An investigation of a new 2D CDM model in predicting failure in HFQing of an automotive panel

Abstract

Abstract. In this paper a comparative analysis of failure prediction when using the solution heat treatment cold die forming and quenching process, known as HFQ TM , for forming an aluminium alloy AA6082 automotive panel part (bulkhead panel), is presented. An experimental programme has been designed and a series of tests have been carried out to investigate the effect of process parameters on the success of forming the complex-shaped automotive panel component using the high strength aluminium alloy. A set of unified viscoplastic plane-stress continuum damage mechanics (2D-CDM) constitutive equations was calibrated for AA6082 over a temperature range of 450 • C-525 • C and strain rates of 0.1, 1.0 and 10 s −1 , and then was integrated into the commercial finite element code, LS-DYNA, via a user-defined material subroutine, UMAT, for the forming process simulation. The results show that the CDM model can be used to provide accurate formability and failure predictions.

Hot Sheet Metal Forming Strategies for High‐Strength Aluminum Alloys: A Review—Fundamentals and Applications

“…[156] Further numerical and experimental investigations were conducted to investigate the thickness distribution in complex-shaped components of AA6082 after both the new hot forming process and cold forming. [162] The FE model developed showed good agreement with the experimental results obtained after hot forming Figure 17. Illustration and comparison of the formed parts after using the HFQ process in a) AA6082 and c) AA7075 versus the b) conventional forming process AA6082 and d) AA 7075 at room temperature.…”

“…[ 156 ] Further numerical and experimental investigations were conducted to investigate the thickness distribution in complex‐shaped components of AA6082 after both the new hot forming process and cold forming. [ 162 ] The FE model developed showed good agreement with the experimental results obtained after hot forming ( Figure ). In addition, this study demonstrated the advantages of the new process, in terms of better formability, over the traditional cold forming process for complex‐shaped components (Figure 20c,d).…”

“…Comparison of experimental and FE simulation results giving local thinning distribution in an AA6082 component after forming using the HFQ process. Reproduced with permission [162]. Copyright 2015, Mohamed et al, published by EDP Sciences.…”

“…Illustration of the formed geometry after a) cold forming and after application of the b) HFQ process. Reproduced with permission [162]. Copyright 2015, EDP Sciences.…”

Rapid feasibility assessment of components to be formed through hot stamping: A deep learning approach

“…Published literature on HFQ® focuses largely on the development of advanced material models that predict the material constitutive behaviour under HFQ® conditions [4,6,[8][9][10]. These models are then used to accurately simulate the forming response of HFQ® formed components using Finite Element (FE) simulations [5,9,11] in order to assess their manufacturing feasibility. Though useful, forming simulations usually take place late in design processes, when the component design is near completion.…”