Prediction of crack location and propagation in stretch flanging process of aluminum alloy AA-5052 sheet using FEM simulation

Dewang, Yogesh; Hora, M. S.; Panthi, S.K.

doi:10.1016/s1003-6326(15)63846-8

Cited by 20 publications

(9 citation statements)

References 19 publications

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“…Die was constrained in all directions to represent it as a stationary body whereas the punch moves only in downward z-direction to deform the sheet and form the flange in all cases of simulation. The constant force of 20 kN was applied at the blank-holder [7,31]. The clearance between the punch and die was considered as 1 mm [5,6] and coefficient of friction was assumed to be 0.1 in all the cases [7,23,26,31,42].…”

Section: Fem Modelling and Simulationmentioning

confidence: 99%

“…A series of stretch-bending and incremental sheet forming tests were performed using different punch diameter. Dewang et al [31] predicted the crack location and propagation in the stretch flanging process of aluminium alloy AA-5052 sheet using FEM simulation and validated with experimental results. Wang et al [32] employed the flat blank holder and curved blank holder in deep drawing process to study the influence of blank holder type on the drawability of 5182-O aluminium sheet at room temperature.…”

Section: Introductionmentioning

confidence: 99%

“…Steel, copper and aluminium specimen were used to perform the tensile test experiments and to compare the FEM results in terms ductile fracture strain at various fracture location. It can be summarise from the literature review that in stretch flanging process [14,[37][38][39] deformation behaviour of sheet and fracture in sheet have been widely investigated considering various parameters such as material parameters [1,17,23], geometrical parameters [1,4,11,13,16,23,26,31,37,40,41], blank holding force [7,31], friction coefficient [7,23,26,31,42]. Different punch shape has also been used in other sheet metal forming processes such as stretch, shrink, hole flanging and deep drawing process [2, 27-29, 33, 35, 36, 41].…”

Section: Introductionmentioning

confidence: 99%

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Effect of punch profile on deformation behaviour of AA5052 sheet in stretch flanging process

Kumar

Ahmed

Panthi

2020

Archiv.Civ.Mech.Eng

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Stretch flanging is a type of bending process widely used in automobile and aerospace industries. Forming of the stretch flange is mainly affected by three important parameters: materials of the sheet, the geometry of tools and different process parameters. This work focuses on the effect of punch profile on deformation behavior of AA5052 alloy sheet to form the stretch flange. Six punches of different geometry i.e. cylindrical, two stepped, three stepped, six stepped, conical and hemispherical are used. Results are presented in the form of edge crack in the sheet at edge corner and its propagation towards center, forming load comparison for different punch profile and distribution of radial and circumferential strain in the sheet. It is observed that the punch profile has a considerable effect on the deformation behavior of the sheet. Circumferential strain, radial strain and load requirement to form the flange are found to be minimum in hemispherical punch profile as compared to other punch profiles. Experiments are performed to validate the FE simulation results and results are found in very good agreement in terms of edge crack length. Fractography study shows uniform and large number of small size dimples at the fractured surface for hemispherical and conical punch profile.

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Section: Fem Modelling and Simulationmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Effect of punch profile on deformation behaviour of AA5052 sheet in stretch flanging process

Kumar

Ahmed

Panthi

2020

Archiv.Civ.Mech.Eng

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“…In the last decade, a number of investigations were conducted at various length scales to understand the deformation and damage mechanisms leading to crack propagation. A number of continuum mechanics-based approaches, such as finite element method (FEM) [1][2][3][4][5][6], crystal plasticity finite element method (CPFEM) [7][8][9] and extended finite element method (XFEM) [10], were employed for understanding crack propagation at mesoscopic or macroscopic scales. Continuum mechanics-based approaches are not capable of providing an insight into fracture at the atomic scale and also are unsuitable for addressing the physics of the process.…”

Section: Introductionmentioning

confidence: 99%

Orientation-dependent crack-tip blunting and crack propagation in a single crystal BCC iron

2018

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Atomistic simulations of cracks with four different orientations in body-centered cubic single crystal iron are presented using molecular dynamics. Crystal orientation has considerable effect on the activation and evolution of crack propagation mechanisms. The results reveal that (a) crack-tip blunting depends on the crystallographic orientation, (b) continuous generation of dislocations form crack tip occurs for large crack-tip blunting, and (c) absence of deformation activities like dislocation generation, twin formation, etc. at the crack tip results in crack propagation in a brittle manner.

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“…Edge cracking and its location are also predicted experimentally using AA 5052 sheets. The present study aims to study the stretch flanging process using experimental methods and to simulate the stretching flange process using FEM software package ABAQUS (Dewang. Y, 2015).…”

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confidence: 99%

Experimental and Finite Element Analysis of Nonaxisymmetric Stretch Flanging Process Using Aa 5052

Nikam¹,

Jaiswal²

2021

JER is an international, peer-reviewed journal that publishes f

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This paper deals with experimental and finite element analysis of the stretch flanging process using AA- 5052 sheets of 0.5 mm thick. A parametrical study has been done through finite element simulation to inspect the influence of procedural parametrical properties on maximum thinning (%) within the stretch flanging process. The influence of preliminary flange length of sheet metal blank, punch die clearance, and width was examined on the maximum thinning (%). An explicit dynamic finite element method was utilized using the finite element commercial package ABAQUS. Strain measurement was done after conducting stretch flanging tests. A Mesh convergence examination was carried out to ascertain the maximum percentage accuracy in FEM model. It is found through finite element simulation that the width of sheet metal blanks has a greater impact on the maximum percentage of thinning as compared to preliminary flange length, and clearance of the punch dies.

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Prediction of crack location and propagation in stretch flanging process of aluminum alloy AA-5052 sheet using FEM simulation

Cited by 20 publications

References 19 publications

Effect of punch profile on deformation behaviour of AA5052 sheet in stretch flanging process

Effect of punch profile on deformation behaviour of AA5052 sheet in stretch flanging process

Orientation-dependent crack-tip blunting and crack propagation in a single crystal BCC iron

Experimental and Finite Element Analysis of Nonaxisymmetric Stretch Flanging Process Using Aa 5052

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