Experimental and numerical investigation of a strain rate controlled hydraulic bulge test of sheet metal

Suttner, Sebastian; Merklein, Marion

doi:10.1016/j.jmatprotec.2016.04.022

Cited by 42 publications

(17 citation statements)

References 15 publications

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“…It has also been reported in the literature that the direct usage of a HBT curve underestimates the dome height in the case of numerical simulation of hydraulic bulging of plain sheets. 17 It is also due to the lower maximum thinning of 31.29% when the extrapolated uniaxial tensile curve has been used as compared to the peak thinning of 36.29% obtained after using the stress-strain curve obtained from HBT at the same dome height of the TWB 0.5 mm-1.0 mm. The major and minor strains of the TWB 0.5 mm-1.0 mm at the same dome height are shown in Figure 14.…”

Section: Experimental Validation Of Fea Resultsmentioning

confidence: 98%

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Formability prediction of tailor-welded blanks in hydraulic bulging using flow curves from biaxial tensile tests

Kumar

Digavalli

2020

Proceedings of the Institution of Mechanical Engineers, Part L:

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In this work, the formability of laser-welded tailored blanks of low carbon steel of two different thickness combinations in hydraulic bulging has been studied by numerical simulation. For material modeling, flow curves of the parent sheets were obtained in biaxial stress condition by conducting hydraulic bulge tests. These curves were used to extrapolate the uniaxial tensile curves up to large strains using the work equivalence principle. The limiting dome height in conventional forming and hydraulic bulging of tailor-welded blanks has been predicted in finite element simulations using the flow curves obtained directly from the hydraulic bulge tests and the extrapolated uniaxial tensile curves. Hydraulic bulging and conventional forming experiments on tailor-welded blanks have also been conducted to validate the predicted results. It has been found out that the predicted limiting dome height of the tailor-welded blanks in conventional forming and hydraulic bulging using extrapolated uniaxial tensile curves is closer to the experimental values when compared to the results obtained by using stress–strain curves obtained from hydraulic bulge tests. It has also been found that using an extrapolated uniaxial tensile curve it is also possible to predict strain distribution and percentage thinning more accurately. It has been observed that with an increase in thickness ratio, the peak pressure increased but the predicted values of peak pressure using flow curves obtained directly from hydraulic bulge tests are closer to the experimental values.

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Section: Experimental Validation Of Fea Resultsmentioning

confidence: 98%

“…Suttner et al 17 carried out FE simulations of hydraulic bulging of AA5182-0 sheet of thickness 1.2 mm to predict the dome height vs. time curves. In the simulations, the biaxial flow curve obtained from the HBT fitted using Hockett-Sherby law and the effective stress-strain curve transformed using Yld-2000 criterion was used.…”

Section: Introductionmentioning

confidence: 99%

Formability prediction of tailor-welded blanks in hydraulic bulging using flow curves from biaxial tensile tests

Kumar

Digavalli

2020

Proceedings of the Institution of Mechanical Engineers, Part L:

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“…This information is used to control the speed of the hydraulic pressure transducer (Pregler GmbH Co. KG, Deggendorf, Germany). The experimental setup, used within this contribution is based on the hydraulic bulge testing setup, introduced by Suttner and Merklein [20]. This testing setup in Figure 1 is integrated in a hydraulic press (HPDZb 630, Schuler Hydrap GmbH & Co. KG, Plüderhausen, Germany) with a maximum force of 6300 kN.…”

Section: Methodsmentioning

confidence: 99%

Improvement of Numerical Modelling Considering Plane Strain Material Characterization with an Elliptic Hydraulic Bulge Test

Lenzen¹,

Merklein²

2018

JMMP

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A precise characterization of material behavior is necessary to identify yield criteria or hardening laws for an accurate numerical design of sheet metal forming processes. Current models like Yld2000-2d or Hill'48 do not consider the plane strain state, though this condition is primary cause of failure in deep drawing. It is anticipated that an improved yield locus contour which considers the stress under plane strain conditions leads to better results in numerical simulations of a deep drawing process. Within this contribution, a new experimental setup to characterize both principal stress components under plane strain as additional input data for material modelling is presented. Therefore, hydraulic bulge tests are carried out with a novel elliptical die, which implements a plane strain condition. Moreover, the improvement of the material model is investigated exemplarily for the three sheet metal alloys DC06, DP600 and AA5182. The resulting material parameters are used to identify the yield locus for plane strain by varying the yield locus exponent of Yld2000-2d. The results prove that considering plane strain yield locus results in a better sheet thickness distribution in comparison to conventional modelling of the deep drawing process.

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“…The experimental value of this parameter was found to be 1.03, which is identical to the identified value in Table 3. Moreover, the hardening curve was calculated from the pressure and curvature measurement of the sheet, by following the procedure described in [51]. By using the bulge test, it was found that the yield curve is about 2 per cent lower than the reference curve obtained by the uniaxial test in the rolling direction.…”

Section: Experimental Verification Of Identified Anisotropymentioning

confidence: 99%

Calibration of Advanced Yield Criteria Using Uniaxial and Heterogeneous Tensile Test Data

Maček

Starman

Mole

et al. 2020

Metals

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Conventionally, plastic anisotropy is calibrated by using standard uniaxial tensile and biaxial test results. Alternatively, heterogeneous strain field specimens in combination with full-field measurements can be used for this purpose. As reported by the literature, such an approach reduces the number of required tests enormously, but it is challenging to obtain reliable results. This paper presents an alternative methodology, which represents a compromise between the conventional and heterogeneous strain field calibration technique. The idea of the method is to use simple tests, which can be conducted on the uniaxial testing machine, and to avoid the use of advanced measuring equipment. The procedure is accomplished by conducting standard tensile tests, which are simple and reliable, and by a novel heterogeneous strain field tensile test, to calibrate the biaxial stress state. Moreover, only two of the parameters required for full characterisation need to be inversely identified from the test response; the other parameters are directly determined from the uniaxial tensile test results. This way, a dimension of optimization space is reduced substantially, which increases the robustness and effectiveness of the optimization algorithm.

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Experimental and numerical investigation of a strain rate controlled hydraulic bulge test of sheet metal

Cited by 42 publications

References 15 publications

Formability prediction of tailor-welded blanks in hydraulic bulging using flow curves from biaxial tensile tests

Formability prediction of tailor-welded blanks in hydraulic bulging using flow curves from biaxial tensile tests

Improvement of Numerical Modelling Considering Plane Strain Material Characterization with an Elliptic Hydraulic Bulge Test

Calibration of Advanced Yield Criteria Using Uniaxial and Heterogeneous Tensile Test Data

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