Parameter identification and blanking simulations of DP1000 and Al6082-T6 using Lemaitre damage model

doi:10.1007/s40436-021-00350-5

Advances in Manufacturing ›› 2021, Vol. 9 ›› Issue (3): 457-472.doi: 10.1007/s40436-021-00350-5

Parameter identification and blanking simulations of DP1000 and Al6082-T6 using Lemaitre damage model

Sheng Cai¹, Lin Chen²

1 Department of Vehicle Engineering, College of Engineering, China Agricultural University, Beijing 100083, People's Republic of China;
2 CW Bearing GmbH, 22113 Hamburg, Germany

收稿日期:2020-09-25 修回日期:2021-02-03 出版日期:2021-09-25 发布日期:2021-09-13
通讯作者: Lin Chen E-mail:Chen.15@gmx.de
基金资助:
The authors would like to acknowledge the support provided by the German Academic Exchange Service (DAAD).

Parameter identification and blanking simulations of DP1000 and Al6082-T6 using Lemaitre damage model

Sheng Cai¹, Lin Chen²

1 Department of Vehicle Engineering, College of Engineering, China Agricultural University, Beijing 100083, People's Republic of China;
2 CW Bearing GmbH, 22113 Hamburg, Germany

Received:2020-09-25 Revised:2021-02-03 Online:2021-09-25 Published:2021-09-13
Supported by:
The authors would like to acknowledge the support provided by the German Academic Exchange Service (DAAD).

摘要/Abstract

摘要： This work provides numerical and experimental investigations of blanking process, where the shear-enhanced Lemaitre's damage model is fully characterized and successfully applied in blanking process to predict the cutting force and cutting edge geometry under different blanking process parameters. Advanced high strength steel DP1000 and an aluminum alloy Al6082-T6 are selected for series of experiments. To obtain the damage parameters in Lemaitre's damage model the flat rectangular notched specimens tensile test was conducted and the inverse parameter identification procedure was performed. For characterizing the crack closure parameter h in the shear enhanced Lemaitre's damage model, an in-plane torsion test with novel specimen design was conducted. The finite element model (FEM) of this test was established with the minimum mesh size of 0.01 mm which was consistent with the minimum mesh size in the shear zone of the FEM for blanking process simulation. The longitudinal strain distributions of four kinds of initial notch radius or centralhole specimen were measured and compared with simulation results to validate the FEMs for these four tests. Deformation analysis of blanking of a circular work piece also was performed under three clearances. The effects of blanking conditions on sheared part morphology were detected. Stress triaxiality distribution of the blank sheet was revealed taking advantage of the successfully established FEM. The availability of the testing method and the determination method of the parameters was investigated.

The full text can be downloaded at https://link.springer.com/article/10.1007%2Fs40436-021-00350-5

关键词: Blanking, Lemaitre damage model, Stress triaxiality, Finite element model (FEM)

Abstract: This work provides numerical and experimental investigations of blanking process, where the shear-enhanced Lemaitre's damage model is fully characterized and successfully applied in blanking process to predict the cutting force and cutting edge geometry under different blanking process parameters. Advanced high strength steel DP1000 and an aluminum alloy Al6082-T6 are selected for series of experiments. To obtain the damage parameters in Lemaitre's damage model the flat rectangular notched specimens tensile test was conducted and the inverse parameter identification procedure was performed. For characterizing the crack closure parameter h in the shear enhanced Lemaitre's damage model, an in-plane torsion test with novel specimen design was conducted. The finite element model (FEM) of this test was established with the minimum mesh size of 0.01 mm which was consistent with the minimum mesh size in the shear zone of the FEM for blanking process simulation. The longitudinal strain distributions of four kinds of initial notch radius or centralhole specimen were measured and compared with simulation results to validate the FEMs for these four tests. Deformation analysis of blanking of a circular work piece also was performed under three clearances. The effects of blanking conditions on sheared part morphology were detected. Stress triaxiality distribution of the blank sheet was revealed taking advantage of the successfully established FEM. The availability of the testing method and the determination method of the parameters was investigated.

The full text can be downloaded at https://link.springer.com/article/10.1007%2Fs40436-021-00350-5

Key words: Blanking, Lemaitre damage model, Stress triaxiality, Finite element model (FEM)

Sheng Cai, Lin Chen. Parameter identification and blanking simulations of DP1000 and Al6082-T6 using Lemaitre damage model[J]. Advances in Manufacturing, 2021, 9(3): 457-472.

参考文献

1. Dixit PM, Dixit US (2008) Modeling of metal forming and machining processes. Springer, Berlin
2. Chang TM, Swift HW (1950) Shearing of metalbars. J Inst Met 78:119-146
3. Taupin E, Breitling J, Wu WT et al (1996) Material fracture and burr formation in blanking results of FEM simulations and comparison with experiments. J Mater Process Technol 59(1/2):68-78
4. Hambli R, Poitiron A (2000) Finite element modeling of sheetmetal blanking operations with experimental verification. J Mater Process Technol 102(1/3):257-265
5. Hambli R (2001) Comparison between Lemaitre and Gurson damage models in crack growth simulation during blanking process. Int J Mech Sci 43:2769-2790
6. Goijaerts AM, Govaert LE, Baaijens FPT (2001) Evaluation of ductile fracture models for different metals in blanking. J Mater Process Technol 110:312-323
7. Hambli R (2002) Prediction of burr height formation in blanking processes using neural network. Int J Mech Sci 44:2089-2102
8. Rachik M, Roelandt JM, Maillard A (2002) Some phenomenological and computational aspects of sheet metal blanking simulation. J Mater Process Technol 128:256-265
9. Farzin M, Javani HR, Mashayekhi M et al (2006) Analysis of blanking process using various damage criteria. J Mater Process Technol 177:287-290
10. Gram MD, Wagoner RH (2011) Fine blanking of high strength steels:control of material properties for tool life. J Mater Process Technol 211:717-728
11. Saanouni K, Belamri N, Autesserre P (2010) Finite element simulation of 3D sheet metal guillotining using advanced fully coupled elastoplastic-damage constitutive equations. Finite Elem Anal Des 46:535-550
12. Lemaitre J (1996) Course on damage mechanics. Springer, Berlin
13. Soyarslan C, Tekkaya AE, Akyuz U (2008) Application of continuum damage mechanics in discontinuous crack formation:forward extrusion chevron predictions. Z Angew Math Mech 88(6):436-453
14. Tekkaya AE, Allwood JM, Bariani PF et al (2015) Metal forming beyond shaping:predicting and setting product properties. CIRP Ann Manuf Technol 64(2):629-653
15. Gachet JM, Delattre G, Bouchard PO (2015) Improved fracture criterion to chain forming stage and in use mechanical strength computations of metallic parts-application to half-blanked components. J Mater Process Technol 216:260-277
16. Dalloz A, Besson J, Gourgues-Lorenzon AF et al (2009) Effect of shear cutting on ductility of a dual phase steel. Eng Fract Mech 76:1411-1424
17. Isik K, Doig M, Richter H et al (2012) Enhancement of Lemaitre model to predict cracks at low and negative triaxialities in sheet metal forming. Key Eng Mater 639:427-434
18. Bao Y, Wierzbicki T (2004) On fracture locus in the equivalent strain and stress triaxiality space. Int J Mech Sci 46(1):81-98
19. Soyarslan C, Gharbi MM, Tekkaya AE (2012) A combined experimental-numerical investigation of ductile fracture in bending of a class of ferritic-martensitic steel. Int J Solids Struct 49:1608-1626
20. Bonora N, Gentile D, Pirondi A et al (2005) Ductile damage evolution under triaxial state of stress:theory and experiments. Int J Plast 21:981-1007
21. VDI 2906-2 (1994) Quality of cut faces of (sheet) metal parts after cutting, blanking, trimming or piercing. Verein Deutscher Ingenieure, Düsseldorf, Beuth Verlag, Berlin
22. Wu X, Bahmanpour H, Schmid K (2012) Characterization of mechanically sheared edges of dual phase steels. J Mater Process Technol 212:1209-1224
23. Tekiner Z, Nalbant M, Gürün H (2006) An experimental study for the effect of different clearances on burr, smooth-sheared and blanking force on aluminium sheet metal. Mater Des 27:1134-1138
24. Çavuşoğlu O, Gürün H (2017) The relationship of burr height and blanking force with clearance in the blanking process of AA5754 aluminium alloy. Trans Famena 41:55-62
25. Behrens BA, Bouguecha A, Vucetic M et al (2014) Numerical and experimental determination of cut-edge after blanking of thin steel sheet of DP1000 within use of stress based damage model. Proc Eng 81:1096-1101

[1]	Sheng Cai, Lin Chen. Experimental and numerical investigations of the mechanical behavior of half sandwich laminate in the context of blanking[J]. Advances in Manufacturing, 2020, 8(2): 177-188.
[2]	Ehsan Jafarzadeh, Mohammad R. Movahhedy, Saeed Khodaygan, Mohammad Ghorbani. Prediction of machining chatter in milling based on dynamic FEM simulations of chip formation[J]. Advances in Manufacturing, 2018, 6(3): 334-344.
[3]	Vahid Zal, Hassan Moslemi Naeini, Ahmad Reza Bahramian, Behnam Abbaszadeh. Experimental evaluation of blanking and piercing of PVC based composite and hybrid laminates[J]. Advances in Manufacturing, 2016, 4(3): 248-256.

Parameter identification and blanking simulations of DP1000 and Al6082-T6 using Lemaitre damage model

Parameter identification and blanking simulations of DP1000 and Al6082-T6 using Lemaitre damage model

PDF

可视化

摘要/Abstract

引用本文

使用本文

参考文献

相关文章 3

编辑推荐

Metrics

本文评价