To see the other types of publications on this topic, follow the link: Roll-Forming, Finite Element Method, Plane Strain, Strain Hardening.
Journal articles on the topic 'Roll-Forming, Finite Element Method, Plane Strain, Strain Hardening'
Create a spot-on reference in APA, MLA, Chicago, Harvard, and other styles
Consult the top 15 journal articles for your research on the topic 'Roll-Forming, Finite Element Method, Plane Strain, Strain Hardening.'
Next to every source in the list of references, there is an 'Add to bibliography' button. Press on it, and we will generate automatically the bibliographic reference to the chosen work in the citation style you need: APA, MLA, Harvard, Chicago, Vancouver, etc.
You can also download the full text of the academic publication as pdf and read online its abstract whenever available in the metadata.
Browse journal articles on a wide variety of disciplines and organise your bibliography correctly.
1
Satish, D. Raja, D. Ravi Kumar, and Marion Merklein. "Effect of temperature and punch speed on forming limit strains of AA5182 alloy in warm forming and improvement in failure prediction in finite element analysis." Journal of Strain Analysis for Engineering Design 52, no. 4 (May 2017): 258–73. http://dx.doi.org/10.1177/0309324717704995.
Full textAbstract:
Formability of AA5182-O aluminum alloy sheets in the warm working temperature range has been studied. Forming limit strains of sheets of two different thicknesses have been determined experimentally in different modes of deformation (biaxial tension, plane strain and tension–compression) by varying temperature and punch speed. A correlation has been established for plane strain intercept of the forming limit diagram (FLD0) with temperature, punch speed and thickness from the experimental results. This correlation has been used to plot the forming limit diagrams for failure prediction in the finite element analysis of warm deep drawing of cylindrical cups. The effect of strain and strain rate on material flow behavior has been incorporated using a strain rate–sensitive power hardening law in which the strain hardening exponent and strain rate sensitivity index have been experimentally determined. The predictions from simulations have been validated by warm deep drawing experiments. Large improvement in accuracy of failure prediction has been observed using the FLDs plotted based on the developed correlation when compared to the existing method of calculating FLD0 using only strain hardening coefficient and thickness. The results clearly indicate the importance of incorporating temperature and punch speed in failure prediction of Al alloys using FLDs in the warm working temperature range.
2
Pourboghrat, F., K. Chung, and O. Richmond. "A Hybrid Membrane/Shell Method for Rapid Estimation of Springback in Anisotropic Sheet Metals." Journal of Applied Mechanics 65, no. 3 (September 1, 1998): 671–84. http://dx.doi.org/10.1115/1.2789110.
Full textAbstract:
A semi-analytical method to predict springback in sheet metal forming processes has been developed for the case of plane strain. In the proposed hybrid method, for each deformation increment, bending, and unbending stretches are analytically superposed on membrane stretches which are numerically obtained in advance from a membrane finite element code. Springback is then obtained by the unloading of a force and a bending moment at the boundary of each element treated as a shell. Hill’s 1948 yield criterion with normal anisotropy is used in this theory along with kinematic and isotropic hardening laws during reverse loading. The method has been applied for the springback prediction of a 2008-T4 aluminum alloy in plane-strain draw-bending tests. The results indicate the necessity of including anisotropic hardening (especially Bauschinger effects) and elastoplastic unloading in order to achieve good agreement with experimental results.
3
Li, Jun Chao, Pei Geng, and Jun Jie Pan. "Influences of Process Parameters on Forming Performance of Sheet Metal Incremental Forming Based on Numerical Simulation." Advanced Materials Research 562-564 (August 2012): 294–97. http://dx.doi.org/10.4028/www.scientific.net/amr.562-564.294.
Full textAbstract:
In order to investigate the process of ISF through numerical and experimental approaches, finite element method (FEM) models for two truncated pyramids were developed to simulate the process and the simulated thickness distributions were compared with experimental results. The influences of process parameters on equivalent plastic strain, the maximum equivalent plastic stress and forming force were also discussed. The results show that ISF process is basically to be a plane strain deformation. Wall angle is a more significant influence factor of forming performance than tool diameter and depth increment. With increasing tool diameter, decreasing wall angle and step increment, uniform thickness distribution will be achieved. However, more wall angel, less tool diameter and depth increment contributes to decrease forming force. Additionally, process parameters have no connection with work hardening for a certain material during ISF.
4
Ha, Jinjin, Johnathon Fones, Brad L. Kinsey, and Yannis P. Korkolis. "Plasticity and Formability of Annealed, Commercially-Pure Aluminum: Experiments and Modeling." Materials 13, no. 19 (September 25, 2020): 4285. http://dx.doi.org/10.3390/ma13194285.
Full textAbstract:
The plasticity and formability of a commercially-pure aluminum sheet (AA1100-O) is assessed by experiments and analyses. Plastic anisotropy of this material is characterized by uniaxial and plane-strain tension along with disk compression experiments, and is found to be non-negligible (e.g., the r-values vary between 0.445 and 1.18). On the other hand, the strain-rate sensitivity of the material is negligible at quasistatic rates. These results are used to calibrate constitutive models, i.e., the Yld2000-2d anisotropic yield criterion as the plastic potential and the Voce isotropic hardening law. Marciniak-type experiments on a fully-instrumented hydraulic press are performed to determine the Forming Limit Curve of this material. Stereo-type Digital Image Correlation is used, which confirms the proportional strain paths induced during stretching. From these experiments, limit strains, i.e., the onset of necking, are determined by the method proposed by ISO, as well as two methods based on the second derivative. To identify the exact instant of necking, a criterion based on a statistical analysis of the noise that the strain signals have during uniform deformation versus the systematic deviations that necking induces is proposed. Finite element simulation for the Marciniak-type experiment is conducted and the results show good agreement with the experiment.
5
Choi, Hongjin, Seonghwan Choi, Soo-Chang Kang, and Myoung-Gyu Lee. "Fully Implicit Stress Update Algorithm for Distortion-Based Anisotropic Hardening with Cross-Loading Effect: Comparative Algorithmic Study and Application to Large-Size Forming Problem." Applied Sciences 11, no. 12 (June 14, 2021): 5509. http://dx.doi.org/10.3390/app11125509.
Full textAbstract:
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.
6
Hong, Jong-Hwa, Donghoon Yoo, Yong Nam Kwon, and Daeyong Kim. "Pneumatic Experimental Design for Strain Rate Sensitive Forming Limit Evaluation of 7075 Aluminum Alloy Sheets under Biaxial Stretching Modes at Elevated Temperature." Metals 10, no. 12 (December 5, 2020): 1639. http://dx.doi.org/10.3390/met10121639.
Full textAbstract:
A pneumatic experimental design to evaluate strain rate sensitive biaxial stretching forming limits for 7075 aluminum alloy sheets was attempted with the finite element method. It was composed of apparatus geometric design with pressure optimization as the process design. The 7075 aluminum alloy material was characterized by conventional Voce-type hardening law with power law strain rate sensitivity relationship. For optimization of the die shape design, the ratio of minor to major die radius (k) and profile radius (R) were parametrically studied. The final shape of die was determined by how the history of targeted deformation mode was well maintained and whether the fracture was induced at the pole (specimen center), thereby preventing unexpected failure at other locations. As a result, a circular die with k = 1.0 and an elliptic die with k = 0.25 were selected for the balanced biaxial mode and near plane strain mode, respectively. Lastly, the pressure inducing fracture at the targeted strain rate was studied as the process design. An analytical solution that had been previously studied to maintain constant strain rate was properly modified for the designed model. The results of the integrated design were compared with real experimental results. The shape and thickness distribution of numerical simulation showed good agreement with those of the experiment.
7
Chung, Kwansoo, and Sergei Alexandrov. "Ideal Flow in Plasticity." Applied Mechanics Reviews 60, no. 6 (November 1, 2007): 316–35. http://dx.doi.org/10.1115/1.2804331.
Full textAbstract:
Ideal plastic flows constitute a class of solutions in the classical theory of plasticity based on, especially for bulk forming cases, Tresca’s yield criterion without hardening and its associated flow rule. They are defined by the condition that all material elements follow the minimum plastic work path, a condition which is believed to be advantageous for forming processes. Thus, the ideal flow theory has been proposed as the basis of procedures for the direct preliminary design of forming processes, which mainly involve plastic deformation. The aim of the present review is to provide a summary of both the theory of ideal flows and its applications. The theory includes steady and nonsteady flows, which are divided into three sections, respectively: plane-strain flows, axisymmetric flows, and three-dimensional flows. The role of the method of characteristics, including the computational aspect, is emphasized. The theory of ideal membrane flows is also included but separately because of its advanced applications based on finite element numerical codes. For membrane flows, restrictions on the constitutive behavior of materials are significantly relaxed so that more sophisticated anisotropic constitutive laws with hardening are accounted for. In applications, the ideal plastic flow theory provides not only process design guidelines for current forming processes under realistic tool constraints, but also proposes new ultimate optimum process information for futuristic processes.
8
Isik, Kerim, and Celal Soyarslan. "Continuum Damage Mechanics (CDM) Based Local Approach to the Sheet-Bulk Metal Formability Prediction." Advanced Materials Research 769 (September 2013): 205–12. http://dx.doi.org/10.4028/www.scientific.net/amr.769.205.
Full textAbstract:
Since sheet-bulk metal forming processes inherit properties of both sheet and bulk metal forming processes, their analysis requires on one side following certain methods conventionally devised in these process classes analyses whereas on the other side leaving certain customs out. For instance, inherent anisotropy of the rolled sheet has to be taken into account whereas due to non-vanishing out of plane stress component, analysis with thin shells using the plane stress state assumption is no more applicable. Similarly, methods based on necking instabilities, i.e. forming limit diagrams, which are typically used in sheet metal formability assessment; fall short in sheet-bulk metal formability prediction. In the present study, we propose a local approach to fracture, more specifically a phenomenologically based Lemaitre variant CDM model, devised frequently in bulk metal forming analysis, as an alternative. For this purpose, a combined nonlinear isotropic-kinematic hardening plasticity with Hill48 type initial anisotropy is fully coupled with isotropic damage. Together with the concept of effective stress and equivalent strain principle, quasi-unilateral damage evolution is used, where the energetic contribution of the compressive stress state to the damage driving force is scaled with a so-called crack closure parameter, . For the quasi unilateral damage evolution is inactive whereas for it is fully active which completely suppresses the development of damage under compressive stress states. The framework devises state coupling between elasticity and damage and kinematic coupling between plasticity and damage which increases the relative effect of on the eventual damage development. To this end, a direct extension to the finite strains for metal forming analysis is realized using a corotational formulation and the developed framework is implemented as a VUMAT subroutine for ABAQUS Explicit. For evaluation of the predictive capability of the model, teeth forming process results for DC04 reported in Soyarslan et al. 2011, An Experimental and Numerical Assessment of Sheet-Bulk Formability of Mild Steel DC04, Journal of Manufacturing Science and Engineering, Vol. 133 6, (2011) S. (061008) 1-9, are used. Mechanical material characterization studies are realized using a hybrid experimental-numerical procedure. This methodology relies on minimizing the difference between the experimentally handled global clamp force demand diagrams and the diagrams from the simulations at the complete range of the experiments involving fracture. As known finite element solutions with softening material models are prone to pathological mesh dependence. For this fact, a crack band method is used where the minimum element size, as a controlling parameter of the localization size, is also fitted through the characterization studies and identically used in the process simulations. The simulations show that a correct prediction of the zone and time of fracture is possible for the selected process whereas since the teeth formation process is mainly a compressive process, once the quasi-unilateral damage development is not used, i.e. for , a premature crack prediction is recorded which is not compatible with the experimental findings.
9
Kim, N., S. M. Lee, W. Shin, and R. Shivpuri. "Simulation of Square-to-Oval Single Pass Rolling Using a Computationally Effective Finite and Slab Element Method." Journal of Engineering for Industry 114, no. 3 (August 1, 1992): 329–35. http://dx.doi.org/10.1115/1.2899800.
Full textAbstract:
This paper presents details of a quasi three-dimensional finite element formulation for shape rolling, TASKS. This formulation uses a mix of two-dimensional finite element and slab element techniques to solve a generalized plane strain problem. Consequently, quasi steady state metal forming problems such as rolling of shapes can be analyzed with minimal computational effort. To verify the capability of the formulation square-to-round single pass rolling is simulated by TASKS and results compared with a fully three-dimensional simulation reported in literature. The results indicate reasonable agreement in roll forces, torques, and effective strain distributions during rolling. However, due to the generalized plane strain assumptions, nonhomogenieties in the rolling direction cannot be simulated. The large computational economy realized via TASKS gives this formulation the power to analyze roll pass designs with reasonable computational resources.
10
Li, Da Yong, Ying Bing Luo, and Ying Hong Peng. "Solid Shell Element and its Application in Roll Forming Simulation." Key Engineering Materials 340-341 (June 2007): 347–52. http://dx.doi.org/10.4028/www.scientific.net/kem.340-341.347.
Full textAbstract:
Solid shell element models which possess only translational degrees of freedom and are applicable to thin structure analyses has drawn much attention in recent years and presented good prospect in sheet metal forming. In this study, a solid shell element model is introduced into the dynamic explicit elastic-plastic finite element method. The plane stress constitutive relation is assumed to relieve the thickness locking and the selected reduced integration method is used to overcome volumetric locking. The assumed natural strain method is adopted to resolve shear locking and trapezoidal locking problem. Two benchmark examples and a stage of roll forming process are calculated, and the calculating results are compared with those by solid element model, which demonstrates the effectiveness of the element.
11
Naofal, Naeini, and Mazdak. "Effects of Hardening Model and Variation of Elastic Modulus on Springback Prediction in Roll Forming." Metals 9, no. 9 (September 12, 2019): 1005. http://dx.doi.org/10.3390/met9091005.
Full textAbstract:
In this paper, the uniaxial loading–unloading–reloading (LUR) tensile test was conducted to determine the elastic modulus depending on the plastic pre-strain. To obtain the material parameters and parameter of Yoshida-Uemori’s kinematic hardening models, tension–compression experiments were carried out. The experimental results of the cyclic loading tests together with the numerically predicted response of the plastic behavior were utilized to determine the parameters using the Ls-opt optimization tool. The springback phenomenon is a critical issue in industrial sheet metal forming processes, which could affect the quality of the product. Therefore, it is necessary to represent a method to predict the springback. To achieve this aim, the calibrated plasticity models based on appropriate tests (cyclic loading) were implemented in commercial finite element (FE) code Ls-dyna to predict the springback in the roll forming process. Moreover, appropriate experimental tests were performed to validate the numerical results, which were obtained by the proposed model. The results showed that the hardening models and the variation of elastic modulus have significant impact on springback accuracy. The Yoshida-Uemori’s hardening represents more accurate prediction of the springback during the roll forming process when compared to isotropic hardening. Using the chord modulus to determine the reduction in elastic modulus gave more accurate results to predict springback when compared with the unloading and loading modulus to both hardening models.
12
Knieps, Fabian, Benjamin Liebscher, Ioana Moldovan, Manuel Köhl, and Johannes Lohmar. "Characterization of High-Strength Packaging Steels: Obtaining Material Data for Precise Finite Element Process Modelling." Metals 10, no. 12 (December 16, 2020): 1683. http://dx.doi.org/10.3390/met10121683.
Full textAbstract:
The steadily increasing demand for downgauging to reduce costs in packaging steel applications requires the development of high-strength packaging steel grades to meet strength requirements. At the same time, the demand for a simulative, computer-aided layout of industrial forming processes is growing to reduce costs in tool constructions for downgauging manners. As part of this work, different high-strength packaging steels were characterized for use in a finite element based process layout and validated using application-oriented experiments. Due to a low hardening rate and the occurrence of Lüders bands, high-strength packaging steels show a low amount of elongation in tensile tests, while for other stress states higher degrees of deformation are possible. Thus, common extrapolation methods fail to reproduce the flow curve of high-strength packaging steels. Therefore, a new approach to extrapolate the flow curve of high-strength packaging steels is presented using the tensile test and bulge test data together with a combined Swift–Voce hardening law. Furthermore, it is shown that the use of complex anisotropic yield locus models such as Yld2000-2d is necessary for high-strength packaging steels in order to be able to precisely simulate application-oriented loads in between plane strain and biaxial tension in validation experiments. Finally, the benefit of a material selection process for packaging steel applications guided by finite element simulations based on precisely characterized material behaviour is demonstrated.
13
Quagliato, Luca, Dongwook Kim, Donghwi Park, and Naksoo Kim. "Numerical investigation on the influence of the electro-resistance welding pipe manufacturing process on the local variation of the yield strength of the pipe material." Advances in Mechanical Engineering 12, no. 5 (May 2020): 168781402091780. http://dx.doi.org/10.1177/1687814020917803.
Full textAbstract:
In the present research work, a finite element model of the electro-resistance welding pipe forming process chain is developed using the ABAQUS/Explicit software. The forming process, which is composed of 22 tandem roll stations, has been fully modeled in the developed finite element simulation. In order to account for the Bauschinger effect on the pipe material properties as a consequence of the loading and the unloading during the process, a non-linear kinematic hardening model has been utilized in all the proposed finite element simulation models. The constants for the non-linear kinematic hardening model were estimated by means of cyclic experiments on the K55 steel pipe material. In order to properly simulate the electric arc welding (electro-resistance welding) operation, the ABAQUS welding interface has been utilized to account for the joining between the two edges of the formed pipe as well as to assess the influence of the welding-induced temperature field on the residual stresses on the pipe material. The sizing operation, which is the final station of the electro-resistance welding process, has been also accounted in the developed finite element method model and is composed of six tandem rolls. To export and import the results between two different modules, a mapping strategy has been utilized and allowed exporting the element results, in terms of stress, strain, and temperature, and importing them into the following simulation module. Finally, in order to estimate the influence of each process station on the yield strength of the material, a finite element simple tension test simulation has been implemented in ABAQUS/Static, mapping the results of each station on the tensile specimen. This mapping operation allowed to estimate the yield stress of the material after each of the three process stations, a consequence of the residual stresses present in the material, and has been carried out on eight circumferential locations around the pipe, evenly spaced with a 22.5° angle. The model has been validated by comparing the geometrical results, in terms of average pipe diameter and thickness, obtained from the finite element model with those of the relevant industrial production, showing deviations equal to 1.25% and 1.35% (forming) and 1.29% and 1.43% (sizing), respectively, proving the reliability of the proposed process chain analysis simulation. The results will show how the process-induced residual stresses arising on the pipe material make the material yield strength to vary from station to station as well as having different values along the circumferential direction of the pipe.
14
Carretta, Yves, Romain Boman, Nicolas Legrand, Maxime Laugier, and J. P. Ponthot. "Numerical Simulations of Asperity Crushing Using Boundary Conditions Encountered in Cold-Rolling." Key Engineering Materials 554-557 (June 2013): 850–57. http://dx.doi.org/10.4028/www.scientific.net/kem.554-557.850.
Full textAbstract:
The general framework of this paper is in the field of numerical simulation of asperity crushing. Different material forming processes, such as strip-rolling and deep drawing, imply mixed lubrication. In this lubrication regime, two types of contact are present at the same time: a direct contact between the two solids at the asperity level and also valleys filled with pressurized oil. Theses contact conditions have a large influence on friction and wear taking place during the upsetting process. As this mixed type of contact is not yet fully understood from the physics point of view, numerical models are essential to achieve a better understanding. For example, semi-analytical asperity crushing models have been developed by Wilson&Sheu [1] and Sutcliffe [2] to take into account the influence of bulk plastic deformations on asperity crushing. The finite element method has also been used to model asperity crushing. Ike&Makinouchi [3] studied the behavior of 2D triangular-shaped asperities under different boundary conditions. Krozekwa et al. [4] modeled 3D triangular asperities behavior, for various bulk strain directions. More recently, Lu et al. [5] compared experimental results of pyramid-shaped asperity and ridge-shaped asperity crushing with finite element simulation results. As in the three former references mentioned above, it has been decided, to study the interaction between a rigid plane and a simplified geometry asperity without lubricant. In this article, numerical asperity crushing results obtained with Metafor[6], a home made large strains software, will be presented. Those results will illustrate the influence of boundary conditions, contact pressure, large bulk strain and geometry of asperities on the evolution of the contact area. As the asperity crushing behaviour is known to be very sensitive to the boundary conditions, in this article, we will also present results using boundary conditions from a cold rolling model named MetaLub. MetaLub [7-8] is a software developed at the University of Liege in partnership with ArcelorMittal R&D center. It iteratively solves the equations resulting from the discretisation using the slab method of the strip coupled to a mixed lubrication model at the interface. This lubrication model takes into account the evolution of the oil film thickness as well as the asperity crushing along the roll bite. We will compare the evolution of the relative contact area obtained with MetaLub to the results obtained with finite elements simulations using the same boundary conditions. [1] Wilson, W.R.D and Sheu, S. Real area of contact and boundary friction in metal forming. Int. J. Mech. Sci. 1988, 30(7), 475-489. [2] Sutcliffe, M.P.F Surface asperity deformation in metal forming processes. Int. J. Mech. Sci., 1988, 30(11), 847-868. [3] Ike, H. and Makinouchi, A. Effect of lateral tension and compression on plane strain flattening processes of surface asperities lying over a plastically deformable bulk. Wear, 1990, 140, 17-38. [4] Korzekwa, D.A., Dawson, P.R. and Wilson W.R.D., Surface asperity deformation during sheet forming. Int. J. Mech. Sci., 1992, 34(7), 521-539. [5] Lu, C., Wei, D., Jiang, Z., and Tieu, K., Experimental and theoretical investigation of the asperity flattening process under large bulk strain, Proc. Inst. Mech. Eng. J. 222 (2008), 271–278. [6] LTAS-MN2L. ULg. http://metafor.ltas.ulg.ac.be/. [7] Stéphany, A., Contribution à l’étude numérique de la lubrification en régime mixte en laminage à froid. PhD dissertation (in French), Université de Liège (2008) [8] Carretta, Y., Stephany, A., Legrand, N., Laugier, M., and Ponthot, J.-P., MetaLub – A slab method software for the numerical simulation of mixed lubrication regime. Application to cold rolling. In Proceedings of the 4th International Conference on Tribology In Manufacturing Processes (ICTMP), 2010,799-808.
15
Görtan, Mehmet Okan, and Ümit Türkmen. "Finite Element Analysis of Stretch Forming of an Open Profile Made of Ultra-High Strength Martensitic MS1500 Steel." ESAFORM 2021, March 30, 2021. http://dx.doi.org/10.25518/esaform21.3969.
Full textAbstract:
Stretch forming process is primarily used for generating curved structures from sheet metals such as car body panels or aircraft fuselage panels. Although there are large number of studies about stretch forming, these investigations focus mainly on flat sheet metals. However, various parts especially in the automotive industry, such as passenger car fenders are first preformed to a profile and afterwards stretch formed to generate desired final geometry. Moreover, as a consequence of weight reduction activities, these fender parts are usually made of ultra-high strength steels (UHSS) in the last two years. In the current study, stretch forming characteristics of an open profile made of martensitic UHSS (MS1500) are investigated using finite elements method (FEM). Used geometry was an asymmetrical hat profile which was preformed using roll forming prior to stretch forming. Mechanical properties of the material used is characterized using tensile test and modeled using Swift isotropic strain hardening rule. Strain and stress distribution along the bend section, geometry and springback in the final part as well as forming force have been investigated using finite element (FE) simulations. A twist has been observed in the final product along its longitudinal axis. To validate the FE results, experiments have been conducted. Twist problem is also detected in the manufactured samples. The amount of springback in produced part was similar to the experiments. It is found that FE simulations can model stretch forming process of open profiles accurately.