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Research Papers

Advances in Virtual Metal Forming Including the Ductile Damage Occurrence: Application to 3D Sheet Metal Deep Drawing

[+] Author and Article Information
K. Saanouni

Mechanical Engineering and Mechanics of Materials Department, ICD/LASMIS, FRE CNRS 2848, University of Technology of Troyes, BP 2060, 10010 Troyes Cedex, Francesaanouni@utt.fr

H. Badreddine, M. Ajmal

Mechanical Engineering and Mechanics of Materials Department, ICD/LASMIS, FRE CNRS 2848, University of Technology of Troyes, BP 2060, 10010 Troyes Cedex, France

J. Eng. Mater. Technol 130(2), 021022 (Mar 28, 2008) (11 pages) doi:10.1115/1.2884339 History: Received July 30, 2007; Revised January 28, 2008; Published March 28, 2008

An advanced numerical methodology to simulate virtually any sheet or bulk metal forming including various kinds of initial and induced anisotropies fully coupled to the isotropic ductile damage is presented. First, the fully coupled anisotropic constitutive equations in the framework of continuum damage mechanics under large plastic deformation are presented. Special care is paid to the strong coupling between the main mechanical fields such as elastoplasticity, mixed nonlinear isotropic and kinematic hardenings, ductile isotropic damage, and contact with friction in the framework of nonassociative and non-normal formulation. The associated numerical aspects concerning both the local integration of the coupled constitutive equations as well as the (global) equilibrium integration schemes are presented. The local integration is outlined, thanks to the Newton iterative scheme applied to a reduced system of ordinary differential equations. For the global resolution of the equilibrium problem, the classical dynamic explicit (DE) scheme with an adaptive time step control is used. This fully coupled procedure is implemented into the general purpose finite element code for metal forming simulation, namely, ABAQUS/EXPLICIT . This gives a powerful numerical tool for virtual optimization of metal forming processes before their physical realization. This optimization with respect to the ductile damage occurrence can be made either to avoid the damage occurrence to have a nondamaged part as in forging, stamping, deep drawing, etc., or to favor the damage initiation and growth for some metal cutting processes as in blanking, guillotining, or machining by chip formation. Two 3D examples concerning the sheet metal forming are given in order to show the capability of the proposed methodology to predict the damage initiation and growth during metal forming processes.

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Copyright © 2008 by American Society of Mechanical Engineers
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Figures

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Figure 1

Stress and Lankford strain ratios obtained with the three models. (a) Stress ratio σyψ∕σy0. (b) Lankford coefficient ε22pψ∕ε33pψ.

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Figure 2

Schematization and initial mesh of the Swift test

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Figure 3

Force-displacement curves obtained with the three models for the deep drawing test

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Figure 4

Damage maps obtained with the three models for different punch displacements for the deep drawing test. (a1) Model 1, U=14.19mm. (a2) Model 1, U=14.315mm. (b1) Model 2, U=13.19mm. (b2) Model 2, U=13.315mm. (c1) Model 3, U=17.25mm. (c2) Model 3, U=17.375mm.

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Figure 5

Damage and thickness distributions obtained with the three models along a meridian line of the deformed sheet. (a) Model 1, U=14.19mm. (b) Model 2, U=13.19mm. (c) Model 3, U=17.25mm. (d) Meridian line of the deformed sheet.

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Figure 6

Distribution the plastic equivalent strain along the quarter of the sheet boundary obtained with the three models

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Figure 7

Evolution of some local mechanical fields in fully damaged point. (a) Equivalent plastic deformation versus punch displacement. (b) Damage evolution. (c) Stress evolution. (d) Fully damaged element.

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Figure 8

Mesh characteristics of the exhaust pipe deep drawing simulation

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Figure 9

Punch force versus displacement curves obtained with the three models for the exhaust pipe

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Figure 10

Damage maps obtained with the three models for different punch displacements for the exhaust pipe drawing simulation. (a) Model 1, U=30.80mm. (b) Model 2, U=29.40mm. (c) Model 3, U=31.12mm.

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