Ultimate strength evaluation of multi-stage cold forming technique for manufacture of thin-walled vessels
DOI:
https://doi.org/10.7242/1999-6691/2020.13.2.10Keywords:
multi-stage technological process, cold sheet stamping, numerical calculation, plasticity, limit strains, estimationAbstract
The multi-stage process of cold forging of thin-walled steel vessels was evaluated taking into account technological heredity. The quality of the product is evaluated by the degree of deviation of its stress- strain state from the ultimate states of the forming limit diagram. The process is calculated based on the model of large plastic deformations of the anisotropic shell, which takes into account the dynamics and contact interactions of the shell with the tool. The model was numerically implemented in the LS-DYNA®package. Numerical simulation was performed using the simulation tools of the package library, such as the models of plastic flow of an anisotropic sheet with the power law isotropic strain hardening, associated with the Barlat criterion Yld 2000-2d, the Peng-Landel potential of nonlinear elastic behavior of a polyurethane die, and the Coulomb friction law of contact interaction of the product with the tool. The model constants for low-carbon sheet steel DC04EK 0.7 mm and polyurethane SKU-PFL were determined from the experimental data. The forming limit curve was plotted using as the basic data the distortions of the coordinate grid near the zones of strain localization and failure of the vessel during the technological process without intermediate annealing and the results of failure tests under uniaxial tension. The features of the strain paths are studied at thе control points of the vessel at each stage of the technological process, including the sequence of drawing, bulging and reducing operations. The calculated strain paths were verified by the experiment, in which pressing equipment was used as the test facility. It was found that the operation of work piece bulging after its rapid drawing leads to the limit state and therefore requires a preliminary recovery of the plasticity resource by annealing. The obtained results demonstrate the advantages of forming the relief of the vessel by smaller degrees of bulging and greater degrees of reducing for eliminating the limit states and intermediate annealing.
Downloads
References
Banabic D. Sheet metal forming processes. Constitutive modelling and numerical simulation. Springer, 2010. 301 p. http://dx.doi.org/10.1007/978-3-540-88113-1">https://doi.org/10.1007/978-3-540-88113‒1
Hu P., Ma N., Liu L., Zhu Y. Theories, methods and numerical technology of sheet metal cold and hot forming. Analysis, simulation and engineering applications. Springer, 2013. 210 p. https://doi.org/10.1007/978-1-4471-4099-3">https://doi.org/10.1007/978-1-4471-4099-3
Bruschi S., Altan T., Banabic D., Bariani P.F., Brosius A., Cao J., Ghiotti A., Khraisheh M., Merklein M., Tekkaya A.E. Testing and modelling of material behaviour and formability in sheet metal forming. CIRP Annals, 2014, vol. 63, pp. 727‑749. https://doi.org/10.1016/j.cirp.2014.05.005">https://doi.org/10.1016/j.cirp.2014.05.005
Keller I.E., Petukhov D.S., Kazantsev A.V., Trofimov V.N. The limit diagram under hot sheet metal forming. A review of constitutive models of material, viscous failure criteria and standard tests. Vestn. Sam. Gos. Tekhn. Univ., Ser. Fiz.-Mat. Nauki – Journal of Samara State Technical University, Ser. Physical and Mathematical Sciences, 2018, vol. 22, no. 3, pp. 447-486. https://doi.org/10.14498/vsgtu1608">https://doi.org/10.14498/vsgtu1608.
Bariani P.F., Dal Negro T., Bruschi S. Testing and modelling of material response to deformation in bulk metal forming. CIRP Annals, 2004, vol. 53, pp. 573-595. https://doi.org/10.1016/S0007-8506(07)60030-4">https://doi.org/10.1016/S0007-8506(07)60030-4
Kim B.J., Van Tyne C.J., Lee M.Y., Moon Y.H. Finite element analysis and experimental confirmation of warm hydroforming process for aluminum alloy. J. Mater. Process. Tech., 2007, vol. 187-188, pp. 296-299. https://doi.org/10.1016/j.jmatprotec.2006.11.201">https://doi.org/10.1016/j.jmatprotec.2006.11.201
Shafaat M.A., Abbasi M., Ketabchi M. Investigation into wall wrinkling in deep drawing process of conical cups. J. Mater. Process. Tech., 2011, vol. 211, pp. 1783-1795. https://doi.org/10.1016/j.jmatprotec.2011.05.026">https://doi.org/10.1016/j.jmatprotec.2011.05.026
Andrade F.X.C., Feucht M., Haufe A., Neukamm F. An incremental stress state dependent damage model for ductile failure prediction. Int. J. Fract., 2016, vol. 200, pp. 127-150. https://doi.org/10.1007/s10704-016-0081-2">https://doi.org/10.1007/s10704-016-0081-2
Neto D.M., Oliveira M.C., Dick R.E., Barros P.D., Alves J.L., Menezes L.F. Numerical and experimental analysis of wrinkling during the cup drawing of an AA5042 aluminium alloy. Int. J. Mater. Form., 2017, vol. 10, pp. 125-138. https://doi.org/10.1007/s12289-015-1265-4">https://doi.org/10.1007/s12289-015-1265-4
Khan A.S., Huang S. Continuum theory of plasticity. John Wiley & Sons, 1995. 421 p.
Barlat F., Brem J.C., Yoon J.W., Chung K., Dick R.E., Lege D.J., Pourboghrat F., Choi S.-H., Chu E. Plane stress yield function for aluminum alloy sheets – part 1: theory. Int. J. Plast., 2003, vol. 19, pp. 1297-1319. https://doi.org/10.1016/S0749-6419(02)00019-0">https://doi.org/10.1016/S0749-6419(02)00019-0
Adamov A.A., Keller I.E., Petukhov D.S. Experimental identification of plasticity and failure laws of anisotropic low-carbon sheet steel for cold forming modeling. PPP – Problems of strength and plasticity, 2019, vol. 81, no. 2, pp. 202-211. https://doi.org/10.32326/1814-9146-2019-81-2-202-211">https://doi.org/10.32326/1814-9146-2019-81-2-202-211
LS-DYNA® Keyword user's manual. Volume II. Material models. Version R11.0. LSTC, 2019. 1613 p. https://www.lstc.com/download/manuals">https://www.lstc.com/download/manuals
Keller I.E., Kazantsev A.V., Adamov A.A., Petukhov D.S. Simulation of multi-stage cold forming of a thin-walled vessel. PPP– Problems of strength and plasticity, 2020, vol. 82, no. 1, pp. 75-88. https://doi.org/10.32326/1814-9146-2020-82-1-75-88">https://doi.org/10.32326/1814-9146-2020-82-1-75-88
Maker B.N., Zhu X. 6th Int. LS-DYNA Conf. Detroit, USA, April, 2000. 12 p. https://www.dynalook.com/conferences/international-conf-2000/session12-1.pdf/view">https://www.dynalook.com/conferences/international-conf-2000/session12-1.pdf/view
Maker B.N., Zhu X. 3rd European LS-DYNA Conf. Paris, France, June, 2001. 10 p. https://www.dynalook.com/conferences/european-conf-2001/58.pdf/view">https://www.dynalook.com/conferences/european-conf-2001/58.pdf/view
LS-DYNA® Keyword user's manual. Volume I. Version R11.0. LSTC, 2018. 3186 p. https://www.lstc.com/download/manuals">https://www.lstc.com/download/manuals
Hill R. A theory of the yielding and plastic flow of anisotropic metals. Proc. R. Soc. Lond. A, 1948, vol. 193, pp. 281-297. https://doi.org/10.1098/rspa.1948.0045">https://doi.org/10.1098/rspa.1948.0045
Yoon J.W., Dick R.E., Barlat F. A new analytical theory for earing generated from anisotropic plasticity. Int. J. Plast., 2011, vol. 27, pp. 1165-1184. https://doi.org/10.1016/j.ijplas.2011.01.002">https://doi.org/10.1016/j.ijplas.2011.01.002
Chung K., Kim D., Park T. Analytical derivation of earing in circular cup drawing based on simple tension properties. Eur. J. Mech. Solid, 2011, vol. 30, pp. 275-280. https://doi.org/10.1016/j.euromechsol.2011.01.006">https://doi.org/10.1016/j.euromechsol.2011.01.006
Isik K., Silva M.B., Tekkaya A.E., Martins P.A.F. Formability limits by fracture in sheet metal forming. J. Mater. Process. Tech., 2014, vol. 214, pp. 1557-1565. https://doi.org/10.1016/j.jmatprotec.2014.02.026">https://doi.org/10.1016/j.jmatprotec.2014.02.026
ISO 12004-2:2008. Metallic materials – Sheet and strip – Determination of forming-limit curves – Part 2: Determination of forming limit curves in the laboratory. International Organization for Standardization, 2008. 27 p. https://www.iso.org/standard/43621.html">https://www.iso.org/standard/43621.html
Graf A., Hosford W.F. Effect of changing strain paths on forming limit diagrams of Al 2008-T4. MTA, 1993, vol. 24, pp. 2503-2512. https://doi.org/10.1007/BF02646529">https://doi.org/10.1007/BF02646529
Graf A., Hosford W.F. The influence of strain-path changes on forming limit diagrams of Al 6111 T4. Int. J. Mech. Sci., 1994, vol. 36, pp. 897-910. https://doi.org/10.1016/0020-7403(94)90053-1">https://doi.org/10.1016/0020-7403(94)90053-1
Downloads
Published
Issue
Section
License
Copyright (c) 2020 Computational Continuum Mechanics
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.