Abstract
Automotive and construction industries demand for roll-formed high strength Dual-Phase steels due to their excellent structural performances and attractive appearances have increased dramatically over the last decade. However, their compromised ductility gives rise to problems and faces numerous manufacturing issues. These problems pertain to ductile fracture defect, which is often observed on tight radii during roll forming. The partial heating roll forming method is a recently proposed roll forming method alternative to the conventional cold roll forming method, aimed at reducing ductile fracture by partially heating only the bend areas. In this paper, the ductile fracture during the partial heating roll forming processes of DP980 high strength steel is evaluated by implementing the phenomenological Generalized Incremental Stress State Dependent Damage (GISSMO) model using the FE code LS-DYNA. To this aim, instability and fracture strains from the uniaxial, plane-strain, and shear tensile tests at different temperatures were evaluated. The basic tensile test results are in good agreement with the experimental results found in the literature. Subsequently, the instability and plastics strain at fracture from basic tensile tests were calibrated to numerical simulations of roll forming processes for ductile fracture predictions. Based on the results, the instability and fracture strain increase as the material’s temperature increases. Moreover, the ductile fracture investigation of DP980 during the cold roll forming process showed that fractures were observed on the profile's bend areas. However, no visible cracks were observed on the partial heated roll-formed profile.
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Abbreviations
- \(A, B,\) and,\(C\) :
-
Johnson–Cook material constants in Eq. 10
- \({A}_{0}\) :
-
Nominal cross-sectional area
- \({A}_{1}\; and \; {A}_{2}\) :
-
Effective plastic strains at fracture in shear and uniaxial tension
- \({A}_{eff}\) :
-
Effective cross-sectional area
- \(D\) :
-
Damage factor
- \(\dot{D}\) :
-
Incremental damage
- \({D}_{crit}\) :
-
Critical damage
- εcrit :
-
Effective plastic strain when instability occurs
- εp :
-
Accumulated plastic strain
- \({\varepsilon }_{f}\) :
-
Effective plastic strain at fracture
- \({\dot{\varepsilon }}_{p}\) :
-
Equivalent plastic strain increment
- F :
-
Instability function
- \(\dot{F}\) :
-
Incremental material's instability function
- \(m\) :
-
Fading exponent
- \(n\) :
-
Damage exponent
- \({\eta }_{0}\) :
-
Stress triaxiality in uniaxial tension
- η :
-
Stress triaxiality
- \({\upeta }_{avg}\) :
-
Average stress triaxiality
- \(\bar{\sigma }\) :
-
Damage uncoupled elements flow stress
- \({\upsigma }_{1}, {\upsigma }_{2}, {\mathrm{and\,\sigma }}_{3}\) :
-
Principal stresses
- \({\sigma }_{eff}\) :
-
Effective stress
- \({\sigma }_{H}\) :
-
Hydrostatic stress
- \({\sigma }_{true}\) :
-
True stress
- \({\sigma }_{updated}\) :
-
Damage coupled elements flow stress
- \({\upsigma }_{\mathrm{vm}}\) :
-
Von Mises stress
- \(T\) :
-
Forming temperature
- \({T}_{m}\) :
-
Melting temperature
- \({T}_{r}\) :
-
Room temperature
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Mehari, Z.A., Han, J. Numerical prediction of ductile fracture during the partial heating roll forming process of DP980. Int J Fract 234, 97–112 (2022). https://doi.org/10.1007/s10704-021-00572-5
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DOI: https://doi.org/10.1007/s10704-021-00572-5