Fracture prediction of AA6061-T6 sheet in bending process using Gurson–Tvergaard–Needleman model

Khademi, Maziar; Naeini, H. Moslemi; Mirnia, Mohammad Javad; Kasaei, Mohammad Mehdi; Silva, Lucas F. M. da

doi:10.1177/14644207221134504

Cited by 2 publications

(2 citation statements)

References 40 publications

(47 reference statements)

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“…The first strategy involves considering the influence of damage induced during plastic deformation on the overall plastic behavior of the sheet metals. Models that adopt this approach are referred to as coupled models [23]. In contrast, the second strategy assumes that the plastic behavior of the sheet is independent of the damage that occurs during deformation.…”

Section: Ductile Fracture Modellingmentioning

confidence: 99%

Ductile Fracture Prediction in Hole Hemming of Aluminum and Magnesium Sheets

Kasaei,

Pereira,

Carbas

et al. 2023

Metals

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The present work proposes a suitable approach for predicting ductile fracture in a new joining process by plastic deformation called hole hemming. This process creates a combined form- and force-fit joint and enables the joining of lightweight materials with varying formability without requiring heating or auxiliary elements. In this process, the joinability of materials is limited by the occurrence of fracture in the outer sheet, highlighting the crucial need to accurately predict its damage during the process design phase. In this study, five different fracture criteria, including the McClintock, Rice–Tracey, Normalized Cockroft–Latham, and Brozzo and Modified Mohr–Coulomb (MMC) criteria, are examined during the joining of a challenging combination of lightweight materials (aluminum AA6082-T4 and magnesium AZ31). These criteria are calibrated by a hybrid experimental–numerical method using three tests with distinct stress states. These criteria are then implemented into the finite element model of the hole hemming process, utilizing an appropriate user subroutine. The results show that the flange edge of the outer sheet is the most prone region to fracture during the joining process, and a criterion must be able to model the fracture behavior of the material from uniaxial tension to shear to accurately predict fracture in this area. Among the examined criteria, only the MMC criterion was capable of such modeling and accurately predicted the critical displacement of the punch in the hemming stage with a negligible error (about 1%). On the other hand, the prediction accuracy of the other criteria varied significantly depending on the calibration test, resulting in errors ranging from 8.6% to 75.5%. The error of 8.6% was achieved with the Normalized Cockroft–Latham criterion calibrated by a uniaxial tension test. Thus, based on the results, the MMC criterion is recommended for ductile fracture prediction in the hole hemming process, offering valuable insights to assist in process design.

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Section: Ductile Fracture Modellingmentioning

confidence: 99%

Ductile Fracture Prediction in Hole Hemming of Aluminum and Magnesium Sheets

Kasaei,

Pereira,

Carbas

et al. 2023

Metals

Self Cite

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“…The essence of side trimmer trimming strip is the fracture behavior of the material, for such problems, the finite element method is commonly used as an auxiliary means to research the fracture behavior of various materials [23,24]. With the help of mature finite element software, various scholars have made multi-dimensional studies on the fracture behavior of various types of materials, including ferrous metals, non-ferrous metals, and composites, etc., which have achieved promising results and proved the effectiveness of their methods in such research [25,26].…”

Section: Introductionmentioning

confidence: 99%

Research on the Pre-Control of Side Scrap Blockage Failure during Trimming with the Side Trimmer

Wu,

Wang,

Yang

et al. 2023

Metals

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In the coupled pickling line and tandem cold mill (PL-TCM), the hot-rolled strip needs to be trimmed on both sides of the strip before the tandem cold rolling process to ensure stable operation of the rolling process. The equipment for trimming the strip is the side trimmer, and during trimming a failure of the side scrap blockage is often caused by the variation in the width of the hot-rolled strip and the deviation during the actual operation. For this problem, this paper established a finite element model of strip trimming by side trimmer, analyzed the influence of side scrap width, structure parameters, and strip specifications on the equivalent plastic strain at the trimmed position of the strip, and obtained the influence law of each factor during the trimming process. On this basis, by collecting the historical data of side scrap blockage failure of the side trimmer, the threshold value of the side scrap width setting is obtained. Combining the width data of the hot-rolled strip and the actual operation status monitoring of the strip in the inlet section of the PL-TCM, the side scrap blockage risk identification function and the speed reduction strategy of the side trimmer are designed to form the side scrap blockage pre-control model together. After applying the side scrap blockage pre-control model to a PL-TCM, a 40.5% reduction in side scrap blockage failures was achieved compared with the same length of time before the application, which achieved satisfactory results.

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Fracture prediction of AA6061-T6 sheet in bending process using Gurson–Tvergaard–Needleman model

Cited by 2 publications

References 40 publications

Ductile Fracture Prediction in Hole Hemming of Aluminum and Magnesium Sheets

Ductile Fracture Prediction in Hole Hemming of Aluminum and Magnesium Sheets

Research on the Pre-Control of Side Scrap Blockage Failure during Trimming with the Side Trimmer

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