Abstract
The present paper aimed to discuss the fracture in a symmetrical channel-shaped product during the roll forming process using Lou–Huh ductile fracture criterion. Employing the roll forming process is increasing to manufacture different products due to high manufacturing speed, and low cost. Fracture is one of the main limiting factors in the roll forming process. Abaqus FEA was employed to simulate the fracture phenomenon. To calibrate the Lou–Huh ductile failure criterion, uniaxial tensile, plane-strain, and in-plane shear tests were used to obtain three constants of the fracture criterion. To validate the numerical results, the experimental tests were carried out on a 6061-T6 aluminum sheet (thickness of 2 mm, bending radius of 1 mm, and bending angles of 30° and 45°). The results showed that the fracture was only observed at the bending angle of 45°. The numerical model was validated by comparing the numerical and experimental results. The difference between the fracture location in the numerical and experimental results was 12.4%. Moreover, the effects of sheet thickness, bending radius, and bending angle on fracture were examined using the Lou–Huh ductile fracture criterion.
Similar content being viewed by others
References
Wang, H.; Yan, Y.; Jia, F.; Han, F.: Investigations of fracture on DP980 steel sheet in roll forming process. J. Manuf. Process. 22, 177–184 (2016)
Danish, M.; Nadhari, W.N.A.W.; Ahmad, T.; Hashim, R.; Sulaiman, O.; Ahmad, M.; Abd.Karim, N.; Salleh, K.M.: Surface measurement of binderless bio-composite particleboard through contact angle and fractal surfaces. Measurement 140, 365–372 (2019)
Elyasi, M.; Ghadikolaee, H.T.; Hosseinzadeh, M.: Investigation of dimensional accuracy in forming of metallic bipolar plates with serpentine flow field. Int. J. Adv. Manuf. Technol. 96, 1045–1060 (2018)
Seong, D.Y.; Haque, M.Z.; Kim, J.B.; Stoughton, T.B.; Yoon, J.W.: Suppression of necking in incremental sheet forming. J. Solids Struct. 51, 2840–2849 (2014)
Mirnia, M.J.; Shamsari, M.: Numerical prediction of failure in single point incremental forming using aphenomenological ductile fracture criterion. J. Mater. Process. Technol. 244, 17–43 (2017)
Habibi, N.; Zarei, A.; Abedi, H.: An investigation into the fracture mechanism of twinning-induced-plasticity steel sheets under various strain paths. J. Mater. Process. Technol. 224, 102–1166 (2015)
Bao, Y.; Wierzbicki, T.: A comparative study of three groups of ductile fracture loci in the 3D space. Eng. Fract. Mech. 135, 147–167 (2015)
Zhan, M.; Gu, C.; Jiang, Z.; Hu, L.; Yang, H.: Application of ductile fracture criteria in spin-forming and tube-bending processes. Comput. Mater. Sci. 47, 353–365 (2009)
Hansheng, S.; Gelegele, T.: Investigation of anisotropy problems in the sheet metal forming using finite element method. Int. J. Mater. Form. 4(4), 357–369 (2011)
Lihe, N.; Seong, D.Y.; Haque, M.Z.; Kim, J.B.; Stoughton, T.B.; Yoon, J.W.: Suppression of necking in incremental sheet forming. Int. J. Solids Struct. 51, 2840–2849 (2009)
Hee, L.; Liu, J.; Cui, Z.; Yang, C.; Chen, F.: Ductile fracture prediction of 316LN stainless steel in hot deformation process. J. Iron Steel Res. 21, 923–930 (2014)
Linardona, C.; Favierb, D.; Chagnonb, G.; Grueza, B.: A conical mandrel tube drawing test designed to assess failure criteria. J. Mater. Process. Technol. 214, 347–357 (2013)
Hashemi, S.J.; Moslemi Naeini, H.; Liaghat, G.H.; Azizi Tafti, R.: Prediction of bulge height in warm hydroforming of aluminum tubes using ductile fracture criteria. Arch. Civ. Mech. Eng. 15, 19–29 (2015)
Jiang, L.J.; Peng, D.; Li, Y.: Research on strip deformation in the cage roll forming process of ERW round pipes. J. Mater. Process. Technol. 209(10), 4850–4856 (2009)
Gatea, S.; Ou, H.; Lu, B.; McCartney, G.: Modelling of ductile fracture in single point incremental forming using a modified GTN model. Eng. Fract. Mech. 186, 59–79 (2017)
Dadgar Asl, Y.; Sheikhi, M.M.; Pourkamali Anaraki, A.; Panahizadeh Rahimloo, V.; Hosseinpour Gollo, M.: Experimental and numerical analysis of fracture on flexible roll forming process of channel section in aluminum 6061–T6 sheet. Modares Mech. Eng. 16(5), 329–338 (2016) (in Persian)
Paralikas, J.; Salonitis, K.; Chryssolouris, G.: Investigation of the effects of main roll forming process parameters on quality for aV-section profile from AHSS. Int. J. Adv. Manuf. Technol. 44, 223–237 (2009)
Talebi-Ghadikolaee, H.; Moslemi Naeini, H.; Mirnia, M.J.; Mirzai, M.A.; Gorji, H.; Alexandrov, S.: Fracture analysis on U-bending of AA6061 aluminum alloy sheet using phenomenological ductile fracture criteria. Thin-Walled Struct. 148, 106566 (2020)
Talebi-Ghadikolaee, H.; Elyasi, M.; Mirnia, M.J.: Investigation of failure during rubber pad forming of metallic bipolar plates. Thin-Walled Struct. 150, 106671 (2020)
Lou, Y.; Huh, H.: Evaluation of ductile fracture criteria in a general three-dimensional stress state considering the stress triaxiality and the lode parameter. Acta Mech. Solida Sin. 26, 642–658 (2013)
Talebi-Ghadikolaee, H.; Moslemi Naeini, H.; Mirnia, M.J.; Mirzai, M.A.; Alexandrov, S.; Gorji, H.: Experimental and numerical investigation of failure during bending of AA6061 aluminum alloy sheet using the modified Mohr-Coulomb fracture criterion. Int. J. Adv. Manuf. Technol. 105, 5217–5237 (2019)
Acknowledgments
The authors would like to acknowledge the financial support provided by the Iran National Science Foundation [Project No. 96004204]. Also, the author would like to thank Dr. Hamed Barghikar and Paya Profile Co. for their assistance with experimental tests.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Zeinali, M.S., Naeini, H.M., Talebi-Ghadikolaee, H. et al. Numerical and Experimental Investigation of Fracture in Roll Forming Process Using Lou–Huh Fracture Criterion. Arab J Sci Eng 47, 15591–15602 (2022). https://doi.org/10.1007/s13369-022-06662-3
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s13369-022-06662-3