Comparison between 3D-reconstruction optical methods applied to bulge-tests through a feed-forward neural network

The mechanical behaviour of rubber-like materials can be investigated through numerous techniques that differ from each other in costs, execution times and parameters described. Bulge test method proved helpful for hyperelastic membranes under plane and equibiaxial stress state. In the present study, bulge tests in force control were carried out on SBR 20% CB-filled specimens. 3D reconstructions of the dome were achieved through two different stereoscopic techniques, the epipolar geometry and the Digital Image Correlation. Through a Feed-Forward Neural Network (FFNN), these reconstructions were compared with the measurements by a laser triangulation sensor taken as reference. 3D-DIC reconstruction was found to be more accurate. Indeed, bias errors of the 3D-DIC and epipolar techniques with respect to the relative reference values, under creep condition, were 0.53 mm and 0.87 mm, respectively.<br /><br />

Characterization of Flow Induced Anisotropy in Sheet Metal at Large Strain

Background Many metals exhibit a stress overshoot, the so-called cross-hardening when subjected to a specific strain-path change. Existing tests for sheet metals are limited to an equivalent prestrain of 0.2 and show varying levels of cross-hardening for identical grades. Objective The aim is to determine cross-hardening at large strains, relevant for forming processes. Mild steel grades (DC04, DC06, DX56) and high strength steel grades (BS600, DP600, ZE800) are investigated to quantify the level of cross-hardening between different grades and reveal which grades exhibit cross-hardening at all. Method A novel test setup for large prestrain using hydraulic bulge test and torsion of curved sheets is developed to achieve an orthogonal strain-path change, i.e. the strain rate tensors for two subsequent loadings are orthogonal. The influence of strain rate differences between the tests and clamping of curved sheets on the determined cross-hardening are evaluated. The results are compared to experiments in literature. Results Cross-hardening for sheet metal at prestrains up to 0.6 true plastic strain are obtained for the first time. For DX56 grade the maximum cross-hardening for all prestrains have a constant level of approximately 6%, while the maximum cross-hardening for DC04 and DC06 grades increases, with levels between 7 and 11%. The high strength grades BS600 and ZE800 do not show cross-hardening behavior, while, differencing from previous publications, cross-hardening is observed for dual phase steel DP600. Conclusion Depending on the microstructure of the steel grade the cross-hardening increases with large prestrain or remains constant.

CHARACTERIZATION OF FLOW CURVES FOR ULTRA-THIN STEEL SHEETS WITH THE IN-PLANE TORSION TEST

The in-plane torsion test is a shear test that has already been successfully used to determine flow curves up to high strains for thin sheets with thicknesses between 0.5 mm and 3.0 mm. In the same way as with other shear tests, the formation of wrinkles is a major challenge in determining flow curves with the in-plane torsion test, especially when testing ultra-thin sheets with a thickness between 0.1 mm and 0.5 mm. A new method for suppressing wrinkling is introduced, in which the formation of wrinkles is avoided by arranging and gluing single sheets to multi-layered specimens. The influence of the used adhesive on the determination of flow curves is negligible. The proposed method is used to identify flow curves for two materials, the high strength steel TH620 and the soft steel TS230, used in the packaging industry. The Materials are tested in sheet thicknesses between 0.17 mm and 0.6 mm. The determined equivalent plastic strains for the TH620 with a sheet thickness of 0.20 mm, could be increased from 0.38 (bulge-test) to over 0.8 with the new method by using four-layered specimens.

Inverse Identification for the Balanced Biaxial Yield Stress of AA5182-O Alloy Sheet

Advanced yield functions, such as Yld2004, could describe the elastic boundary of materials better than the traditional. However the balanced biaxial yield stress σb which is essential to determine the parameters of advanced yield functions is hard to measure using frequently used test equipment. This work presented an inverse method to calibrate σb of AA5182-O alloy sheet based on the Erichsen test. The maximum punch force (MPF) measured from this test was used for the inverse identification. A modification coefficient was used to drop down the simulation MPF from shell element, as the application of shell element result in higher simulation punch force. Then the relationship between σb and MPF was established based on the plane stress Yld2004. With this relationship and the real measured MPF, σb could be inversely identified. Additionally, a hydraulic bulge test was performed to verify the accuracy of this inversely obtained σb.

Characterization of Flow Curves for Ultra-Thin Steel Sheets With the In-Plane Torsion Test

The in-plane torsion test is a shear test that has already been successfully used to determine flow curves up to high strains for thin sheets with thicknesses between 0.5 mm and 3.0 mm. In the same way as with other shear tests, the formation of wrinkles is a major challenge in determining flow curves with the in-plane torsion test, especially when testing ultra-thin sheets with a thickness between 0.1 mm and 0.5 mm. A new method for suppressing wrinkling is introduced, in which the formation of wrinkles is avoided by arranging and gluing single sheets to multi-layered specimens. The influence of the used adhesive on the determination of flow curves is negligible. The proposed method is used to identify flow curves for two materials, the high strength steel TH620 and the soft steel TS230, used in the packaging industry. The Materials are tested in sheet thicknesses between 0.17 mm and 0.6 mm. The determined equivalent plastic strains for the TH620 with a sheet thickness of 0.20 mm, could be increased from 0.38 (bulge-test) to over 0.8 with the new method by using four-layered specimens.

Design and Analysis of a Bulge Test Device

The aim of this work is to present the methodological process to design a device capable of performing Bulge tests. This kind of device allows obtaining more information about the plastic behavior of a material than the one provided by a traditional tensile test. The engineering specifications of the device were evaluated through the QFD methodology. Then, a basic design of the device was performed based on available analytical models such as thick-walled pressure vessel theory, annular plate theory, and a basic plasticity model for the biaxial stress state. Later, a detailed design of the device was proposed, which was evaluated by means of a 3D model of finite elements and a linearstatic analysis for the main components. Finally, a 2D axisymmetric model and a dynamic non-linear analysis were performed to validate the proposed design. The main novelty of the work consists of articulating the methodology of the mechanical design process and the conception, design, and validation of a Bulge device while solving the deficiencies found in the literature regarding the design and validation processes of this type of devices.

Analysis of Equibiaxial Tension Tests for Hyperelastic EAP Film

Equibiaxial tension tests for hyperelastic electroactive polymers (EAPs) are important means to obtain the mechanical properties. There are three main methods: equibiaxial planar tension, radial tension and bulge test. The finite element analysis software is used to model and analyze the influence of testing apparatus, specimen geometric parameters on the test results and accuracy. The results show that the uniformity of the deformation of the square film can be effectively improved by using single corner point fixed tension in equibiaxial planar tension test, and the force error also decreased; the number of the cuts and the size of punched holes should be appropriate in radial tension test of circular diaphragm specimen to avoid the material strength failure caused by excessive tension along the edge of transition arc between grips and excessive deformation of tensile belt between the cuts; in bulge test, the sampled deformation data should be near the spherical pole to obtain more accurate stress-strain relationship owing to contour error and non-uniform deformation, a certain range of model parameters will limit the scope of simulation analysis. This paper proposed research provides guidance for the design of equibiaxial tension test apparatus and method to obtain more accurate test results.