Details
| Original language | English |
|---|---|
| Pages (from-to) | 5-15 |
| Number of pages | 11 |
| Journal | Production Engineering |
| Volume | 10 |
| Issue number | 1 |
| Publication status | Published - 14 Jan 2016 |
Abstract
Sheet-bulk metal forming processes combine conventional sheet forming processes with bulk forming of sheet semi-finished parts. In these processes the sheets undergo complex forming histories. Due to in- and out-of-plane material flow and large accumulated plastic strains, the conventional failure prediction methods for sheet metal forming such as forming limit curve fall short. As a remedy, damage models can be applied to model damage evolution during those processes. In this study, damage evolution during the production of two different toothed components from DC04 steel is investigated. In both setups, a deep drawn cup is upset to form a circumferential gearing. However, the two final products have different dimensions and forming histories. Due to combined deep drawing and upsetting processes, the material flow on the cup walls is three-dimensional and non-proportional. In this study, the numerical and experimental investigations for those parts are presented and compared. Damage evolution in the process chains is simulated with a Lemaitre damage criterion. Microstructural analysis by scanning electron microscopy is performed in the regions with high mechanical loading. It is observed that the evolution of voids in terms of void volume fraction is strongly dependent on the deformation path. The comparison of simulation results with microstructural data shows that the void volume fraction decreases in the upsetting stage after an initial increase in the drawing stage. Moreover, the concurrent numerical and microstructural analysis provides evidence that the void volume fraction decreases during compression in sheet-bulk metal forming.
Keywords
- FE simulation, Lemaitre damage model, Sheet-bulk metal forming
ASJC Scopus subject areas
- Engineering(all)
- Mechanical Engineering
- Engineering(all)
- Industrial and Manufacturing Engineering
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In: Production Engineering, Vol. 10, No. 1, 14.01.2016, p. 5-15.
Research output: Contribution to journal › Article › Research › peer review
}
TY - JOUR
T1 - Investigations of ductile damage during the process chains of toothed functional components manufactured by sheet-bulk metal forming
AU - Isik, Kerim
AU - Gerstein, Gregory
AU - Schneider, Thomas
AU - Schulte, Robert
AU - Rosenbusch, Daniel
AU - Clausmeyer, Till
AU - Nürnberger, Florian
AU - Vucetic, Milan
AU - Koch, Sergej
AU - Hübner, Sven
AU - Behrens, Bernd Arno
AU - Tekkaya, A. Erman
AU - Merklein, Marion
N1 - Funding information: The authors gratefully acknowledge funding by the German Research Foundation (DFG) within the scope of the Transregional Collaborative Research Centre on sheet-bulk metal forming (SFB/TR 73) in the subprojects A1 “Process combination for manufacturing of teethed, thin-walled functional components out of tailored blanks”, A7 “Improvement of combined cutting and deep drawing processes by means of overlaying dynamic process forces”, C4 “Analysis of load history dependent evolution of damage and microstructure for the numerical design of sheet-bulk metal forming processes”.
PY - 2016/1/14
Y1 - 2016/1/14
N2 - Sheet-bulk metal forming processes combine conventional sheet forming processes with bulk forming of sheet semi-finished parts. In these processes the sheets undergo complex forming histories. Due to in- and out-of-plane material flow and large accumulated plastic strains, the conventional failure prediction methods for sheet metal forming such as forming limit curve fall short. As a remedy, damage models can be applied to model damage evolution during those processes. In this study, damage evolution during the production of two different toothed components from DC04 steel is investigated. In both setups, a deep drawn cup is upset to form a circumferential gearing. However, the two final products have different dimensions and forming histories. Due to combined deep drawing and upsetting processes, the material flow on the cup walls is three-dimensional and non-proportional. In this study, the numerical and experimental investigations for those parts are presented and compared. Damage evolution in the process chains is simulated with a Lemaitre damage criterion. Microstructural analysis by scanning electron microscopy is performed in the regions with high mechanical loading. It is observed that the evolution of voids in terms of void volume fraction is strongly dependent on the deformation path. The comparison of simulation results with microstructural data shows that the void volume fraction decreases in the upsetting stage after an initial increase in the drawing stage. Moreover, the concurrent numerical and microstructural analysis provides evidence that the void volume fraction decreases during compression in sheet-bulk metal forming.
AB - Sheet-bulk metal forming processes combine conventional sheet forming processes with bulk forming of sheet semi-finished parts. In these processes the sheets undergo complex forming histories. Due to in- and out-of-plane material flow and large accumulated plastic strains, the conventional failure prediction methods for sheet metal forming such as forming limit curve fall short. As a remedy, damage models can be applied to model damage evolution during those processes. In this study, damage evolution during the production of two different toothed components from DC04 steel is investigated. In both setups, a deep drawn cup is upset to form a circumferential gearing. However, the two final products have different dimensions and forming histories. Due to combined deep drawing and upsetting processes, the material flow on the cup walls is three-dimensional and non-proportional. In this study, the numerical and experimental investigations for those parts are presented and compared. Damage evolution in the process chains is simulated with a Lemaitre damage criterion. Microstructural analysis by scanning electron microscopy is performed in the regions with high mechanical loading. It is observed that the evolution of voids in terms of void volume fraction is strongly dependent on the deformation path. The comparison of simulation results with microstructural data shows that the void volume fraction decreases in the upsetting stage after an initial increase in the drawing stage. Moreover, the concurrent numerical and microstructural analysis provides evidence that the void volume fraction decreases during compression in sheet-bulk metal forming.
KW - FE simulation
KW - Lemaitre damage model
KW - Sheet-bulk metal forming
UR - http://www.scopus.com/inward/record.url?scp=84954328451&partnerID=8YFLogxK
U2 - 10.1007/s11740-016-0656-9
DO - 10.1007/s11740-016-0656-9
M3 - Article
AN - SCOPUS:84954328451
VL - 10
SP - 5
EP - 15
JO - Production Engineering
JF - Production Engineering
SN - 0944-6524
IS - 1
ER -