Numerical prediction of sheared edge profiles in sheet metal trimming using ductile fracture modeling

被引:32
作者
Basak, Shamik [1 ,2 ,3 ]
Kim, Chanyang [1 ,2 ]
Jeong, Woojin [1 ,2 ]
Jung, Young Il [4 ]
Lee, Myoung-Gyu [1 ,2 ]
机构
[1] Seoul Natl Univ, Dept Mat Sci & Engn, 1 Gwanak Ro, Seoul 08826, South Korea
[2] Seoul Natl Univ, RIAM, 1 Gwanak Ro, Seoul 08826, South Korea
[3] Indian Inst Technol Roorkee, Dept Mech & Ind Engn, Roorkee 247667, Uttar Pradesh, India
[4] Hyundai Motor Co, Sheet Met Dev Team, 150 Hyundaiyeonguso Ro, Hwaseong Si 18220, Gyeonggi Do, South Korea
关键词
Trimming; Hosford-Coulomb ductile fracture model; Sheared edge; Burrs; Finite element modeling; HIGH-STRENGTH STEEL; YIELD FUNCTION; BURR FORMATION; BLANKING; DEFORMATION; SURFACE; DAMAGE; TOOL; SIMULATIONS; PLASTICITY;
D O I
10.1016/j.ijmecsci.2022.107109
中图分类号
TH [机械、仪表工业];
学科分类号
0802 ;
摘要
In this study, experimental and numerical analyses are conducted to investigate sheared edges after trimming three automotive sheet metals including TRIP steel, hot-stamped (HS) steel, and aluminum alloy (AA) 5182. The Hosford-Coulomb (HC) ductile fracture model is used to predict the fracture initiation accurately, and a hybrid experimental-numerical technique is adopted to calibrate the HC model parameters. Further, the calibrated HC fracture loci are incorporated into the finite element (FE) simulations to predict the quality of trimmed surfaces and burr formations. It is observed that the experimental shear surface quality and the load progression curves are estimated successfully within an error margin of 10% from the FE simulations. It is interesting to observe a second load peak at the end of trimming, which can be explained by the striking of the moving punch with the curvilinear trimmed part of the sheet, and this is referred to as the second shearing phenomenon. Additionally, a correlation between the shear surface quality and mechanical properties of the three sheets is investigated based on the proposed numerical modeling. A reduction in the shear zone height and burr height for the HS sheet is observed compared to that of the TRIP steel and the highest burr is predicted for AA5182. It is also found the burr formation of the aluminum is more sensitive to the cutting clearance compared to the TRIP and HS materials. Furthermore, the burr height is less influenced by the material ductility at the very small clearance value, whereas comparatively at a larger clearance value (beyond 5% clearance), the ductility of the material primarily influences the formation of the burr.
引用
收藏
页数:21
相关论文
共 60 条
[1]   Paint-bake effect on the plasticity and fracture of pre-strained aluminum 6451 sheets [J].
Abi-Akl, Rami ;
Mohr, Dirk .
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES, 2017, 124 :68-82
[2]   Trim Die Damage and "Self-Reconditioning" Effect on Trimmed Edge of Sheet Metal Blanks [J].
Al-Shawk, Ameer ;
Wu, Xin ;
Yang, Qingyu .
INTERNATIONAL DEEP DRAWING RESEARCH GROUP 37TH ANNUAL CONFERENCE, 2018, 418
[3]   ON CROPPING AND RELATED PROCESSES [J].
ATKINS, AG .
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES, 1980, 22 (04) :215-231
[4]   Influence of Evolution in Anisotropy During Strain Path Change on Failure Limits of Sheet Metals [J].
Bandyopadhyay, Kaushik ;
Basak, Shamik ;
Choi, Hongjin ;
Panda, Sushanta K. ;
Lee, Myoung-Gyu .
METALS AND MATERIALS INTERNATIONAL, 2021, 27 (09) :3225-3237
[5]   Numerical Analysis of the Deformation of a Shearing Machine Tool under Excessive Blade Clearance [J].
Bantes, Fotios ;
Vosniakos, George-Christopher ;
Kostazos, Protesilaos .
JOURNAL OF APPLIED AND COMPUTATIONAL MECHANICS, 2021, 7 (02) :496-504
[6]   A 6-COMPONENT YIELD FUNCTION FOR ANISOTROPIC MATERIALS [J].
BARLAT, F ;
LEGE, DJ ;
BREM, JC .
INTERNATIONAL JOURNAL OF PLASTICITY, 1991, 7 (07) :693-712
[7]   Plane stress yield function for aluminum alloy sheets - part 1: theory [J].
Barlat, F ;
Brem, JC ;
Yoon, JW ;
Chung, K ;
Dick, RE ;
Lege, DJ ;
Pourgoghrat, F ;
Choi, SH ;
Chu, E .
INTERNATIONAL JOURNAL OF PLASTICITY, 2003, 19 (09) :1297-1319
[8]   Analyses of shearing mechanism during shear-cutting of 980 MPa dual-phase steel sheets using ductile fracture modeling and simulation [J].
Basak, Shamik ;
Kim, Chanyang ;
Jung, Youn Il ;
Jin, Hong-Kyo ;
Lee, Myoung-Gyu .
INTERNATIONAL JOURNAL OF MATERIAL FORMING, 2022, 15 (01)
[9]   Formability and fracture in deep drawing sheet metals: Extended studies for pre-strained anisotropic thin sheets [J].
Basak, Shamik ;
Panda, Sushanta Kumar ;
Lee, Myoung-Gyu .
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES, 2020, 170
[10]   Necking and fracture limit analyses of different pre-strained sheet materials in polar effective plastic strain locus using Yld2000-2d yield model [J].
Basak, Shamik ;
Panda, Sushanta Kumar .
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY, 2019, 267 :289-307