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Ductile damage prediction of AA 5754 sheet during cold forming condition

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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.

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Abbreviations

σ y :

Flow stress

\({\overline \varepsilon ^p}\) :

Plastic strain

\(\dot \varepsilon \) :

Strain rate

T :

Temperature

A, B, n, C and m :

Material constants

\({\dot \varepsilon ^*}\) :

Normalized plastic strain rate

T*:

Homologous temperature

ε f :

Failure strain

σ* :

Stress triaxiality

D1 to D5 :

Damage constants

\(\widetilde\sigma \) :

Effective stress

r :

Damage accumulated plastic strain

σ 0 :

Yield stress

Qi and Cj :

Isotropic hardening parameters

\({\dot \varepsilon _{pl}}\) :

Accumulated plastic strain

D :

Damage variable

r D :

Damage threshold

S:

Damage material constant

σ 1 :

Maximal principal stress

y :

Damage parameter expresses the triaxiality effect

σ m :

Von Mises stress

E :

Young’s modulus

R v :

Triaxiality factor

v :

Poisson’s ratio

σ H :

Hydrostatic stress

f*:

Effective void volume fraction

q i :

Material constant

f :

Void volume fraction

f f :

Void volume fraction at failure

f c :

Critical void volume fraction

\(\dot \varepsilon _{kk}^p\) :

Volumetric plastic strain rate

\({\dot \varepsilon ^p}\) :

Effective plastic strain rate

f n :

Volume fraction of nucleating void

ε n :

Mean void nucleation strain

s n :

Standard deviation of void nucleation strain

ΔD:

Incremental damage accumulation

Δεp :

Equivalent plastic strain increment

D crit :

Damage threshold

\(\widetilde{F}s\) :

Fading exponent

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Acknowledgements

The authors would like to thank the Faculty of Engineering, Suez University, Egypt, for using the tools and facilities of the experimental part in this work.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Helwan University, Helwan, Egypt

    Mohamed Amer, Mohamed Mohamed & Abdel Aziz Hegazy

  2. Mechanical Engineering Department, The British University in Egypt (BUE), El Shorouk City, Egypt

    Mostafa Shazly

  3. Impression Technologies Limited, Coventry, CV5 9PF, UK

    Mohamed Mohamed

Authors
  1. Mohamed Amer
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  2. Mostafa Shazly
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  4. Abdel Aziz Hegazy
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Corresponding author

Correspondence to Mostafa Shazly.

Additional information

Mohamed Amer is a lecturer assistant in the Department of Mechanical Engineering at Helwan University, Cairo, Egypt. He received his M.Sc. from Helwan University, Egypt. His research interests include sheet metal forming, damage mechanics, finite element simulation, solid mechanics, material characterization.

Mostafa Shazly is a Professor of Solid Mechanics at the Mechanical Engineering Department and Director of Centre of Advanced Materials, The British University in Egypt. He received his B.Sc. and M.Sc. in Mechanical Design and Production Engineering from Cairo University in 1996 and 1999, respectively. He received his Ph.D. in Mechanical Engineering in 2005 from Case Western Reserve University, OH, USA. His research interests are in the field of dynamic deformation of materials and structure, mechanics of solids, and finite element simulations.

Mohamed Mohamed is a Principal Technical Specialist-Simulation and Modelling in Impression Technologies Ltd, UK. He received Ph.D. of Mechanical Engineering from Imperial College London in 2010. He was a process modelling team leader at Advanced Forming Research Center, Scotland, UK. His research interests include sheet metal forming, material modelling, damage mechanics, finite element simulation.

Abdel Aziz Hegazy is an Emeritus Professor of Production Engineering at The Department of Mechanical Engineeing, Faculty of Engineering, Helwan University.

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Amer, M., Shazly, M., Mohamed, M. et al. Ductile damage prediction of AA 5754 sheet during cold forming condition. J Mech Sci Technol 34, 4219–4228 (2020). https://doi.org/10.1007/s12206-020-0914-9

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  • DOI: https://doi.org/10.1007/s12206-020-0914-9

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