A three-dimensional stress-strain model with an isotropic-kinematic hardening rule has been successfully applied to obtain estimated stress histories from the rosette strain histories. The strains are measured on surface elements near the notch root of SAE axle shafts subjected to variable-amplitude multiaxial service loading conditions. The critical plane approach is adopted to predict fatigue lives by examining the detailed stress and strain states on all potential critical planes of an element. Several commonly used damage criteria as well as a work-based criterion proposed here are evaluated by comparing the predicted and experimentally observed fatigue lives for a wide range of tests. The encouraging results demonstrate the current model's capability of simulating complex tests and predicting fatigue lives.

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Please cite this article as: Mamutov, A.V., Golovashchenko, S.F., Mamutov, V.S., Bonnen, Jn.J.F.,Modeling of electrohydraulic forming of sheet metal parts, Journal of Materials Processing Technology (2014), http://dx.Highlights  Numerical model of EHF process is based upon LS-DYNA software  Practical approach to define energy deposition law in plasma channel is developed  Numerical model of EHF process has been validated experimentally  Results on multistage EHF of an automotive panel illustrated EHF capabilities ABSTRACT Electrohydraulic forming (EHF) is based upon the electro-hydraulic effect: a complex phenomenon related to the high voltage discharge inside the water filled chamber. The resulting shockwave in the liquid is propagated towards the blank, and the mass and momentum of the water in the shock wave accelerates the sheet metal blank toward the die. Methodology of numerical simulation of EHF processes was developed based upon LS-DYNA commercial code using Arbitrary Lagrange-Eulerian (ALE) Multi-Material formulation. The model incorporates Page 3 of 54 A c c e p t e d M a n u s c r i p t 3 energy deposition inside the plasma channel, expansion of the channel driven by high pressure inside of it, propagation of the pressure pulse through the water filled chamber in contact with the rigid walls of the chamber and with the sheet metal blank being deformed. Comparison of the numerical and experimental results was performed on maximum pressure measured on the wall of the cylindrical chamber employing the membrane method.The model was used to simulate multistage EHF of a complex geometry automotive part.Analysis of the results showed the complex nature of multistage EHF process: a clearly recognizable wave picture during the initial stage of the channel expansion which transitions to almost incompressible water flow during later stages.

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