Ductile damage prediction of AA 5754 sheet during cold forming condition
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DOI 10.1007/s12206-020-0914-9
Journal of Mechanical Science and Technology 34 (10) 2020 Original Article DOI 10.1007/s12206-020-0914-9 Keywords: · AA 5754 · Cold forming · Damage models · Formability · FE model
Correspondence to: Mostafa Shazly [email protected]
Citation: Amer, M., Shazly, M., Mohamed, M., Hegazy, A. A. (2020). Ductile damage prediction of AA 5754 sheet during cold forming condition. Journal of Mechanical Science and Technology 34 (10) (2020) 4219~4228. http://doi.org/10.1007/s12206-020-0914-9
Received March 16th, 2020 Revised
June 1st, 2020
Accepted July 26th, 2020
Ductile damage prediction of AA 5754 sheet during cold forming condition Mohamed Amer1, Mostafa Shazly2, Mohamed Mohamed1,3 and Abdel Aziz Hegazy1 1
2
Department of Mechanical Engineering, Helwan University, Helwan, Egypt, Mechanical Engineering 3 Department, The British University in Egypt (BUE), El Shorouk City, Egypt, Impression Technologies Limited, Coventry CV5 9PF, UK
Abstract
Aluminium sheet parts manufactured by cold-forming processes are subjected to ductile damage due to the plastic deformation. Tool design based on the experience and failure prediction using simple criteria in sheet metal forming can cause high cost of material scrap and tools modifications. Consequently, the ability to predict ductile damage gives full control of the forming process. This work was conducted to evaluate the predictive capability of different damage models for AA 5754 under cold forming condition. The models are calibrated using published tensile and forming limit diagram data for AA 5754. A set of experimental cup tests for AA 5754 sheet were conducted to validate the selected models. An FE model was developed to simulate the cup test process using LS-DYNA software. The selected models used were the Johnson-Cook, continuum damage model (CDM), Gurson model and the generalized incremental stress state-dependent model (GISSMO) model. The experimental results of the cup tests were compared with the simulation results from different damage models concluding that the Gissmo model was able to show a good agreement with the experimental results.
† Recommended by Editor Hyung Wook Park
1. Introduction
© The Korean Society of Mechanical Engineers and Springer-Verlag GmbH Germany, part of Springer Nature 2020
Weight reductions to reduce fuel consumption and save costs while maintaining adequate strength is the main goal for automotive industries. Aluminium alloys have been used as a good replacement to steel to achieve this weight reduction due to their favourable properties (e.g. lightweight, high specific strength and good corrosion resistance). However, under cold forming conditions, aluminium alloys have low formability limits [1]. Therefore, ductile damage is inevitable due to the plastic straining process. Several damage models have been proposed to quantify and predict ductile damage [2-15]. In the industrial field, simple failure criteria (e.g. plastic strain and max thinning) and experience (trial and error) to avoid fail
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