Models for ductile damage and fracture prediction in cold bulk metal forming processes: a review

Cao, Trong-Son

doi:10.1007/s12289-015-1262-7

Cited by 77 publications

(49 citation statements)

References 199 publications

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“…Cao 10,11 reviewed ductile damage models developed over 50 years and described their advantages and disadvantages in detail. He divided these into three groups from the perspective of their definition of damage as follows:…”

Section: Ductile Damage and The Fracturing Of Metalmentioning

confidence: 99%

A roll-bending approach to suppress the edge cracking of silicon steel in the cold rolling process

Byon

Roh

Yang

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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The range of roll-bending that inhibits the edge cracking of high-silicon (3.0 wt%) steel strip during cold rolling was investigated by performing a pilot cold rolling test. In the rolling test, roll-bending was emulated by lathe-machining the work roll surface to be concave (corresponding to negative roll-bending) or convex (corresponding to positive roll-bending). Crack growth length that propagated during rolling and crack growth direction were measured. Three-dimensional finite element analysis coupled with ductile fracture criterion was conducted to predict the crack growth length and crack growth direction. The reliability of the finite element analysis was verified by comparing the predictions with measurements. A series of finite element simulations were then conducted with different levels of roll-bending, expressed as the ratio of the radius of curvature of work roll surface ( R) to its barrel length ( L).The difference between the measurements and the predictions of the crack growth length and crack growth direction was 6.5% and 8.3%, respectively, when the initial notch length was 6 mm. Even if a high reduction ratio for a given pass was applied to the silicon steel strip, edge cracking did not occur if the L/ R ratio was less than −0.15, with a negative value corresponding to a concave surface profile, representing negative bending.

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Section: Ductile Damage and The Fracturing Of Metalmentioning

confidence: 99%

A roll-bending approach to suppress the edge cracking of silicon steel in the cold rolling process

Byon

Roh

Yang

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…If the yield condition Φ trial ≤ 0 is satisfied, there is no plastic behaviour or damage evolution and the state variables are updated as trial values at t n+1 , using Eq. (15).…”

Section: Implementation Of a Ductile Damage Model In Fe Simulationmentioning

confidence: 99%

“…Continuum damage mechanics (CDM) has been a reliable tool to predict failure [15] and [16]. The conventional approach to CDM has focused on the interaction of the progressive deterioration of mechanical strength [17], which is formulated within the irreversible thermodynamics framework.…”

Section: Introductionmentioning

confidence: 99%

Computational and Numerical Analysis of Ductile Damage Evolution under Load-Unload Tensile Test in Dual Phase Steel

2018

SV-JME

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Dual-phase (DP) sheet steels are used in the automotive industry. They have a microstructure that consists of a ferrite matrix with dispersed martensite islands giving a combination of good formability and high strength. However, they also exhibit ductile failure caused mainly by high strain incompatibility in both phases, which continues to be an issue of discussion among researchers. To capture the mechanical degradation of a DP sheet steel, this research focuses on the damage characterization using a continuum damage model and loadingunloading uniaxial tensile tests to quantify ductile failure without incurring expensive and difficult mechanical tests, which has the potential to provide an understanding of the identification of damage parameters in the metal-forming industry. By comparing experimental tests and computation simulations, the model presents minimum errors considering triaxiality as a constant value. Key words: continuum damage mechanics, dual-phase steels, load-unload test Highlights • Progressive deterioration of mechanical strength in a dual-phase steel is investigated by means of indirect measurement of elastic modulus. • The development of a hybrid calibration procedure between conventional experimental tests and numerical simulations to predict mechanical response is assessed. • A coupled isotropic J2 plasticity with hardening saturation and a ductile damage model is used. • Initial fracture takes place in a strain localization region.

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“…The bending radius of the SPM after springback can be obtained with Equations (9) and 10 (11) As can be seen from Equation 11 The centroid of the cross section is…”

Section: Bending Analysis Of Ormmentioning

confidence: 99%

“…Otherwise, they need to spend a lot of time afterwards to modify process parameters. It is easy to cause the following defects: low precision of the contours, difficulty controlling the forming process, and sometimes fractures may occur and lead to the integral panels being completely scrapped [9]. In addition, the materials of integral panels are expensive and the bending process is the last step in the manufacturing process.…”

Section: Introductionmentioning

confidence: 99%

An Equivalent Calculation Method for Press-Braking Bending Analysis of Integral Panels

Zhang

Tian

et al. 2018

Metals

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Press-braking bending is widely applied in the manufacture of aircraft integral panels because of the advantages of strong adaptability to different contours, simplicity of bending tools, short manufacturing time and low process cost. However, a simulation of bending process requires long-time calculation and consumes extensive computational resources. Considering the factors that the original model (ORM) of an integral panel is large and the press-braking bending is used only for the local area of integral panels with heavy thickness in practice, an equivalent calculation method for press-braking bending analysis of integral panels is proposed. The local bending area of an integral panel is simplified to a model of plate in this method. An exponential strengthening model is used to derive the equations of stress, strain and forming radius of the ORM and its simplified model (SPM). Meanwhile, the equivalent parameters of the SPM are determined and deduced based on three principles: that the material begin to be yielded simultaneously, the ultimate stress of the ORM is the same as that of the SPM at the same punch displacement, and the forming radii of neutral surfaces of the ORM and the SPM are identical after springback. The distribution of the stress and strain determined by finite element (FE) simulations are compared, and the FE simulations indicate that the contour curve of the SPM is in fairly good agreement with the profile of the ORM under the same bending process parameters, and the maximum difference is 13.17%. The computational efficiency is increased by more than 48%. Therefore, the proposed approach is quite suitable for industrial applications to improve the bending quality and efficiency of integral panels.

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Models for ductile damage and fracture prediction in cold bulk metal forming processes: a review

Cited by 77 publications

References 199 publications

A roll-bending approach to suppress the edge cracking of silicon steel in the cold rolling process

A roll-bending approach to suppress the edge cracking of silicon steel in the cold rolling process

Computational and Numerical Analysis of Ductile Damage Evolution under Load-Unload Tensile Test in Dual Phase Steel

An Equivalent Calculation Method for Press-Braking Bending Analysis of Integral Panels

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