This paper is a review of the mechanical testing methods developed by the author's research group: multiaxial stress test methods using a cruciform test piece and a tubular test piece. The former is useful for small strain ranges under several percent while the latter is useful for larger strain ranges (from yielding to fracture). These test methods are useful to determine appropriate materials model for performing accurate metal forming simulations. Special attention is given to the measurement and modeling of the anisotropic plastic deformation behavior of sheet metals commonly used in industry and to the validation of the material models based on phenomenological yield functions for large plastic strain ranges. The effects of material models used in metal forming simulations on the improvement of the predictive accuracy for forming defects are also discussed.Keywords: anisotropy; finite element analysis; formability; material model; mechanical test; sheet metal forming; yield function
IntroductionThe establishment of trial-and-error-less manufacturing enhanced by forming simulation methods such as finite element analysis (FEA) is strongly desired in industry to shorten the product development period and reduce costs for prototype manufacturing. Improvement of the predictive accuracy for defect formation (such as fracture and springback) using FEA is key to realizing trial-and-error-less manufacturing. A material model is one of the key factors that affect the accuracy of FEA [1][2]. In metal forming processes, materials are subjected to multiaxial stress states and stress reversals. Therefore, the validity of the material models used in FEA should also be checked by multiaxial stress tests and stress reversal tests [3]. This paper reviews advanced material test methods for metal sheets and tubes to determine accurate material models for use in metal forming simulations. Special attention is given to the anisotropic plastic deformation behavior of lightweight metals, such as high-strength steels (HSS), aluminum alloys, and pure titanium sheets commonly used in industry, and to the validation of the material models based on anisotropic yield functions determined for large plastic strain ranges. Additionally, the effects of the material models on the improvement of the predictive accuracy of the forming simulations are discussed.