Advanced FE model validation of cold-forming process using DIC: Air bending of high strength steel

Gothivarekar, Sanjay; Coppieters, Sam; Velde, A. Van de; Debruyne, Dimitri

doi:10.1007/s12289-020-01536-1

Cited by 20 publications

(7 citation statements)

References 16 publications

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“…The paper [12] studied the ability of a three-layer corrugated metal gasket to prevent leakage when the outer layer thickness and flange roughness are adjusted. The leakage rate was tested using the helium leakage quantity test experimentally.…”

Section: Literature Review and Problem Statementmentioning

confidence: 99%

Development of an A1100 aluminum corrugated metal gaskets

Nurhadiyanto,

Mujiyono,

Ristadi

et al. 2023

EEJET

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Corrugated metal gaskets (CMG) made from SUS304 have previously been developed, however a coating process with a softer material is necessary for its design to be optimal. The coating process is time consuming and expensive. This research aims to develop CMG from aluminum by simulation analysis and form a CMG design made of aluminum A1100. The method used is development research. The optimum CMG thickness is analyzed using ANSYS Finite Element Analysis (FEA). The control variables being investigated are contact area and contact stress. The independent variable being investigated is the material thickness of CMG. An aluminum gasket is then constructed using a cold-forming process based on the optimum design. The control variables in the leak test are axial force and water pressure. Experiments were also carried out to test the aluminum gasket for leakage. A leakage test is carried out using a water pressure test. Simulation analysis showed results that were in line with experimental leak tests. FEA simulation results show that the optimum gasket thickness is between 3 and 5 mm, with 5 mm being the most optimal. However, CMG with thicknesses of 4 and 5 have similar contact stress and contact area. Leakage test results also show similarities with simulation results. CMG with a thickness of 5 mm has the best performance. The experimental results show that CMG made from aluminum A1100 is suitable for use as a gasket to prevent leakage, it prevents leakage at fluid pressure up to 12 MPa and axial force 100 kN. The results show that aluminum CMG performs on par with SUS304 CMG coated with nickel or copper. This research succeeded in developing CMG made of aluminum

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Section: Literature Review and Problem Statementmentioning

confidence: 99%

Development of an A1100 aluminum corrugated metal gaskets

Nurhadiyanto,

Mujiyono,

Ristadi

et al. 2023

EEJET

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“…Likewise, the differences in the extent of multi-breakage and the bend shapes are studied, and these observations are correlated with the findings from the bending force and strain measurements and tensile tests. Bending tests with DIC strain measuring have been previously done by many authors [6,[20][21][22][23][24][25], some of which have also measured the strain evolution during bending [20,23,24].…”

Section: Pourboghrat and Stelsonmentioning

confidence: 99%

Strain distribution during air bending of ultra-high strength steels

Pokka¹,

Arola²,

Kaijalainen³

et al. 2021

Esaform 2021

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Air bending is a widely used method for forming ultra-high strength steels (UHSS). However, the limited formability of UHSS poses some challenges for the bending process in the form of strain localisation, surface defects, punch detachment (multi-breakage) and pseudo-polygonal “nut-like” shape of the bend. In this study, the bendability of three UHSS grades (700, 900 and 1100 MPa) is investigated with 3-point bending tests, utilising Digital Image Correlation (DIC) for measuring the strain distributions on the outer curvature. The differences in the extent of multi-breakage and the bend shapes are also studied, and these observations are correlated with the findings from the bending force and strain measurements. The differences between the investigated UHSS grades are significant. The 900 MPa grade produces more localised strain distributions and pronounced multi-breakage compared to the other grades, along with a more polygonal “nut-like” geometry. The reasons and effects of the multi-breakage phenomenon, as well as the causes for the observed differences in the behaviour of the materials are discussed in this paper. The presented results and the measurement data provide more information about the behaviour of the investigated materials in bending, and can be used for improving bending simulation, numerical models, and workshop instructions.

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“…The mesh has a minimum element size of 0.5 mm and a total of 50322 linear brick (C3D8R) elements. Two implicit steps simulate the last bending operation in obtaining the final shape of the specimen: a static step for bending, followed by a dynamic step for springback [20]. For bending, a straight-angle punch stroke of -18.7 mm is imposed [4].…”

Section: Cold-bending and F Cold-bending And Fatigue Model Atigue Modelmentioning

confidence: 99%

The effect of kinematic hardening on the fatigue behaviour of bent high strength steel

Gothivarekar¹,

Coppieters²,

Talemi³

et al. 2021

Esaform 2021

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The integration of forming in the fatigue modelling of cold-formed components significantly improves the predictive accuracy of the estimated life. The current study investigated the fatigue behaviour of a bent specimen made from a 5 mm thick, S900MC high strength steel plate. Because of its superior static and dynamic strength, this grade is progressively used for hollow cold-formed sections in mobile applications. However, it exhibits a strong stress saturation as well as limited formability. In this regard, a finite element modelling framework was adopted from previous research and further developed to integrate bending in the fatigue modelling and life estimation procedure. However, this framework currently ignores the possible influence of kinematic hardening and associated Bauschinger effect. For this reason, a numerical study was performed that compares isotropic with kinematic hardening for this specific application. First, the characteristic behaviour of these models was verified in a virtual tension-compression test. Subsequently, they were implemented in forming simulation followed by fatigue loading. Herein, the stress-strain evolution was investigated and a multi-axial fatigue criteria was used to map the sensitivity of the estimated life to the type of hardening. In general, the stress that entered the fatigue calculation was at least 21% lower for the kinematic model. As a result, a significant increase of 65% was observed for the estimated fatigue life, yielding a better comparison with experimental data.

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Advanced FE model validation of cold-forming process using DIC: Air bending of high strength steel

Cited by 20 publications

References 16 publications

Development of an A1100 aluminum corrugated metal gaskets

Development of an A1100 aluminum corrugated metal gaskets

Strain distribution during air bending of ultra-high strength steels

The effect of kinematic hardening on the fatigue behaviour of bent high strength steel

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