Abstract
In a number of sheet metal stamping and joining processes, the material undergoes large plastic deformation exceeding the range of plastic strain achievable in a standard tensile test prior to material plastic instability. In order to extend the range of effective strains, the multistep rolling process was employed which enabled prestraining of aluminum sheet above 2.0 of true strain. Tensile testing of rolled samples was used to identify the flow stress corresponding to the level of prestrain: By varying the prestrain level, several data points were obtained for the studied flow curve. The numerical simulation using Abaqus software for the cold rolling process of aluminum strips confirmed that majority of the strip is deformed in plane strain compression condition. Performed simulation of the LDH test determined that earlier fracture might occur if the curve obtained via rolling–tensile testing approach is used versus traditional power law approximation and Voce law approximation. The results of simulation for the multistep drawing of a cylindrical cup revealed possible wrinkling in the die entry area during redrawing stage of the process if the rolling–tensile testing flow curve is employed.
Similar content being viewed by others
References
S.S. Hecker, M.G. Stout, and D.T. Eash, Experiments on Plastic Deformation at Finite Strains, Proceedings of the Workshop on Plasticity of Metals at Finite Strain: Theory, Experiment, and Computation, 1982, p 162–201
ASTM Standard E8/E8m, Standard Test Methods for Tension Testing of Metallic Materials, ASTM Stand. E8/E8M, 2008, 28(03.01), p 743–746
W.J. Dan, W.G. Zhang, S.H. Li, and Z.Q. Lin, An Experimental Investigation of Large-Strain Tensile Behavior of a Metal Sheet, Mater. Des., 2007, 28(7), p 2190–2196
W.W. Cai, J.E. Carsley, D.B. Hayden, L.G. Hector Jr., and T.B. Stoughton, Estimation of Metal Hardening Models at Large Strains, Proceedings of the ASME International Manufacturing Science and Engineering Conference 2007, MSEC2007, 2007
A.J. Ranta-Eskola, Use of the Hydraulic Bulge Test in Biaxial Tensile Testing, Int. J. Mech. Sci., 1979, 21(8), p 457–465
G. Gutscher, H.-C. Wu, G. Ngaile, and T. Altan, Determination of Flow Stress for Sheet Metal Forming Using the Viscous Pressure Bulge Test, J. Mater. Process. Technol., 2004, 146, p 1–7
L.M. Smith, C. Wanintrudal, W. Yang, and S. Jiang, A New Experimental Approach for Obtaining Diffuse-Strain Flow Stress Curves, J. Mater. Process. Technol., 2009, 209(8), p 3830–3839. https://doi.org/10.1016/j.jmatprotec.2008.09.010
H. Ford, Advanced Mechanics of Materials, Longmans, London, 1963
J.G. Sevillano, P. van Houtte, and E. Aernoudt, Large Strain Work Hardening and Textures, Prog. Mater Sci., 1980, 25(2–4), p 69–134
M.S. Mohebbi, A. Akbarzadeh, Y.-O. Yoon, and S.-K. Kim, Flow Stress Analysis of Ultrafine Grained AA 1050 by Plane Strain Compression Test, Mater. Sci. Eng. A, 2014, 593, p 136–144
S.M. Byon, S.I. Kim, and Y. Lee, A Numerical Approach to Determine Flow Stress–Strain Curve of Strip and Friction Coefficient in Actual Cold Rolling Mill, J. Mater. Process. Technol., 2008, 201(1–3), p 106–111
H. Ford, Researches into the Deformation of Metals by Cold Rolling, Proc. lnstn Mech. Engrs., 1948, 159, p 39–67
Q. Liu, X. Huang, D.J. Lloyd, and N. Hansen, Microstructure and Strength of Commercial Purity Aluminium (AA 1200) Cold-Rolled to Large Strains, Acta Mater., 2002, 50(15), p 3789–3802
C. Hubert, L. Dubar, M. Dubar, and A. Dubois, Experimental Simulation of Strip Edge Cracking in Steel Rolling Sequences, J. Mater. Process. Technol., 2010, 210(12), p 1587–1597
V.L. Kolmogorov, A.A. Bogatov, B.A. Migachev, E.G. Zudov, Yu.E. Freidenzon, and M.E. Freidenzon, Plasticity and Fracture [in Russian], Metallurgiya, Moscow, 1977
B. Avitzur, Handbook of Metal Forming Process, John Wiley and Sons, Inc., Canada, 1983
A.I. Tselikov, A.D. Tomlenov, V.I. Zyuzin, A.V. Tretyakov, and G.S. Nikitin, Teoriya prokatki: Spravochnik (Theory of Rolling: A Handbook), Metallurgiya, Moscow, 1982
A.P. Grudev, Vneshnee trenie pri prokatke [External Friction During Rolling], Metallurgiya Publ., Moscow, 1973, 288 p
R.H. Wagoner and J.Chenot, Fundamentals of Metal Forming, 1997
M. Jain, D.J. Lloyd, and S.R. Macewen, Hardening Laws, Surface Roughness and Biaxial Tensile Limit Strains of Sheet Aluminium Alloys, Int. J. Mech. Sci., 1996, 38(2), p 219–232
J.W. Yoon and F. Barlat, Modeling and Simulation of the Forming of Aluminum Sheet Alloys, ASM Handb., 2006, 14B, p 792–826
J.K. Lee, G.L. Kinzel, and R.H Wagoner, Proceedings of the 3rd International Conference NUMISHEET ‘96: Numerical Simulation of 3D Sheet Forming Processes: Verification of Simulation with Experiments, Dearborn, Michigan, September 29-October 3, 1996, p 428–432
R. Porcaro, M. Langseth, A.G. Hanssen, H. Zhao, S. Weyer, and H. Hooputra, Crashworthiness of Self-Piercing Riveted Connections, Int. J. Impact Eng., 2008, 35(11), p 1251–1266
N.H. Hoang, R. Porcaro, M. Langseth, and A.G. Hanssen, Self-Piercing Riveting Connections Using Aluminum Rivets, Int. J. Solids Struct., 2010, 47, p 427–439
L.A. Shofman, Elements of Theory of Cold Forming, Oborongiz, Moscow, 1952
E.N. Moshnin, Tekhnologiia shtampovki krupnogabaritnykh detalei [Metal Stamping of Large Parts], Mashinostroenie publ., Moscow, 1973
Y.S. Kim, Y.J. Son, and J.Y. Park, Bifurcation Analysis of Wrinkling Formation for Anisotropic Sheet, KSME Int. J., 1999, 13, p 221–228
K. Pöhlandt, R.S. Raghupathi, J.D. Saniter, W.J. Sauer, J.A. Schey, K.J. Weinmann, and G.E.O. Widera, Handbook of Metal Forming, Society of Manufacturing Engineers, K. Lange, Ed., 1985
W.F. Hosford and R.M. Caddell, Metal Forming: Mechanics and Metallurgy, Met. Form. Mech. Metall., 2011, p 1–331
H.S. Cheng, J. Cao, and Z.C. Xia, An Accelerated Springback Compensation Method, Int. J. Mech. Sci., 2007, 49(3), p 267–279
X. Xue, J. Liao, G. Vincze, A.B. Pereira, and F. Barlat, Experimental Assessment of Nonlinear Elastic Behaviour of Dual-Phase Steels and Application to Springback Prediction, Int. J. Mech. Sci., 2016, 117, p 1–15
Acknowledgments
The authors would like to thank Dr. Yevgeniya Katykova of Oakland University for her contribution to the initial phase of this work and Mr. Christopher Maris and Mr. Jia Cheng of University of Windsor for their contribution to developing experimental data on tensile performance of rolled samples.
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Golovashchenko, S., Reinberg, N., Hassannejadasl, A. et al. Hardening of A6111-T4 Aluminum Alloy at Large Strains and Its Effect on Sheet Forming Operations. J. of Materi Eng and Perform 28, 2465–2476 (2019). https://doi.org/10.1007/s11665-019-03977-5
Received:
Revised:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11665-019-03977-5