Fully Implicit Stress Update Algorithm for Distortion−Based Anisotropic Hardening with Cross−Loading Effect: Comparative Algorithmic Study and Application to Large−Size Forming Problem

A fully implicit stress integration algorithm is developed for the distortional hardening model, namely the e−HAH model, capable of simulating cross−hardening/softening under orthogonal loading path changes. The implicit algorithm solves a complete set of residuals as nonlinear functions of stress, a microstructure deviator, and plastic state variables of the constitutive model, and provides a consistent tangent modulus. The number of residuals is set to be 20 or 14 for the continuum or shell elements, respectively. Comprehensive comparison programs are presented regarding the predictive accuracy and stability with different numerical algorithms, strain increments, material properties, and loading conditions. The flow stress and r−value evolutions under reverse/cross−loading conditions prove that the algorithm is robust and accurate, even with large strain increments. By contrast, the cutting−plane method and partially implicit Euler backward method, which are characterized by a reduced number of residuals, result in unstable responses under abrupt loading path changes. Finally, the algorithm is implemented into the finite element modeling of large−size, S−rail forming and the springback for two automotive steel sheets, which is often solved by a hybrid dynamic explicit–implicit scheme. The fully implicit algorithm performs well for the whole simulation with the solely static implicit scheme.