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Formability analysis of pre-strained AA5754-O sheet metal using Yld96 plasticity theory : role of amount and direction of uni-axial pre-strain

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Dhara, Sisir, Basak, S., Panda, S. K., Hazra, S. K. , Shollock, Barbara A. and Dashwood, R. J. (2016) Formability analysis of pre-strained AA5754-O sheet metal using Yld96 plasticity theory : role of amount and direction of uni-axial pre-strain. Journal of Manufacturing Processes, 24 . pp. 270-282. doi:10.1016/j.jmapro.2016.09.014

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Official URL: http://dx.doi.org/10.1016/j.jmapro.2016.09.014

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Abstract

Automotive industries are very much interested in formability of different pre-strained aluminum alloy sheets in the context of multistage stamping to fabricate complex components. In the present work, different uni-axial pre-strains of 6.4% and 12.2% were induced in AA5754-O aluminum alloy both along rolling direction (RD) and transverse direction (TD). The true stress-strain response, limiting dome height (LDH) and strain based forming limit diagram (ε-FLD) of as received and all pre-strained materials were evaluated experimentally. The anisotropy constitutive material model was developed using the Yld96 plasticity theory in-conjunction with the Hollomon isotropic hardening law to predict the yield strength evolution of the pre-strained materials. Also, it was found that the limiting strains in ε-FLD shifted significantly depending on the amount and direction of uni-axial pre-strain. Hence, the limiting strains of the as-received materials were transposed into stress space to estimate the stress based forming limit diagram (σ-FLD) using the anisotropy constitutive material model. Further, the dynamic shifts of ε-FLDs of four different pre-strained materials were predicted by successfully decoupling the σ-FLD of as-received materials within root mean square error of 0.008. Finite element models of both uni-axial pre-straining and subsequent LDH tests were developed, and the forming behavior of the pre-strained materials were predicted implementing the Yld96 plasticity model and estimated σ-FLD. It was found that LDH was significantly influenced by the amount of pre-strain, and the maximum thinning location shifted close to pole in the case of 12.2% pre-strained materials. However, the effect of uni-axial pre-strain direction on both LDH and maximum thinning location in AA5754-O material was very negligible.

Item Type: Journal Article
Subjects: Q Science > QC Physics
T Technology > TA Engineering (General). Civil engineering (General)
T Technology > TL Motor vehicles. Aeronautics. Astronautics
T Technology > TS Manufactures
Divisions: Faculty of Science > WMG (Formerly the Warwick Manufacturing Group)
Library of Congress Subject Headings (LCSH): Sheet-metal, Aluminum in automobiles, Finite element method, Steel, High strength -- Mechanical properties, Metals -- Plastic properties
Journal or Publication Title: Journal of Manufacturing Processes
Publisher: Elsevier
ISSN: 1526-6125
Official Date: October 2016
Dates:
DateEvent
October 2016Published
29 October 2016Available
21 September 2016Accepted
Volume: 24
Page Range: pp. 270-282
DOI: 10.1016/j.jmapro.2016.09.014
Status: Peer Reviewed
Publication Status: Published
Access rights to Published version: Restricted or Subscription Access

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