TY - JOUR

T1 - Fracture Characterisation and Modelling of AHSS Using Acoustic Emission Analysis for Deep Drawing

AU - Stockburger, Eugen

AU - Wester, Hendrik

AU - Behrens, Bernd Arno

N1 - Funding Information: This research was funded by the German Research Foundation (Deutsche Forschungsgemeinschaft, DFG) within the project “Improving the fracture characterisation of advanced high-strength steel sheets by coupling measuring systems for optical forming analysis with acoustic emission technology” with the grant number “385276585”.

PY - 2023/7/5

Y1 - 2023/7/5

N2 - Driven by high energy prices, AHSS are still gaining importance in the automotive industry regarding electric vehicles and their battery range. Simulation-based design of forming processes can contribute to exploiting their potential for lightweight design. Fracture models are frequently used to predict the material’s failure and are often parametrised using different tensile tests with optical measurements. Hereby, the fracture is determined by a surface crack. However, for many steels, the fracture initiation already occurs inside the specimen prior to a crack on the surface. This leads to inaccuracies and more imprecise fracture models. Using a method that detects the fracture initiation within the specimen, such as acoustic emission analysis, has a high potential to improve the modelling accuracy. In the presented paper, tests for fracture characterisation with two AHSS were performed for a wide range of stress states and measured with a conventional optical as well as a new acoustical measurement system. The tests were analysed regarding the fracture initiation using both measurement systems. Numerical models of the tests were created, and the EMC fracture model was parametrised based on the two evaluation areas: a surface crack as usual and a fracture from the inside as a novelty. The two fracture models were used in a deep drawing simulation for analysis, comparison and validation with deep drawing experiments. It was shown that the evaluation area for the fracture initiation had a significant impact on the fracture model. Hence, the failure prediction of the EMC fracture model from the acoustic evaluation method showed a higher agreement in the numerical simulations with the experiments than the model from the optical evaluation.

AB - Driven by high energy prices, AHSS are still gaining importance in the automotive industry regarding electric vehicles and their battery range. Simulation-based design of forming processes can contribute to exploiting their potential for lightweight design. Fracture models are frequently used to predict the material’s failure and are often parametrised using different tensile tests with optical measurements. Hereby, the fracture is determined by a surface crack. However, for many steels, the fracture initiation already occurs inside the specimen prior to a crack on the surface. This leads to inaccuracies and more imprecise fracture models. Using a method that detects the fracture initiation within the specimen, such as acoustic emission analysis, has a high potential to improve the modelling accuracy. In the presented paper, tests for fracture characterisation with two AHSS were performed for a wide range of stress states and measured with a conventional optical as well as a new acoustical measurement system. The tests were analysed regarding the fracture initiation using both measurement systems. Numerical models of the tests were created, and the EMC fracture model was parametrised based on the two evaluation areas: a surface crack as usual and a fracture from the inside as a novelty. The two fracture models were used in a deep drawing simulation for analysis, comparison and validation with deep drawing experiments. It was shown that the evaluation area for the fracture initiation had a significant impact on the fracture model. Hence, the failure prediction of the EMC fracture model from the acoustic evaluation method showed a higher agreement in the numerical simulations with the experiments than the model from the optical evaluation.

KW - butterfly specimen

KW - enhanced Mohr–Coulomb fracture model

KW - HCT780C

KW - HCT980X

UR - http://www.scopus.com/inward/record.url?scp=85169039759&partnerID=8YFLogxK

U2 - 10.3390/jmmp7040127

DO - 10.3390/jmmp7040127

M3 - Article

AN - SCOPUS:85169039759

VL - 7

JO - Journal of Manufacturing and Materials Processing

JF - Journal of Manufacturing and Materials Processing

IS - 4

M1 - 127

ER -