A linked FEM-damage percolation model of aluminum alloy sheet forming

Chen, Z. T.; Worswick, M. J.; Cinotti, N.; Pilkey, A. K.; Lloyd, D.

Affiliations

¹Department of Mechanical Engineering, University of Waterloo, Waterloo, Ontario, Canada N2L 3G

²Department of Mechanical Engineering, Queens University, Kingston, Ontario, Canada K7L 3N6

³ALCAN International Limited, Kingston Research and Development Centre, Kingston, Ontario, Canada K7L 5L9

Abstract and keywords

A so-called damage percolation model is linked with a finite element model of a sheet forming process to offer a comprehensive study of ductile damage evolution. In the current study, a damage percolation code is linked with LS-DYNA, an explicit dynamic FEM code used to introduce local strain gradients and compliance effects due to damage-induced softening. The linked model utilizes a Gurson-based yield surface to account for the softening effects of void damage, while the local damage development and void linkage events are modeled using the damage percolation code. The percolation code accepts detailed second phase particle fields from image analysis of a 2.0×1.6 mm optical micrograph of AA5182 aluminum alloy sheet. The model is applied to a stretch-flange stamping process which is known to be a damage-sensitive operation. The critical conditions for fracture are predicted for various initial stretch flange hole sizes.

Keywords: Ductile damage; Damage percolation; Metal forming; Strain gradient; Stretch flange; Aluminum alloy sheet

Links

DOI: 10.1016/S0749-6419(03)00061-5

WoS: 000185218900005

History

Revised: 2002-10-29

Online: 2003-07-18

Cited Works (13)

Year	Entry
1990	Worswick MJ, Pick RJ. Void growth and constitutive softening in a periodically voided solid. J Mech Phys Solids. 1990;38(5):601-625.
1997	Pilkey AK. Effect of Second-Phase Particle Clustering on Aluminum-Silicon Alloy Sheet Formability [PhD thesis]. Carleton University; July 15, 1997.
1984	Tvergaard V, Needleman A. Analysis of the cup-cone fracture in a round tensile bar. Acta Metall. 1984;32(1):157-169.
2001	Worswick MJ, Chen ZT, Pilkey AK, Lloyd D, Court S. Damage characterization and damage percolation modelling in aluminum alloy sheet. Acta Mater. August 16, 2001;49(14):2791-2803.
1981	Tvergaard V. Influence of voids on shear band instabilities under plane strain conditions. Int J Fract. 1981;17(4):389-407.
1998	Pilkey AK, Worswick MJ, Thomson CIE, Burger G, Lloyd DJ. Effect of second-phase particle clustering on formability of Al-Si sheet. In: Wilkinson DS, Poole W, Alpas A, eds. Advances in Industrial Materials. The Metallurgical Society of CIM; 1998:105-121.
1975	Gurson AL. Plastic Flow and Fracture Behavior of Ductile Materials Incorporating Void Nucleation, Growth, and Interaction [PhD thesis]. Providence, RI: Brown University; June 1975.
1993	Thomason PF. Ductile fracture by the growth and coalescence of microvoids of non-uniform size and spacing. Acta Metall Mater. July 1993;41(7):2127-2134.
1977	Gurson AL. Continuum theory of ductile rupture by void nucleation and growth, I: yield criteria and flow rules for porous ductile media. J Eng Mater Technol. 1977;99(1):2-15.
2001	Thomson CIA. Modeling the Effects of Particle Clustering on Ductile Failure [PhD thesis]. Carleton University; May 2001.
2000	Lievers WB, Bissoon S, Pilkey AK, Worswick MJ, Jain M, Lloyd DJ. Effect of damage on the bendability of AA6111 aluminum automotive sheet. In: Proceedings of Plasticity 2000. July 17-21, 2000; Whistler, BC.
1998	Worswick MJ, Pelletier P. Numerical simulation of ductile fracture during high strain rate deformation. Euro Phys J Appl Phys. 1998;4(3):257-267.
1999	Thomson CIA, Worswick MJ, Pilkey AK, Lloyd DJ, Burger G. Modeling void nucleation and growth within periodic clusters of particles. J Mech Phys Solids. 1999;47(1):1-26.

Cited By (9)

Year	Entry
2009	Butcher CJ, Chen Z. Continuum void nucleation model for Al-Mg alloy sheet based on measured particle distribution. Acta Mech Solida Sin. October 2009;22(5):391-398.
2004	Duan X, Metzger D, Jian M. Influence of yield criteria on the prediction of shear localization considering the inhomogeneous distribution of microstructure. In: Computer Technology and Applications. ASME/JSME 2004 Pressure Vessels and Piping Conference (PVP2004); July 25-29, 2004; San Diego, CA.59-65.
2004	Worswick MJ, Chen Z, Pilkey K, Lloyd D. Damage percolation modeling in aluminum alloy sheet. In: Raabe D, Roters F, Barlat F, Chen L-Q, eds. Continuum Scale Simulation of Engineering Materials: Fundamentals - Microstructures - Process Applications. Weinheim, Germany: Wiley-VCH Verlag GmbH & Co. KGaA; 2004:805-816.
2013	Chen Z, Butcher C. Micromechanics Modelling of Ductile Fracture. Dordrecht, Netherlands: Springer; 2013. Solid Mechanics and Its Applications; vol 195.
2004	Lievers WB, Pilkey AK, Lloyd DJ. Using incremental forming to calibrate a void nucleation model for automotive aluminum sheet alloys. Acta Mater. June 7, 2004;52(10):3001-3007.
2004	Mackerle J. Finite element analyses and simulations of sheet metal forming processes. Eng Comput. 2004;21(8):891-940.
2009	Butcher CJ, Chen ZT. Damage percolation modeling of void nucleation within heterogeneous particle distributions. Model Simul Mater Sci Eng. 2009;17(7):075003.
2017	Cui Y. Molecular Dynamics Insights Into Nanovoid Behavior in Metals: From Sparsely-Arranged Nanovoids to Densely-Arranged Nanopores [PhD thesis]. Edmonton, AB: University of Alberta; 2017.
2006	Orlov OS. A Three-Dimensional Damage Percolation Model [PhD thesis]. University of Waterloo; 2006.