Calibration of the Ductile Failure Criterion for Nickel-Based Superalloys taking into Account the Localization of the Strain

Static tension test allows characterization of material strength properties. This simple test provides input data for numerical calculation of structural components made of the tested alloy. Elastic, plastic and failure behavior of the structural component in question is simulated, using, for example, the FEM package, based on parameters obtained as the result of tensile testing. When using the results of the tensile test for modeling the material failure it is important to estimate correctly plastic strain corresponding to failure. It is common practice to use elongation of the specimen gage part for the calculation of failure strain. On the other side, the most popular ductile failure criterion used by engineers performing numerical simulation of the material’s behavior relies on the equivalent plastic strain as the criterial quantity. Those two parameters can differ significantly. In order to calculate the equivalent plastic strain correctly, we have to remember about strain localization (necking) appearing during tensile tests and take into account the fact that during tensile testing we have three non-zero strain tensor components. Ignoring this fact, and using only elongation as the criterial quantity can lead to enormous simulation error. This error is analyzed in this paper for nickel based superalloy tested at elevated temperatures.

Predicting Sheet Forming Limit of Aluminum Alloys for Cold and Warm Forming by Developing a Ductile Failure Criterion

In this study, the forming limit of aluminum alloy sheet materials is predicted by developing a ductile failure criterion (DFC). In the DFC, the damage growth is defined by Mclintock formula, stretching failure is defined at localized necking (LN) or fracture without LN, while the critical damage is defined by a so-called effect function, which reflects the effect of strain path and initial sheet thickness. In the first part of this study, the DFC is used to predict forming limit curves (FLCs) of six different aluminum sheet materials at room temperature. Then, the DFC is further developed for elevated temperature conditions by introducing an improved Zener–Hollomon parameter (Z′), which is proposed to provide enhanced representation of the strain rate and temperature effect on limit strain. In warm forming condition, the improved DFC is used to predict the FLCs of Al5083-O and failure in a rectangular cup warm draw process on Al5182 + Mn. Comparison shows that all the predictions match quite well with the experimental measurements. Thanks to the proposal of effect function, the DFC needs calibration only in uniaxial tension, and thus, provides a promising potential to predict forming limit with reduced effort.

Predicting Sheet Forming Limit of Aluminum Alloys for Cold and Warm Forming by Developing a Ductile Failure Criterion

In this study, the forming limit of aluminum alloy sheet materials are predicted by developing a Ductile Failure Criterion (DFAC). In the DFAC, the damage growth is defined by Mclintock formula, stretching failure is defined at Localized Necking (LN) or Fracture without LN, while the critical damage is defined by a so-called effect function, which reflects the effect of strain path and initial sheet thickness. In the first part of this study, the DFAC is used to predict Forming Limit Curves of six different aluminum sheet materials at room temperature. Then, the DFAC is further developed for elevated temperature condition by introducing an improved Zener-Hollomon parameter (Z′), which is proposed to provide enhanced representation of the strain rate and temperature effect on limit strain. In warm forming condition, the improved DFAC is used to predict the FLCs of Al5083-O and failure in a rectangular cup warm draw process on Al5182+Mn. Comparison shows that all the prediction matches quite well with experimental measurement. Thanks to the proposal of effect function, the DFAC only needs a calibration at uniaxial tension and thus provides a promising potential to predict forming limit with reduced efforts.