Failure Strain and Fracture Prediction During Shock Tube Impact Forming of AA 5052-H32 Sheet

2021 ◽  
pp. 1-39
Author(s):  
Saibal Kanchan Barik ◽  
Ganesh R Narayanan ◽  
Niranjan Sahoo
Keyword(s):  
Finite Element ◽  
Flow Stress ◽  
Shock Tube ◽  
Failure Strain ◽  
Experimental Situation ◽  
Rate Sensitivity ◽  
Fracture Pattern ◽  
Failure Model ◽  
Stress Models ◽  
Cook Model

Abstract The present study deals with both numerical and experimental evaluation of failure strain and fracture pattern during shock tube impact forming of 1.5 mm thick AA 5052-H32 sheet. A hemispherical end nylon striker is propelled to deform the sheet at different velocities. Here the main objective is to understand the effect of flow stress models and fracture models on the forming outputs. The experimental situation is modelled in two stages, i.e., incorporating the pressure in the first stage, and displacement of the striker in the second stage in finite element simulation using the finite element (FE) code (DEFORM-3D). A new strategy followed to evaluate the rate-dependent flow stress data from the tensile test of samples sectioned from shock tube-based deformed sheet is acceptable, and finite element simulations incorporating those properties predicted accurate failure strain and fracture pattern. Out of all the flow stress models, the modified Johnson-Cook model has a better flow stress predictability due to the inclusion of the non-linear strain rate sensitivity term in the model. During the prediction of the failure strain and necking location, Cockcroft-Latham failure model, Brozzo failure model, and Freudenthal failure model have a fair agreement with experimental data in combination with the two flow stress models, i.e., Johnson-Cook model and modified Johnson-Cook model.

Prediction of Microstructure During High Temperature Forming of Ti-6Al-4V Alloy

2004 ◽  
Vol 449-452 ◽  
pp. 189-192 ◽  
Author(s):  
You Hwan Lee ◽  
T.J. Shin ◽  
Jong Taek Yeom ◽  
Nho Kwang Park ◽  
S.S. Hong ◽  
...  
Keyword(s):  
Activation Energy ◽  
Finite Element Analysis ◽  
Finite Element ◽  
High Temperature ◽  
Flow Stress ◽  
Rate Sensitivity ◽  
Strain Rates ◽  
Element Analysis ◽  
Strain Data ◽  
Final Microstructure

Prediction of final microstructures after high temperature forming of Ti-6Al-4V alloy was´attempted in this study. Using two typical microstructures, i.e., equiaxed and Widmanstätten microstructures, compression test was carried out up to the strain level of 0.6 at various temperatures (700 ~ 1100°C) and strain rates (10-4 ~ 102/s). From the flow stress-strain data, parameters such as strain rate sensitivity (m) and activation energy (Q) were calculated and used to establish constitutive equations for both microstructures. Then, finite element analysis was performed to predict the final microstructure of the deformed body, which was well accorded with the experimental results.

Conditions for Consistent Implementation of Flow Stress Models Incorporating Dynamic Recrystallization into Finite Element Simulation Codes

2013 ◽  
Vol 762 ◽  
pp. 325-330 ◽  
Author(s):  
Markus Bambach
Keyword(s):  
Finite Element ◽  
Flow Stress ◽  
Dynamic Recrystallization ◽  
Type Model ◽  
Stress Model ◽  
Fe Method ◽  
Analysis And Design ◽  
Evolution Of Microstructure ◽  
Stress Models ◽  
Flow Stress Model

Dynamic recrystallization (DRX) is widely used in industrial hot working processes to control the microstructure and properties of the workpiece and to keep the forming forces low. For the analysis and design of metal forming processes powerful simulation methods, must notably the Finite Element (FE) method, have been developed. Various models are available that consider the coupled evolution of microstructure and flow stress during hot deformation processes. Some of these models have been implemented into FE codes and are widely available now. However, for the implementation of flow stress models incorporating DRX into an FE formulation, special smoothness requirements exist that are not automatically fulfilled by the available flow stress models. This work reviews some conditions that a flow stress model incorporating DRX has to fulfill in order to be consistently embedded into an FE code for large plastic deformation. A specific Sellars-type model is analyzed for consistency with these conditions. It is shown that the use of a classical JMAK equation for the DRX kinetics within these models is problematic for Avrami exponents smaller than or equal to 3, for which the flow stress model is not sufficiently smooth. DRX kinetics based on the work of Cahn are proposed to remedy the differentiability issues.

A Simple Constitutive Model for Prediction of Single-Peak Flow Curves Under Hot Working Conditions

2016 ◽  
Vol 138 (2) ◽  
Author(s):  
Roxana Baktash ◽  
Hamed Mirzadeh
Keyword(s):  
Flow Stress ◽  
Strain Rate ◽  
Peak Flow ◽  
Rate Sensitivity ◽  
Peak Strain ◽  
Flow Curves ◽  
Hollomon Parameter ◽  
Proposed Model ◽  
Stress Coefficient ◽  
Hollomon Equation

The hot flow stress of a typical stainless steel was modeled by the Hollomon equation, a modified form of the Hollomon equation, and another modified form based on the Fields–Backofen equation. The coupled effect of the deformation temperature and strain rate was also taken into account in the proposed formulae by consideration of the Zener–Hollomon parameter or dependency of the constants on temperature. The modified Fields–Backofen equation was found to be appropriate for prediction of flow stress, in which the incorporation of peak strain and consideration of temperature dependencies of the strain rate sensitivity and the stress coefficient were found to be beneficial. Moreover, the simplicity of the proposed model justifies its applicability for expressing hot flow stress characterizing dynamic recrystallization (DRX).

scholarly journals Rib Cortical Bone Fracture Risk as a Function of Age and Rib Strain: Updated Injury Prediction Using Finite Element Human Body Models

2021 ◽  
Vol 9 ◽  
Author(s):  
Karl-Johan Larsson ◽  
Amanda Blennow ◽  
Johan Iraeus ◽  
Bengt Pipkorn ◽  
Nils Lubbe
Keyword(s):  
Finite Element ◽  
Fracture Risk ◽  
Cortical Bone ◽  
Failure Strain ◽  
Risk Function ◽  
Rib Fracture ◽  
Probabilistic Framework ◽  
Age Dependent ◽  
Risk Curve ◽  
Human Body Models

To evaluate vehicle occupant injury risk, finite element human body models (HBMs) can be used in vehicle crash simulations. HBMs can predict tissue loading levels, and the risk for fracture can be estimated based on a tissue-based risk curve. A probabilistic framework utilizing an age-adjusted rib strain-based risk function was proposed in 2012. However, the risk function was based on tests from only twelve human subjects. Further, the age adjustment was based on previous literature postulating a 5.1% decrease in failure strain for femur bone material per decade of aging. The primary aim of this study was to develop a new strain-based rib fracture risk function using material test data spanning a wide range of ages. A second aim was to update the probabilistic framework with the new risk function and compare the probabilistic risk predictions from HBM simulations to both previous HBM probabilistic risk predictions and to approximate real-world rib fracture outcomes. Tensile test data of human rib cortical bone from 58 individuals spanning 17–99 years of ages was used. Survival analysis with accelerated failure time was used to model the failure strain and age-dependent decrease for the tissue-based risk function. Stochastic HBM simulations with varied impact conditions and restraint system settings were performed and probabilistic rib fracture risks were calculated. In the resulting fracture risk function, sex was not a significant covariate—but a stronger age-dependent decrease than previously assumed for human rib cortical bone was evident, corresponding to a 12% decrease in failure strain per decade of aging. The main effect of this difference is a lowered risk prediction for younger individuals than that predicted in previous risk functions. For the stochastic analysis, the previous risk curve overestimated the approximate real-world rib fracture risk for 30-year-old occupants; the new risk function reduces the overestimation. Moreover, the new function can be used as a direct replacement of the previous one within the 2012 probabilistic framework.

scholarly journals Elasto-thermoviscoplastic finite element analyses of cold upsetting and forging processes of S25C steel with dynamic strain aging considered

2021 ◽  
Vol 2047 (1) ◽  
pp. 012001
Author(s):  
S M Ji ◽  
M K Razali ◽  
K H Lee ◽  
W J Chung ◽  
M S Joun
Keyword(s):  
Finite Element ◽  
Flow Stress ◽  
Dynamic Strain Aging ◽  
Strain Aging ◽  
Large Strain ◽  
Flow Behavior ◽  
Cold Forging ◽  
Dynamic Strain ◽  
Strain Effect ◽  
Strain And Strain Rate

Abstract A practical methodology is presented to characterize the thermoviscoplastic flow stress at larger strain over the temperature range of cold metal forming using tensile and compression tests. Its importance is emphasized for non-isothermal finite element (FE) analysis of automatic multi-stage cold forging (AMSCF) process where maximum strain and strain rate exceed around 3.0 and 200/s, respectively. The experimental compressive flow stress is first characterized using traditional bilinear C-m model with high accuracy. It is employed for describing the closed-form function model to extrapolate the experimental flow stress over the experimentally uncovered ranges of state variables. The strain effect on the flow stress is then improved using the experimental tensile flow stress accurately calculated at large strain and room temperature. A complicated flow behavior of S25C characterized by its dynamic strain aging features is expressed by the presented methodology, which is utilized to analyze the test upsetting and AMSCF processes by the elasto-thermoviscoplastic finite element method for revealing the effects of flow stresses on the process.

The Effect of Strain-Rate Upon the Tensile Deformation of Materials

1975 ◽  
Vol 97 (2) ◽  
pp. 151-155 ◽  
Author(s):  
R. G. Davies ◽  
C. L. Magee
Keyword(s):  
Flow Stress ◽  
Strain Rate ◽  
High Speed ◽  
Tensile Deformation ◽  
Rate Sensitivity ◽  
Al Alloys ◽  
Reinforced Plastics ◽  
Strain Behavior ◽  
Static Testing ◽  
Dynamic Factors

The tensile strength of seventeen engineering materials including steels, Al alloys, and fiber-reinforced plastics, has been determined at strain-rates from 10−3 to 103 sec−1. Variable effects on the stress-strain behavior were found in the different materials with the Al alloys showing minimal strain-rate sensitivity and the plastics highest. All results exhibit a logarithmic dependence of flow stress on strain-rate and thus the dynamic factors (ratio of dynamic to low rate or quasi-static strengths) are as dependent upon changes in quasi-static testing speed (∼1 in./min (0.42 mm/s) as they are to changes at high speed (50,000 in./min or 50 mph (22.35 m/s). No significant influence of strain-rate on elongation or reduction in area has been found for any of the materials. Steels, which comprise the majority of the presently investigated materials, exhibit a higher rate sensitivity for yielding than for higher strain deformation. It is shown that the flow stress results for these steels leads to an internally consistent scheme when (1) strength level and (2) strengthening mechanisms are properly accounted for.

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