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

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Original languageEnglish
Article number127
JournalJournal of Manufacturing and Materials Processing
Volume7
Issue number4
Publication statusPublished - 5 Jul 2023

Abstract

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.

Keywords

    butterfly specimen, enhanced Mohr–Coulomb fracture model, HCT780C, HCT980X

ASJC Scopus subject areas

Cite this

Fracture Characterisation and Modelling of AHSS Using Acoustic Emission Analysis for Deep Drawing. / Stockburger, Eugen; Wester, Hendrik; Behrens, Bernd Arno.
In: Journal of Manufacturing and Materials Processing, Vol. 7, No. 4, 127, 05.07.2023.

Research output: Contribution to journalArticleResearchpeer review

Stockburger, E, Wester, H & Behrens, BA 2023, 'Fracture Characterisation and Modelling of AHSS Using Acoustic Emission Analysis for Deep Drawing', Journal of Manufacturing and Materials Processing, vol. 7, no. 4, 127. https://doi.org/10.3390/jmmp7040127
Stockburger, E., Wester, H., & Behrens, B. A. (2023). Fracture Characterisation and Modelling of AHSS Using Acoustic Emission Analysis for Deep Drawing. Journal of Manufacturing and Materials Processing, 7(4), Article 127. https://doi.org/10.3390/jmmp7040127
Stockburger E, Wester H, Behrens BA. Fracture Characterisation and Modelling of AHSS Using Acoustic Emission Analysis for Deep Drawing. Journal of Manufacturing and Materials Processing. 2023 Jul 5;7(4):127. doi: 10.3390/jmmp7040127
Stockburger, Eugen ; Wester, Hendrik ; Behrens, Bernd Arno. / Fracture Characterisation and Modelling of AHSS Using Acoustic Emission Analysis for Deep Drawing. In: Journal of Manufacturing and Materials Processing. 2023 ; Vol. 7, No. 4.
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abstract = "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{\textquoteright}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.",
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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”.

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