Advertisement

Experimental and numerical investigation of failure during bending of AA6061 aluminum alloy sheet using the modified Mohr-Coulomb fracture criterion

  • Hossein Talebi-Ghadikolaee
  • Hassan Moslemi NaeiniEmail author
  • Mohammad Javad Mirnia
  • Mohammad Ali Mirzai
  • Sergei Alexandrov
  • Hamid Gorji
ORIGINAL ARTICLE
  • 73 Downloads

Abstract

In this paper, the modified Mohr-Coulomb (MMC) ductile fracture criterion was adopted to analyze the fracture behavior of the AA6061-T6 aluminum alloy sheet during the U-bending process. Appropriate calibration procedures were employed using various tension tests. A finite element (FE) model was built using the commercial FE code Abaqus/Explicit incorporating the calibrated MMC fracture criterion. It was found that the MMC criterion calibrated by the uniaxial, plane strain, notched, and modified in-plane shear tension tests can predict the onset of fracture in the U-bending process with reasonable accuracy. The error of the predicted fracture displacement was about 2% as compared to experiments. Due to the dependency of the fracture prediction accuracy on the stress state, the effects of process parameters on stress triaxiality and normalized Lode angle parameter were investigated. The negligible effect of process parameters on the stress state confirmed that the calibrated fracture criterion (MMC) was able to predict fracture in different forming conditions with equal accuracy. Also, the proportional stress and strain state in the U-bending process indicate that, besides the high fracture prediction accuracy of the MMC’s damage accumulation function, the fracture forming limit diagram (under proportional loading assumption) can serve as a reliable tool for estimating the onset of fracture in the U-bending process. Therefore, a series of studies were also conducted on damage evolution, crack propagation, principal strains, and fracture displacement during the U-bending process under various forming conditions.

Keywords

Metal-forming process Bending Stress state Ductile fracture Tension test 

Notes

Funding information

This work was supported by the Iran National Science Foundation (Project No. 96004204) and the Russian Foundation for Basic Research (Project No. 17-58-560005).

References

  1. 1.
    Stoughton BT, Yoon JW (2011) A new approach for failure criterion for sheet metals. Int J Plast 27:440–459CrossRefGoogle Scholar
  2. 2.
    Wang H, Yan Y, Han F, Wan M (2017) Experimental and theoretical investigations of the forming limit of 5754O aluminum alloy sheet under different combined loading paths. Int J Mech Sci 133:147–166CrossRefGoogle Scholar
  3. 3.
    Kotkunde N, Krishna G, Shenoy SK, Gupta AK, Singh SK (2015) Experimental and theoretical investigation of forming limit diagram for Ti-6Al-4 V alloy at warm condition. Int J Mater Form 10:255–266CrossRefGoogle Scholar
  4. 4.
    Hashemi R, Madoliat R, Afshar A (2016) Prediction of forming limit diagrams using the modified M-K method in hydroforming of aluminum tubes. Int J Mater Form 9:297–303CrossRefGoogle Scholar
  5. 5.
    Abed-Meraim F, Balan T, Altmeyer G (2014) Investigation and comparative analysis of plastic instability criteria: application to forming limit diagrams. Int J Adv Manuf Technol 71:1247–1262CrossRefGoogle Scholar
  6. 6.
    Fatemi A, Mollaei Dariani B (2015) Forming limit prediction of anisotropic material subjected to normal and through thickness shear stresses using a modified M–K model. Int J Adv Manuf Technol 80:1497–1509CrossRefGoogle Scholar
  7. 7.
    Mackenzie AC, Hancock JW, Brown DK (1977) On the influence of state of stress on ductile failure initiation in high strength steels. Eng Fract Mech 9:167–168CrossRefGoogle Scholar
  8. 8.
    Khan AS, Liu H (2012) A new approach for ductile fracture prediction on Al2024- T351 alloy. Int J Plast 35:1–12CrossRefGoogle Scholar
  9. 9.
    Bao Y, Wierzbicki T (2004) On fracture locus in the equivalent strain and stress triaxiality space. Int J Mech Sci 46:81–98CrossRefGoogle Scholar
  10. 10.
    Wierzbicki T, Bao Y, Bai Y (2005) A new experimental technique for constructing a fracture envelope of metals under multi-axial loading. Proceedings of the 2005 SEM annual conference and exposition on experimental and applied mechanics.  https://doi.org/10.1007/s11340-007-9053-9.CrossRefGoogle Scholar
  11. 11.
    Johnson GR, Cook WH (1985) Fracture characteristics of three metals subjected to various strains, strain rates, temperatures and pressures. Eng Fract Mech 21:31–48CrossRefGoogle Scholar
  12. 12.
    Rice JR, Tracey DM (1969) On the ductile enlargement of voids in triaxial stress fields. J Mech Phys Solids 17:201–217CrossRefGoogle Scholar
  13. 13.
    Oyane M, Sato T, Okimoto K, Shima S (1980) Criteria for ductile fracture and their applications. J Mech Work Technol 4:65–81CrossRefGoogle Scholar
  14. 14.
    Ayada M, Higashino T, Mori K (1987) Central bursting in extrusion of inhomogeneous materials. Adv Technol Plast 1:553–558Google Scholar
  15. 15.
    Bai Y, Wierzbicki T (2010) Application of extended Mohr–Coulomb criterion to ductile fracture. Int J Fract 161:1–20CrossRefGoogle Scholar
  16. 16.
    Mohr D, Marcadet S (2015) Micromechanically-motivated phenomenological Hosford-Coulomb model for predicting ductile fracture initiation at low stress triaxialites. Int J Solids Struct 67:40–55CrossRefGoogle Scholar
  17. 17.
    Lou Y, Huh H (2013) Prediction of ductile fracture for advanced high strength steel with a new criterion: Experiments and simulation. J Mater Process Technol 213:1284–1302CrossRefGoogle Scholar
  18. 18.
    Mirnia MJ, Shamsari M (2017) Numerical prediction of failure in single point incremental forming using a phenomenological ductile fracture criterion. J Mater Process Technol 244:17–43CrossRefGoogle Scholar
  19. 19.
    Mirnia MJ, Vahdani M, Shamsari M (2018) Ductile damage and deformation mechanics in multistage single point incremental forming. Int J Mech Sci 136:396–412CrossRefGoogle Scholar
  20. 20.
    Hashemi SJ, Moslemi Naeini H, Liaghat GH, Azizi Tafti R (2015) Prediction of bulge height in warm hydroforming of aluminum tubes using ductile fracture criteria. Arch Civ Mech Eng 15:19–29CrossRefGoogle Scholar
  21. 21.
    Zhan M, Gu C, Jiang Z, Hu L, Yang H (2009) Application of ductile fracture criteria in spin-forming and tube-bending processes. Comput Mater Sci 47:353–365CrossRefGoogle Scholar
  22. 22.
    Azodi HD, Moslemi Naeini H, Parsa MH, Liaghat GH (2008) Analysis of rupture instability in the hydromechanical deep drawing of cylindrical cups. Int J Adv Manuf Technol 39:734–743CrossRefGoogle Scholar
  23. 23.
    Hongsheng L, Yuying Y, Zhongqi Y, Zhenzhong S, Yongzhi W (2009) The application of a ductile fracture criterion to the prediction of the forming limit of sheet metals. J Mater Process Technol 209:5443–5447CrossRefGoogle Scholar
  24. 24.
    Wang H, Yan Y, Jia F, Han F (2016) Investigations of fracture on DP980 steel sheet in roll forming process. J Manuf Process 22:177–184CrossRefGoogle Scholar
  25. 25.
    Ko YK, Lee JS, Huh H, Kim H, Park SH (2007) Prediction of fracture in hub-hole expanding process using a new ductile fracture criterion. J Mater Process Technol 187:358–362CrossRefGoogle Scholar
  26. 26.
    Luo M, Wierzbicki T (2010) Numerical failure analysis of a stretch-bending test on dual-phase steel sheets using a phenomenological fracture model. Int J Solids Struct 47:3084–3102CrossRefGoogle Scholar
  27. 27.
    Thuillier S, Maout NL, Manach PY (2011) Influence of ductile damage on the bending behaviour of aluminium alloy thin sheets. Mater Des 32:2049–2057CrossRefGoogle Scholar
  28. 28.
    Tsoupis I, Hildering S, Merklein M (2013) Prediction of damage in small curvature bending processes of high strength steels using continuum damage mechanics model in 3D simulation. Prod Eng Res Dev 7:239–249CrossRefGoogle Scholar
  29. 29.
    Mishra A, Thuillier S (2014) Investigation of the rupture in tension and bending of DP980 steel sheet. Int J Mech Sci 84:171–181CrossRefGoogle Scholar
  30. 30.
    Pradeaua A, Thuilliera S, Yoonb JW (2016) Prediction of failure in bending of an aluminium sheet alloy. Int J Mech Sci 119:23–35CrossRefGoogle Scholar
  31. 31.
    Asadian-Ardakani MH, Morovvati MR, Mirnia MJ, Mollaei Dariani B (2017) Theoretical and experimental investigation of deep drawing of tailor-welded IF steel blanks with non-uniform blank holder forces. Proc IMechE B J Eng Manuf 231:286–300CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  • Hossein Talebi-Ghadikolaee
    • 1
  • Hassan Moslemi Naeini
    • 1
    Email author
  • Mohammad Javad Mirnia
    • 2
  • Mohammad Ali Mirzai
    • 3
  • Sergei Alexandrov
    • 4
  • Hamid Gorji
    • 2
  1. 1.Faculty of Mechanical EngineeringTarbiat Modares UniversityTehranIran
  2. 2.Department of Mechanical EngineeringBabol Noshirvani University of TechnologyBabolIran
  3. 3.Department of Mechanical EngineeringUniversity of HormozganHormozaganIran
  4. 4.Ishlinsky Institute for Problems in Mechanics of the Russian Academy of SciencesMoscowRussia

Personalised recommendations