The effects of through-thickness shear stress on the formability of sheet metal–A review

Ma, Li; Wang, Zhongjin

doi:10.1016/j.jmapro.2021.09.019

Cited by 16 publications

(5 citation statements)

References 66 publications

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“…Wang and Wang's [37] research concluded that an FLD that considers induced stress in the thickness direction is more accurate than the FLD of the plane stress mode. In fact, through-thickness shear stresses can improve the forming limit of sheet metals [97]. Moreover, when strain states occur below and within the left diagonal (ε 1 = ε 2 ), the presence of a compressive hydrostatic stress component in the thickness direction mitigates the risk of necking.…”

Section: D Stress Statesmentioning

confidence: 99%

A Review of Sheet Metal Forming Evaluation of Advanced High-Strength Steels (AHSS)

Pereira,

Peixinho,

Costa

2024

Metals

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This paper presents a review on the formability evaluation of AHSS, enhancing necking-based failure criteria limitations. Complementary fracture/damage constitutive modeling approaches specifically tailored to formability evaluation, validated through numerical and experimental methods, are also subjects of research. AHSS are widely processed through sheet metal forming processes. Although an excellent choice when lightweight, high-strength, and ductility are critical factors, their multi-phase microstructure accentuates forming challenges. To accurately model forming behavior, necking-based failure criteria as well as direct fracture models require improvements. As a necking-based failure model, the conventional forming limit diagram/curve (FLD/FLC) presents limitations in estimating direct fracture (surface cracks, edge cracks, shear cracks), as well as deformation histories under non-linear strain paths. Thus, significant research efforts are being made towards the development of advanced fracture constitutive models capable of predicting fracture scenarios without necking, which are more frequently observed in the realm of AHSS. Scientific community research is divided into several directions aiming at improving the forming and fracture behavior accuracy of parts subjected to sheet metal forming operations. In this review paper, a comprehensive overview of ductile fracture modeling is presented. Firstly, the limitations of FLD/FLC in modeling fracture behavior in sheet metal forming operations are studied, followed by recent trends in constitutive material modeling. Afterwards, advancements in material characterization methods to cover a broad range of stress states are discussed. Finally, damage and fracture models predicting failure in AHSS are investigated. This review paper supplies relevant information on the current issues the sheet metal forming community is challenged with due to the trend towards AHSS employment in the automotive industry.

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Section: D Stress Statesmentioning

confidence: 99%

A Review of Sheet Metal Forming Evaluation of Advanced High-Strength Steels (AHSS)

Pereira,

Peixinho,

Costa

2024

Metals

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“…After deformation, they measured the mesh configuration and found the presence of through-thickness shear in the tool direction [11]. The presence of out-of-plane through-thickness stresses can lead to improved formability in the case of ISF, as suggested by Ma and Wang [12]. They further suggested that the conventional M-K model, which includes in-plane stresses only, needs to be extended and should also consider the through-thickness shear stresses.…”

Section: Introductionmentioning

confidence: 97%

A Mathematical Model for Force Prediction in Single Point Incremental Sheet Forming with Validation by Experiments and Simulation

et al. 2023

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Incremental sheet forming (ISF) is an emerging technology that has shown great potential in forming customized three-dimensional (3D) parts without the use of product-specific dies. The forming force is reduced in ISF due to the localized nature of deformation and successive forming. Forming force plays an important role in modeling the process accurately, so it needs to be evaluated accurately. Some attempts have been made earlier to calculate the forming force; however, they are mostly limited to empirical formulae for evaluating the average forming force and its different components. The current work presents a mathematical model for force prediction during ISF in a 3D polar coordinate system. The model can be used to predict forces for axis-symmetric cones of different wall angles and also for incremental hole flanging. Axial force component, resultant force in the r-θ plane, and total force have been calculated using the developed mathematical model appearing at different forming depths. The cone with the same geometrical parameters and experimental conditions was modeled and simulated on ABAQUS, and finally, experiments were carried out using a six-axis industrial robot. The mathematical model can be used to calculate forces for any wall angle, but for comparison purposes, a 45° wall angle cone has been used for analytical, numerical, and experimental validation. The total force calculated from the mathematical model had a very high level of accuracy with the force measured experimentally, and the maximum error was 4.25%. The result obtained from the FEA model also had a good level of accuracy for calculating total force, and the maximum error was 4.89%.

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“…Generally, their constitutive response is modeled and calibrated by mainly considering the in-plane material behavior, while the throughthickness one is often neglected based on the plane stress assumption. However, in some applications -for instance the sheet metal forming of complex geometries -the state of stress can deviate from the plane stress assumption and a complete 3D description is necessary [1].…”

Section: Introductionmentioning

confidence: 99%

“…

Recently, inverse methods such as the Virtual Fields Method (VFM) or the Finite Element Model Updating (FEMU), coupled with a full-field measurement technique, have been distinguished as efficient strategies for the calibration of complex plasticity models [1]. The use of heterogeneous strain fields, in fact, offers a larger amount of material information compared to the classical standard test, enriching the identification process and, in general, reducing the experimental effort for the calibration [2].

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confidence: 99%

A hybrid VFM-FEMU approach to calibrate 3D anisotropic plasticity models for sheet metal forming

ROSSO

2023

Materials Research Proceedings

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Abstract. Recently, inverse methods such as the Virtual Fields Method (VFM) or the Finite Element Model Updating (FEMU), coupled with a full-field measurement technique, have been distinguished as efficient strategies for the calibration of complex plasticity models [1]. The use of heterogeneous strain fields, in fact, offers a larger amount of material information compared to the classical standard test, enriching the identification process and, in general, reducing the experimental effort for the calibration [2]. Here, an inverse identification framework is proposed for the calibration of a full-scale anisotropic plasticity model. The inverse identification procedure employs full-field information from two main experiments: a tensile test on double notched specimens for the calibration of the coefficients expressing the planar anisotropy, and an innovative Iosipescu-like test for the through-thickness shear ones. A hybrid approach is used with the VFM employed to identify the planar coefficients and the FEMU for the through thickness ones.

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The effects of through-thickness shear stress on the formability of sheet metal–A review

Cited by 16 publications

References 66 publications

A Review of Sheet Metal Forming Evaluation of Advanced High-Strength Steels (AHSS)

A Review of Sheet Metal Forming Evaluation of Advanced High-Strength Steels (AHSS)

A Mathematical Model for Force Prediction in Single Point Incremental Sheet Forming with Validation by Experiments and Simulation

A hybrid VFM-FEMU approach to calibrate 3D anisotropic plasticity models for sheet metal forming

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