Effect of pre-cut hole diameter on deformation mechanics in multi-stage incremental hole flanging of deep drawing quality steel

Gandla, Praveen Kumar; Suresh, Kurra; Prasad, K. Sajun; Panda, Sushanta Kumar; Singh, Swadesh Kumar

doi:10.1007/s43452-020-00156-5

Cited by 12 publications

(1 citation statement)

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“…Using the obtained fracture toughness values by Ayada [17], and Rice and Tracy [18] criteria, the highest amount of damage was observed in the middle of the flange walls. Gandla et al [19] assessed the fracture forming limit diagram (FFLD) of deep drawing quality steel sheets with six different ductile damage criteria in IHF. They found that the Ayada criterion provides the best prediction with the experimental FFLD.…”

Section: Introductionmentioning

confidence: 99%

Prediction of Ductile Damage and Fracture in the Single and Multi-stage Incremental Hole-flanging Process Using a New Damage Accumulation Law

Seyyedi

Gorji

Mirnia

et al. 2021

Preprint

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Incremental hole-flanging (IHF) is a process in which a sheet with a pre-cut hole is flanged by the single point incremental forming (SPIF) process. Fracture prediction in IHF, such as SPIF, is associated with many challenges due to the deformation mechanisms. The purpose of this paper is to overcome the existing limitations and challenges, and thus, to predict accurately failure in single, and multi-stage IHF processes. To this end, the modified Mohr-Coulomb (MMC) criterion was implemented using an appropriate user subroutine in a finite element method (FEM) model. The AA6061-T6 aluminum alloy sheet, which has low formability, and is fractured from its free edges in the IHF process, was examined as an example. Initially, a linear damage accumulation law, in which the prediction error is high due to the non-linear stress and strain states in the IHF, was used to predict the fracture. Therefore, in the next step, a non-linear damage accumulation function was utilized. While the non-linear accumulation accurately predicts the single-stage IHF fracture, it is not able to predict the fracture well in the multi-stage IHF. It was observed that in multi-stage IHF, the rate of damage accumulation decreases with increasing the number of forming stages. Accordingly, a new non-linear damage accumulation rule was developed. Experimental and numerical results indicated acceptable accuracy of the proposed non-linear accumulation in the fracture prediction in the single and multi-stage IHF process.

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Section: Introductionmentioning

confidence: 99%