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1
Constitutive modeling and springback
prediction of lightweight alloy sheet
ntnguyen@kangwon.ac.kr
Contents
Constitutive modeling and springback prediction of
lightweight alloy sheet
2. -
1. Background
3.
Copyright ESI Group, 2012 All rights reserved. 2
4.
5. Conclusion
9/13/2012
2
1 Background
Constitutive modeling and springback
prediction of lightweight alloy sheet
NGOC-TRUNG NGUYEN et al.
2. -
1. Background
3.
4.
Copyright ESI Group, 2012 All rights reserved. 3
5. Conclusion
Weight reduction
(*)
while maintaining functional
requirements:
lightweight vehicle: low fuel consumption low emission
Lightweight materials
Why?
lightweight vehicle: low fuel consumption, low emission
materials, energy, and costs are saved
environmental damage is reduced.
Superior properties:
thermal/electrical properties,
damping capacity,
(*) Weight reduction can also be achieved by using thinner sheets of high strength steels
and forming them using advanced forming processes.
FCX [ issue ]
21C
/ recycling /
Copyright ESI Group, 2012 All rights reserved. 4
p g p y,
fatigue properties,
dimensional stability, and
easy machinability
911GT3
E-class
BMW E
-
align
Heating system Jig movement
Temperature RT~400 C
Speed 0.001~1,000 mm/min
Strain measurement Laser extensometer
Side force 10 kN
Copyright ESI Group, 2012 All rights reserved. 15
Heat cartridge
(2, 3)
align
Uniaxial tension test:
Reference test data:
Universal Testing Machine (INSTRON 5882)
Cyclic loading tester
Validation
Universal Testing Machine (INSTRON 5882)
Crosshead speed 2 mm/min, gauge length 50 mm
Room temperature
Temperature measurement:
Heat cartridge installation:
upper die (2EA), lower die (3EA)
Copyright ESI Group, 2012 All rights reserved. 16
temperature: 400
o
C
K-type thermal sensor
Sheet thickness: 2 mm
Result:
uniform distribution of temperature in the gage area
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Upper die 1 Upper die 2
Specimen
F
C
f
s F
T
f
s
Friction effect:
Significant
Contributions:
Cyclic loading tester
Calibration
F
T
F
N
=F
L
-Friction
F
N
=F
L
-2F
v
F
C
F
N
=F
L
+Friction
F
N
=F
L
+2F
v
F
T
=Tension force
F
C
=Compression force
F
N
=Net force
F
L
=Load
F
v
=Vertical force
=Friction coefficient
Lower die 1 Lower die 2
f
s
f
s
Contributions:
Die-to-die
Die-to-specimen
Thermal expansion
Biaxial stress state effect
Insignificant
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Insignificant
1 Background
Constitutive modeling and springback
prediction of lightweight alloy sheet
NGOC-TRUNG NGUYEN et al.
2. -
1. Background
3.
4.
Copyright ESI Group, 2012 All rights reserved. 18
5. Conclusion
9/13/2012
10
Aluminum alloy sheet
Yoshida-Uemori model (1)
Framework:
The yield surface moves kinematically
within a bounding surface within a bounding surface.
The bounding surface can translate
and extend in the stress space.
The yield surface: f = |(o - o) Y = 0
The bounding surface: F = |(o - |) (B + R) = 0
Hardening behavior is characterized by
the relative motion of the two surfaces.
Copyright ESI Group, 2012 All rights reserved. 19
Hardening rules are applied for each surface
A so-called non-isotropic hardening surface describes the
workhardening stagnation effect.
The Youngs modulus is a function of plastic strain.
Aluminum alloy sheet
Yoshida-Uemori model (2)
Non-IH of bounding surface Workhardening stagnation
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IH and non-IH hardening case of bounding surface
g g g
o : backstress (center of the yield surface)
| : center of the bounding surface
B : initial size of the bounding surface
R : isotropic hardening component
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Plastic strain dependency of Youngs modulus
0 0
( )[1 exp( )]
a
p
E E E E c =
Seven
(*)
material parameters (Y , C , B , R
sat
, b , m , h )
- Y : Inner surface size
Aluminum alloy sheet
Yoshida-Uemori model (3)
Parameters:
Initial yield surface: the initial backstress components
The relative motion law:
Isotropic hardening of the bounding surface:
Kinematic hardening of the bounding surface:
*
=
( ) *
*
*
p
a
C
a
Y
c
o
(
| |
=
( |
\ .
a R B Y = +
( )
sat
p
R R R m c =
2
p
b | | c
| |
' '
|
p
D
3( ) :
0
2
0 0
r when R
r
r wh
h
en R
= >
= =
0
0.014
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DIE
Fixed
x
z
y
175 mm
17.5 mm
Results
Aluminum alloy sheet
Springback prediction (3)
Copyright ESI Group, 2012 All rights reserved. 26
9/13/2012
14
1 Background
Constitutive modeling and springback
prediction of lightweight alloy sheet
NGOC-TRUNG NGUYEN et al.
2. -
1. Background
3.
4.
Copyright ESI Group, 2012 All rights reserved. 27
5. Conclusion
Magnesium alloy sheet
Introduction (1)
Characteristics:
Lowest density of all metallic materials
High specific strength: High specific strength:
Mg alloy ~170
Al alloy ~120
Steel ~50
Excellent welding capability
Good corrosion resistance
High thermal-electric conductivity
E ll t EMI hi ldi
Increasing demands
Expanding applicable areas
(Automotive and electronics)
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Excellent EMI shielding
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Magnesium alloy sheet
Introduction (1)
Comparative Material Performance Index
With same thickness, Mg AZ31B is 77.5% lighter than steel
With same stiffness, Mg AZ31B is 62.8% lighter than steel
Copyright ESI Group, 2012 All rights reserved. 29
Room temperature 5
Magnesium alloy sheet
Introduction (2)
Basal plane
Pyramidal plane
Prismatic plane
oo e pe u e
Over about 200
HCP structure
0
1
2
3
4
0 100 200 300 400
( )
(
k
g
f
m
m
)
Low formability
Twinning effect
Anisotropy
No twinning effect
Asymmetry is less
(Tension ~ Compression)
0 45 90 R
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Asymmetry
Bauschinger effect
Good formability
Good formability
Low Bauschinger effect
Low anisotropy
Hurdles: Lower formability at RT and large springback
Cost, high oxidation and low corrosion resistance
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Magnesium alloy sheet
Characterization
Comparative Material Performance
Index
Chaboche type nonlinear kinematic Chaboche type nonlinear kinematic
hardening model
Bauschinger effect,
Transient behavior
But always exponential behavior
New hardening rule:
Anisotropic/asymmetric yielding
Flow asymmetry during cyclic loading
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Accurate modeling of reverse loading behavior Large springback
y y g y g
Correlation between measured stress-strain
responses and calculated ones
Magnesium alloy sheet
Hardening behavior (2)
@RT 150
o
C
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@RT 150
o
C
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Yielding asymmetry + unusual hardening behavior:
Sophisticated yield function:
Magnesium alloy sheet
New constitutive model (1)
Cazacu model Phenomenological yield
surfaces
Sophisticated yield function:
Cazacu and Barlat, 2004; Cazacu et al.,
2006; Kelley and Hosford, 1968).
Co-existence of
phenomenological yield surfaces
for different deformation modes.
Copyright ESI Group, 2012 All rights reserved. 33
Yield surface of
slip mode
Yield surface of
twin mode
slip mode
twin mode
Yield surface of
<a> slip mode
Yield surface of
activated pyramidal
<c + a> slip mode
<a> slip mode
<c + a> slip mode
Yield function:
Co-existence of phenomenological yield surfaces
At any time only one yield surface incorporating the yield condition and flow
Magnesium alloy sheet
New constitutive model (2)
Untwining
0
2 1
> A + A
p p
c c
Consider the history of
deformation: untwining occurs
only after twining
At any time only one yield surface incorporating the yield condition and flow
rule is active, others should be inactive.
The criterion on deformation modes decides which yield surface is active.
Criterion on deformation modes:
Yield surface of
slip mode
Yield surface of
twin mode
Copyright ESI Group, 2012 All rights reserved. 34
0
2 1
< A + A
p p
c c
Occurs when the deformation
does not satisfy either twining or
untwining.
slip mode
twin mode
0
2 1
> A + A
p p
c c
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Isotropic hardening rule:
stress-strain relation is generalized with the S-shaped curve
Magnesium alloy sheet
New constitutive model (3)
Hardening rule
( ) 0 iso
p
local
R o o c = +
( ) a
*
1 loc l
local
*
0
1
1 exp
p
p
b a
Q
d
e
R e
c c
c c
| |
= +
|
| | \ .
+
|
\ .
stress strain relation is generalized with the S shaped curve
sigmoid (S-shape) function
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Kinematic hardening rule:
( )
iso
p p
d d d
C
c c
o
=
Chaboche-type model
g ( p )
Types of sigmoid function
Parameter identification:
Using a computer code
optimization approach
s
o
. tens
o
. comp
o
. re tens
o
Magnesium alloy sheet
New constitutive model (4)
optimization approach
Levenberg-Marquardt algorithm
(PAM-OPT is also applicable)
Input data:
stress - plastic strain curve
cyclic loading test data: separate the cyclic loading test data into 3 curves:
tension from undeformed state (slip)
i f ll i t i (t i )
S
t
r
e
s
s
Plastic strain
SLIP TWIN UNTWIN
p
c
p
U
c
p
T
c
p
S
c
Copyright ESI Group, 2012 All rights reserved. 36
compression following tension (twin)
tension following compression (untwin)
various prestrain cases
Output: material card
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User-defined material (UDM):
Input data:
Method 1: GUI
Magnesium alloy sheet
New constitutive model (5)
Method 1: GUI
Copyright ESI Group, 2012 All rights reserved. 37
User-defined material (UDM):
Input data:
Method 2: User-defined attributes
Magnesium alloy sheet
New constitutive model (6)
Method 2: User defined attributes
Copyright ESI Group, 2012 All rights reserved. 38
9/13/2012
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User defined material (UDM):
Input data:
Method 3: Curves (Lookup table data)
Magnesium alloy sheet
New constitutive model (7)
Method 3: Curves (Lookup table data)
(to appear soon)
Copyright ESI Group, 2012 All rights reserved. 39
Room temperature 150
o
C
Magnesium alloy sheet
New constitutive model (8)
Verification
u
e
s
t
r
e
s
s
(
M
P
a
)
u
e
s
t
r
e
s
s
(
M
P
a
)
Copyright ESI Group, 2012 All rights reserved. 40
True strain True strain
T
r
u
T
r
u
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Magnesium alloy sheet
Springback prediction (1)
Results
Room temperature 150
o
C
Copyright ESI Group, 2012 All rights reserved. 41
Magnesium alloy sheet
Springback prediction (2)
Discussion
The built-in isotropic hardening model in PAM-STAMP fails to
simulate the springback behavior simulate the springback behavior.
The proposed constitutive model can improve much the ability
of springback prediction.
Discrepancies are due to:
Calibration was done only with small prestrain.
Correct measurement of BHF.
Friction coefficient.
Copyright ESI Group, 2012 All rights reserved. 42
Youngs modulus.
Degradation of Youngs modulus is an vital factor:
Different rules of evolution in tension and compression should be used
simultaneously to improve the result.
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1 Background
Constitutive modeling and springback
prediction of lightweight alloy sheet
NGOC-TRUNG NGUYEN et al.
2. -
1. Background
3.
4.
Copyright ESI Group, 2012 All rights reserved. 43
5. Conclusion
Conclusion
Lightweight materials (Al and Mg sheets) show complex
behaviors which require more specific material model and/or
technique to simulate. q
Characterization the cyclic hardening behavior was
conducted using the newly developed cyclic testing machine.
A procedure was developed to obtain the parameters of the
Y-U hardening model from test data.
The practical new constitutive model for Mg alloy sheet was
implemented as the user defined material (MAT184) in PAM-
Copyright ESI Group, 2012 All rights reserved. 44
p ( )
STAMP.
Springback prediction using the new model is quite
promising.
Accuracy of the model can be improved by including more
effects.
9/13/2012
23
Thank you for your attention Thank you for your attention.
Q & A
Copyright ESI Group, 2012 All rights reserved. 45
Constitutive modeling and springback
prediction of lightweight alloy sheet
ntnguyen@kangwon.ac.kr
9/13/2012
24
Copyright ESI Group, 2012 All rights reserved.