydroforming. The results indicate that the fracture often occurs in the transition region between corner and straight side of the tube,and the limit forming pressure is 46.4 MPa. The simulation result agrees with the experimental result,and the FLSD is able to predict the forming limit of tube hydroforming with remarkable accuracy.展开更多
This paper presents the application of anisotropic damage theory to the study of forming limit diagram of A12024T3 aluminum alloy sheet. In the prediction of limiting strains of the aluminum sheet structure, a finite ...This paper presents the application of anisotropic damage theory to the study of forming limit diagram of A12024T3 aluminum alloy sheet. In the prediction of limiting strains of the aluminum sheet structure, a finite element cell model has been constructed. The cell model consists of two phases, the aluminum alloy matrix and the intermetallic cluster. The material behavior of the aluminum alloy matrix is described with a fully coupled elasto-plastic damage constitutive equation. The intermetallic cluster is assumed to be elastic and brittle. By varying the stretching ratio, the limiting strains of the sheet under biaxial stretching have been predicted by using the necking criterion proposed. The prediction is in good agreement with the experimental findings. Moreover, the finite element cell model can provide information for understanding the microscopic damage mechanism of the aluminum alloy. Over-estimation of the limit strains may result if the effect of material damage is ignored in the sheet metal forming study.展开更多
The forming limits of nickel coating on the right region were studied, so as to direct the preparation of the material and help the production of workpieces. The electrodeposited nickel coating was prepared on steel s...The forming limits of nickel coating on the right region were studied, so as to direct the preparation of the material and help the production of workpieces. The electrodeposited nickel coating was prepared on steel substrate to form advanced structures, and its plastic instability was investigated by the Swift Plastic Instability Theory. By using the compound law for laminated sheet metals, explicit equations for the calculation of the instable eigen values were deduced. The forming limit diagrams of the nickel coating on the right region were plotted. It is exhibited that the forming limit of the coating sheet is between the forming limits of the individual nickel coating and steel substrate. The forming limit of the nickel coating is not so good as that of the steel substrate, and the forming limit strain of the coating sheet tends to diminish with the increase of thickness of the coating. The greater the normal anisotropic coefficient of the materials is, the better the forming limit is.展开更多
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 ...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.展开更多
Hot granule medium pressure forming(HGMF) process is a new process in which granule medium replaces the medium in existing flexible-die hot forming process, such as liquids, gases or viscous medium. Hot forming of lig...Hot granule medium pressure forming(HGMF) process is a new process in which granule medium replaces the medium in existing flexible-die hot forming process, such as liquids, gases or viscous medium. Hot forming of light alloy sheet parts can be realized based on the properties of granule medium, such as withstanding high temperature and pressure, filling well, sealing and loading easily. In this work, the forming of AA7075 cylindrical parts by HGMF process is taken as an example to establish the constitutive relation and forming limit diagram(FLD) of AA7075 sheet which is related to temperature by hot uniaxial tensile test of sheet metal. Based on the assumption that granule medium is applied to extended Drucker-Prager linear material model, the finite element model of HGMF process is established and the effect of technological parameters, such as forming temperature, blank-holder gap and drawing ratio, on the sheet metal formability, is studied. The limit drawing ratio curve of AA7075 cylindrical parts at forming temperature of 175-300 °C is obtained by HGMF process test, and the limit drawing ratio reaches the maximum value of 1.71 at 250 °C. The results of numerical simulation are consistent with the results of process test, and the forming force, distribution of wall thichness and form of instability are predicted correctly, which provides reference for the application of HGMF process.展开更多
The conventional forming limit diagram (FLD) is described as a plot of major strain versus minor strain. However, FLD is dependent on forming history and strain path. In the present study, a forming limit stress-bas...The conventional forming limit diagram (FLD) is described as a plot of major strain versus minor strain. However, FLD is dependent on forming history and strain path. In the present study, a forming limit stress-based diagram (FLSD) has been adopted to predict the fracture limit of aluminum alloy (AA) 5052-O1 sheet. Nakazima test is simulated by plastic constitutive formula derived from the modified Gurson-Tvergaard-Needleman (GTN) model. An in situ tensile test with scanning electron microscope (SEM) is proposed to determine the parameters in GTN model. The damage evolution is observed and recorded, and the parameters of GTN model are identified through counting void fraction at three damage stages of AA5052-O 1. According to the experimental results, the original void volume fraction, the volume fraction of potential nucleated voids, the critical void volume fraction, the void volume fraction at the final failure of material are assigned as 0.002 918, 0.024 9, 0.030 103, 0.048 54, respectively. The stress and strain are obtained at the last loading step before crack. FLSD and FLD of AA5052-O 1 are plotted. Compared with the experimental Nakazima test and uniaxial tensile test, the predicted results show a good agreement. The parameters determined by in situ tensile test can be applied to the research of the forming limit for ductile metals.展开更多
The forming limit diagrams ( FLD ) of AZ31B magnesium alloy sheet were tested by means of the electro etching grid method based on the forming experiment of magnesium alloy sheet carried out with a BCS- 30D sheet fo...The forming limit diagrams ( FLD ) of AZ31B magnesium alloy sheet were tested by means of the electro etching grid method based on the forming experiment of magnesium alloy sheet carried out with a BCS- 30D sheet forming testing machine and the strain testing analysis made with an advanced ASAME automatic strain measuring system. Experiments show that, at room temperature, the mechanical properties and deep drawing peorformance of AZ31B cold-rolled magnesium alloy sheet were so poor that it failed to test the forming limit diagrams without an ideal forming and processing capacity, while the hot-rolled magnesium alloy sheet was of a little better plasticity and forming peorformance after testing its forming limit diagrams. It can be concluded that the testing of the forming limit curves ( FLC ) offers the theoretical foundation for the drawing of the deep drawing and forming process of magnesium alloy sheet.展开更多
The forming limit diagram(FLD) is an important tool to be used when characterizing the formability of metallic sheets used in metal forming processes. Experimental measurement and determination of the FLD is timecon...The forming limit diagram(FLD) is an important tool to be used when characterizing the formability of metallic sheets used in metal forming processes. Experimental measurement and determination of the FLD is timeconsuming and therefore the analytical prediction based on theory of plasticity and instability criteria allows a direct and efficient methodology to obtain critical values at different loading paths, thus carrying significant practical importance.However, the accuracy of the plastic instability prediction is strongly dependent on the choice of the material constitutive model [1–3]. Particularly for materials with hexagonal close packed(HCP) crystallographic structure, they have a very limited number of active slip systems at room temperature and demonstrate a strong asymmetry between yielding in tension and compression [4, 5]. Not only the magnitude of the yield locus changes, but also the shape of the yield surface is evolving during the plastic deformation [4]. Conventional phenomenological constitutive models of plasticity fail to capture this unconventional mechanical behavior [4, 6]. Cazacu and Plunkett [6] have proposed generic yield criteria, by using the transformed principal stress, to account for the initial plastic anisotropy and strength differential(SD) effect simultaneously. In this contribution, a generic FLD MATLAB script was developed based on Marciniak–Kuczynski analytical theory and applied to predict the localized necking. The influence of asymmetrical effect on the FLD was evaluated. Several yield functions such as von Mises, Hill, Barlat89, and Cazacu06 were incorporated into analysis. The paper also presents and discusses the influence of different hardening laws on the formability of materials with HCP crystal structures. The findings indicate that the plastic instability theory coupled with Cazacu model can adequately predict the onset of localized necking for HCP materials under different strain paths.展开更多
In the current work,to predict and improve the formability of deep drawing process for steel plate cold rolled commercial grade(SPCC) sheets,three parameters including the blanking force,the die and punch corner radiu...In the current work,to predict and improve the formability of deep drawing process for steel plate cold rolled commercial grade(SPCC) sheets,three parameters including the blanking force,the die and punch corner radius were considered.The experimental plan according to Taguchi's orthogonal array was coupled with the finite element method(FEM) simulations.Firstly,the data from the test of stress-strain and forming limit curves were used as input into ABAQUS/Explicit finite element code to predict the failure occurrence of deep drawing process.The three parameters were then validated to establish their effects on the press formability.The optimum case found via simulation was finally confirmed through an experiment.In order to obtain the complex curve profile of cup shape after deep drawing,the anisotropic behavior of earring phenomenon was modeled and implemented into FEM.After such phenomenon was correctly predicted,an error metric compared with design curve was then measured.展开更多
基金Supported by R&D Program of Beijing Municipal Education Commission of China(Grant No.KZ200010009041)Beijing Municipal University Youth Top Talents Training Program of China(Grant No.CIT&TCD201704014)Natural Science Foundation of China(Grant No.51475003).
文摘The forming limit diagram plays an important role in predicting the forming limit of sheet metals.Previous studies have shown that,the method to construct the forming limit diagram based on instability theory of the original shear failure criterion is efective and simple.The original shear instability criterion can accurately predict the left area of the forming limit diagram but not the right area.In this study,in order to improve the accuracy of the original shear failure criterion,a modifed shear failure criterion was proposed based on in-depth analysis of the original shear failure criterion.The detailed improvement strategies of the shear failure criterion and the complete calculation process are given.Based on the modifed shear failure criterion and diferent constitutive equations,the theoretical forming limit of TRIP780 steel and 5754O aluminum alloy sheet metals are calculated.By comparing the theoretical and experimental results,it is shown that proposed modifed shear failure criterion can predict the right area of forming limit more reasonably than the original shear failure criterion.The efect of the pre-strain and constitutive equation on the forming limits are also analyzed in depth.The modifed shear failure criterion proposed in this study provides an alternative and reliable method to predict forming limit of sheet metals.
文摘In this work, forming limit diagram for aluminum alloy 3105 is performed experimentally and forming limit based on stress (FLSD) calculated from strains that resulted from experimental procedure. In addition, numerical prediction by ductile fracture criteria using simulation is considered and it is shown that they are well suited with the experimental results. The strain paths from finite element simulations are found fairly acceptable to represent both sides of the FLD.
基金Project(06012150C) supported by the Fund for Key Program of the "11th 5-year Plan" of Anhui Province, China
文摘The stress-based forming limit diagram(FLSD) established with limit stress is independent of the strain paths. Compared with traditional strain-based forming limit diagram(FLD),it is more convenient and practical to use as the criterion of forming limit under complex strain paths. The forming limit of 3A21 aluminum alloy sheet was tested and its forming limit diagram(FLD) was determined. Then the FLSD of 3A21 was constituted by transformation formulas between limit strain and limit stress. This FLSD was used in conjunction with LS-DYNA finite element simulations to predict the onset of fracture and limit forming pressure in tube hydroforming. The results indicate that the fracture often occurs in the transition region between corner and straight side of the tube,and the limit forming pressure is 46.4 MPa. The simulation result agrees with the experimental result,and the FLSD is able to predict the forming limit of tube hydroforming with remarkable accuracy.
基金Project supported by the Research Committee of The Hong Kong Polytechnic University (No.G-YX34).
文摘This paper presents the application of anisotropic damage theory to the study of forming limit diagram of A12024T3 aluminum alloy sheet. In the prediction of limiting strains of the aluminum sheet structure, a finite element cell model has been constructed. The cell model consists of two phases, the aluminum alloy matrix and the intermetallic cluster. The material behavior of the aluminum alloy matrix is described with a fully coupled elasto-plastic damage constitutive equation. The intermetallic cluster is assumed to be elastic and brittle. By varying the stretching ratio, the limiting strains of the sheet under biaxial stretching have been predicted by using the necking criterion proposed. The prediction is in good agreement with the experimental findings. Moreover, the finite element cell model can provide information for understanding the microscopic damage mechanism of the aluminum alloy. Over-estimation of the limit strains may result if the effect of material damage is ignored in the sheet metal forming study.
基金Project(KF0613) supported by the Open Project Program of Key Laboratory of Low Dimensional Materials & Application Technology, Ministry of Education, ChinaProject(06IND04) supported by the Key Foundation of Xiangtan University, China
文摘The forming limits of nickel coating on the right region were studied, so as to direct the preparation of the material and help the production of workpieces. The electrodeposited nickel coating was prepared on steel substrate to form advanced structures, and its plastic instability was investigated by the Swift Plastic Instability Theory. By using the compound law for laminated sheet metals, explicit equations for the calculation of the instable eigen values were deduced. The forming limit diagrams of the nickel coating on the right region were plotted. It is exhibited that the forming limit of the coating sheet is between the forming limits of the individual nickel coating and steel substrate. The forming limit of the nickel coating is not so good as that of the steel substrate, and the forming limit strain of the coating sheet tends to diminish with the increase of thickness of the coating. The greater the normal anisotropic coefficient of the materials is, the better the forming limit is.
基金Supported by National Natural Science Foundation of China(Grant Nos.51305386,51305385)Hebei Provincial Natural Science Foundation of China(Grant No.E2013203093)
文摘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.
基金Projects(5130538651305385)supported by the National Natural Science Foundation of ChinaProject(E2013203093)supported by the Natural Science Foundation of Hebei Province,China
文摘Hot granule medium pressure forming(HGMF) process is a new process in which granule medium replaces the medium in existing flexible-die hot forming process, such as liquids, gases or viscous medium. Hot forming of light alloy sheet parts can be realized based on the properties of granule medium, such as withstanding high temperature and pressure, filling well, sealing and loading easily. In this work, the forming of AA7075 cylindrical parts by HGMF process is taken as an example to establish the constitutive relation and forming limit diagram(FLD) of AA7075 sheet which is related to temperature by hot uniaxial tensile test of sheet metal. Based on the assumption that granule medium is applied to extended Drucker-Prager linear material model, the finite element model of HGMF process is established and the effect of technological parameters, such as forming temperature, blank-holder gap and drawing ratio, on the sheet metal formability, is studied. The limit drawing ratio curve of AA7075 cylindrical parts at forming temperature of 175-300 °C is obtained by HGMF process test, and the limit drawing ratio reaches the maximum value of 1.71 at 250 °C. The results of numerical simulation are consistent with the results of process test, and the forming force, distribution of wall thichness and form of instability are predicted correctly, which provides reference for the application of HGMF process.
基金Aeronautical Science Foundation of China (03H53048)
文摘The conventional forming limit diagram (FLD) is described as a plot of major strain versus minor strain. However, FLD is dependent on forming history and strain path. In the present study, a forming limit stress-based diagram (FLSD) has been adopted to predict the fracture limit of aluminum alloy (AA) 5052-O1 sheet. Nakazima test is simulated by plastic constitutive formula derived from the modified Gurson-Tvergaard-Needleman (GTN) model. An in situ tensile test with scanning electron microscope (SEM) is proposed to determine the parameters in GTN model. The damage evolution is observed and recorded, and the parameters of GTN model are identified through counting void fraction at three damage stages of AA5052-O 1. According to the experimental results, the original void volume fraction, the volume fraction of potential nucleated voids, the critical void volume fraction, the void volume fraction at the final failure of material are assigned as 0.002 918, 0.024 9, 0.030 103, 0.048 54, respectively. The stress and strain are obtained at the last loading step before crack. FLSD and FLD of AA5052-O 1 are plotted. Compared with the experimental Nakazima test and uniaxial tensile test, the predicted results show a good agreement. The parameters determined by in situ tensile test can be applied to the research of the forming limit for ductile metals.
文摘The forming limit diagrams ( FLD ) of AZ31B magnesium alloy sheet were tested by means of the electro etching grid method based on the forming experiment of magnesium alloy sheet carried out with a BCS- 30D sheet forming testing machine and the strain testing analysis made with an advanced ASAME automatic strain measuring system. Experiments show that, at room temperature, the mechanical properties and deep drawing peorformance of AZ31B cold-rolled magnesium alloy sheet were so poor that it failed to test the forming limit diagrams without an ideal forming and processing capacity, while the hot-rolled magnesium alloy sheet was of a little better plasticity and forming peorformance after testing its forming limit diagrams. It can be concluded that the testing of the forming limit curves ( FLC ) offers the theoretical foundation for the drawing of the deep drawing and forming process of magnesium alloy sheet.
基金support from the Portuguese Foundation for Science and Technology (FCT) via the projects PTDC/EMS-TEC/2404/2012, and PTDC/EMS-TEC/1805/2012FEDER funds through the program COMPETE-‘‘Programa Operacional Factores de Competitividade’’ is greatly acknowledged
文摘The forming limit diagram(FLD) is an important tool to be used when characterizing the formability of metallic sheets used in metal forming processes. Experimental measurement and determination of the FLD is timeconsuming and therefore the analytical prediction based on theory of plasticity and instability criteria allows a direct and efficient methodology to obtain critical values at different loading paths, thus carrying significant practical importance.However, the accuracy of the plastic instability prediction is strongly dependent on the choice of the material constitutive model [1–3]. Particularly for materials with hexagonal close packed(HCP) crystallographic structure, they have a very limited number of active slip systems at room temperature and demonstrate a strong asymmetry between yielding in tension and compression [4, 5]. Not only the magnitude of the yield locus changes, but also the shape of the yield surface is evolving during the plastic deformation [4]. Conventional phenomenological constitutive models of plasticity fail to capture this unconventional mechanical behavior [4, 6]. Cazacu and Plunkett [6] have proposed generic yield criteria, by using the transformed principal stress, to account for the initial plastic anisotropy and strength differential(SD) effect simultaneously. In this contribution, a generic FLD MATLAB script was developed based on Marciniak–Kuczynski analytical theory and applied to predict the localized necking. The influence of asymmetrical effect on the FLD was evaluated. Several yield functions such as von Mises, Hill, Barlat89, and Cazacu06 were incorporated into analysis. The paper also presents and discusses the influence of different hardening laws on the formability of materials with HCP crystal structures. The findings indicate that the plastic instability theory coupled with Cazacu model can adequately predict the onset of localized necking for HCP materials under different strain paths.
基金Project(107.02-2013.01)supported by the Vietnam’s National Foundation for Science and Technology Development
文摘In the current work,to predict and improve the formability of deep drawing process for steel plate cold rolled commercial grade(SPCC) sheets,three parameters including the blanking force,the die and punch corner radius were considered.The experimental plan according to Taguchi's orthogonal array was coupled with the finite element method(FEM) simulations.Firstly,the data from the test of stress-strain and forming limit curves were used as input into ABAQUS/Explicit finite element code to predict the failure occurrence of deep drawing process.The three parameters were then validated to establish their effects on the press formability.The optimum case found via simulation was finally confirmed through an experiment.In order to obtain the complex curve profile of cup shape after deep drawing,the anisotropic behavior of earring phenomenon was modeled and implemented into FEM.After such phenomenon was correctly predicted,an error metric compared with design curve was then measured.