ESI Korea Forum 2012.09.13 - NGUYEN PDF

9/13/2012
1
Constitutive modeling and springback
prediction of lightweight alloy sheet
September 13, 2012

Copyright ESI Group, 2012 All rights reserved. Copyright ESI Group, 2012. All rights reserved.
p
NGOC-TRUNG NGUYEN
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
NGOC-TRUNG NGUYEN et al.
2. -
1. Background
3.
4.
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 /
p g p y,
fatigue properties,
dimensional stability, and
easy machinability
911GT3
E-class
BMW E
WPM (World Premier Materials) project

.: super-light vehicle
9/13/2012
3
Vehicle components
shallow parts in automobile
body panels and chassis
Applications
Cameracase
Bonnet
Notebook case
Engineblock
y p
applications
seat frame (35% weight
reduction), panel plenum (45%
weight reduction), door inner
and outer
Consumer products
MobilePhone Case
Trunk lid
Side outer
Door
Dash panel
Hood
Loop
Center pillar
Floor
Fender
( + )
Mg Al Ti Zn Steel
1.8
2.7
4.5
7.1
7.8
S
p
e
c
i
f
i
c
g
r
a
v
i
t
y

(
g
/
c
m
3
)
Forming process:
low formability at ambient temperature.
improved formability when drawing
Challenges (1)
improved formability when drawing
against pressure (sheet hydroforming)
and at elevated temperatures (warm
forming).
5xxx series and 6xxx series Al alloys
show increased formability at the range
of 250
o
C to 300
o
C
formability of AZ31B Mg alloy is improved
i ifi l b 200 C
significantly above 200
o
C
FLD of AZ31B magnesium alloy sheet at
different temperatures.
Suitable material model to capture the temperature dependent formability is needed.
9/13/2012
4
Material behavior:
Yielding behavior:
strong anisotropic (strength differential
Challenges (2)
AZ31B
strong anisotropic (strength differential
effect)
Hardening response:
asymmetric
abnormal
large springback (to be discussed later)
Material flow:
softening at elevated temperature
0 45 90 R
AZ31B
@RT
softening at elevated temperature
fracture characteristics (Mg alloy sheet)
Evolution of the elastic modulus
@ RT
Constitutive model
Yield function:
Isotropy: von Mises
Constitutive model (1)
Isotropy: von Mises
Anisotropy: Hill (48, 90), Barlat (89, 2000), Gotoh, Vegter, etc.
Material card: input data from tests
0
45
90
The contours of Yld2000-2D yield function.
9/13/2012
5
Constitutive model
Hardening rule:
Isotropic hardening (Krupkowski power law tabular data etc )
Isotropic hardening (Krupkowski, power law, tabular data, etc.)
Kinematic hardening (linear, nonlinear, Yoshida-Uemori)
Mixed kinematic hardening (Chaboche)
Constitutive model
Cyclic stress-strain behavior
Sheet metal forming: low number of cycles
o
Sheet metal forming: low number of cycles
Features:
Symmetry in yield stress
tension = compression
Symmetry in hardening
concave-down shape
Anisotropy
Bauschinger effect
p
c
Copyright ESI Group, 2012 All rights reserved.
g
Transient behavior
Permanent softening
Hardening rule:
Obtain an accurate stress prediction
10
9/13/2012
6
Springback prediction (1)
Springback phenomenon
Elastic recovery of a portion of
the deformation produced during the deformation produced during
forming.
Stress driven
Proportional to the ratio between
residual stresses and Youngs
modulus
For lightweight materials (with
low Youngs modulus) and HSS
(with high strength) springback
(with high strength) springback
becomes more serious concerns.
Springback results in a difference in
shape between the part and the
tooling.
Springback prediction:
Hardening rule:
Accurate stress prediction Accurate stress prediction
Reverse loading behavior
Advanced hardening rules
Y-U model
Hardening model for Mg alloy sheet
Evolution of the elastic modulus
Source: Mazda Motor Corporation, Japan
9/13/2012
7
1 Background
2. -
1. Background
3.
4.
5. Conclusion
Design requirements:
Horizontal type
Auto-alignment system
Heating
system
Loading dir.
Holding force
control
Strain
measurement
OSU Yes Vertical Hydraulic Indirect
Cyclic loading tester
Requirements
Auto alignment system
Specimen thickness:
0.5~5.0 mm
Max. stroke:
Tension 140 mm
Compression 20 mm
Anti-buckling system
Heating system
y
Tokyo
University
No Horizontal Hydraulic Direct
KNU Yes Horizontal
Hydraulic /
Dead weight
Indirect
g y
Uniform temp. distribution in the gage area
Cyclic loading
Experimental methods for applying
continuous stress reversals to a sheet
specimen.
Indirect strain measuring system
9/13/2012
8
Side force system Jig system Loading dir. Horizontal type
Capacity 30 kN
Temperature RT~400
o
C
Design and specification
side force
Side force

-
align
Heating system Jig movement
Temperature RT~400 C
Speed 0.001~1,000 mm/min
Strain measurement Laser extensometer
Side force 10 kN
Heat cartridge
(2, 3)

align
Uniaxial tension test:
Reference test data:
Universal Testing Machine (INSTRON 5882)
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)

temperature: 400
o
C
K-type thermal sensor
Sheet thickness: 2 mm
Result:
uniform distribution of temperature in the gage area
9/13/2012
9
Upper die 1 Upper die 2
Specimen
F
C
f
s F
T
f
s
Friction effect:
Significant
Contributions:
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
Insignificant
1 Background
2. -
1. Background
3.
4.
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.
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.
Non-IH of bounding surface Workhardening stagnation
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
9/13/2012
11
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
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
Y : Inner surface size

- C : Inner surface
- B : Bounding surface
- R
sat
: Bounding surface
(Isotropic hardening)
- b : Bounding surface
- m: Bounding surface
The non-isotropic hardening (non-IH) surface:
3
p
m b | | c =
|
\ .
p
D
2
3
( , , ) ( ) : ( ) 0
2
g r r
o
' ' ' ' ' ' = = q q q
( ) ' ' ' = q q
3( ) :
0
2
0 0
r when R
r
r wh
h
en R
' ' '
= >
= =
(Isotropic & Kinematic hardening)

- h : Stagnation
(*) Additional parameter(s) can be found in the PAM-STAMP version.
Parameter Test + Procedure
(*)
Plastic strain dependency of Youngs modulus:
PAM-STAMP inputs:
Xi, Younga Cyclic loading test (T-C-T or C-T-C)
Initial yield surface:
X11, X22, X12 Cyclic loading test (T-C-T or C-T-C)
The relative motion law:
Xsati = B Y
Cx1; Cx2; EpRef = c
p
ref
Uniaxial tension test
Cyclic loading test (T-C-T or C-T-C)
Kinematic hardening of the yield surface:
Rsatx = R
sat
AM = m
X11, X22, X12
- Yield locus at origin point (yield point
: 0, 0, 0=)
X
sat
X B Y
y g ( )
Kinematic hardening of the bounding surface:
Bsat = b
sat
The non-isotropic hardening (non-IH) surface:
Hnih = h
Rnih0 = r
0
(*)
Using the optimization technique
- X=B-Y
Xi
- Stagnation
Younga
- Stagnation
EpRef, Rnih0
- default
9/13/2012
12
Procedure:
A computer code was developed
optimization approach
Parameter identification
simplex method
1
(PAM-OPT can be used alternatively)
Input data:
stress - plastic strain curve
cyclic loading test data
various prestrain cases
Y (MPa) C B (MPa) Rsat b (MPa) m h
Value 186.01 561.64 202.20 109.49 33.33 10.20 0.31
Values:
[1] Nelder, J.A., Mead, R. A simplex method for function minimization (1965) Computer Journal, 7, pp. 308-313
NUMISHEET 93 Benchmark model
U-draw bending test
Specimen:
35
Blank
350
RD
Specimen:
Material: Al5052
Shape: width: 35 mm, length: 350 mm
Punch speed: 0.3 mm/s
Stroke: 70 mm
Blank holding force: 1.3 kN
Unit: mm
Die set and dimensions
9/13/2012
13
General property
2.6E-6 kg/mm
3
Elastic property
FE model and inputs:
Boundary condition
PUNCH
HOLDER
Stroke: 70mm
BLANK
BHF: 1.3kN
E 70 GPa
0.3
Plastic property
Krupkowsky's law: = K(
0
+
P)
)
n
K 398.294
n 0.162
0
0.014
DIE
Fixed
x
z
y
175 mm
17.5 mm
Results
9/13/2012
14
1 Background
2. -
1. Background
3.
4.
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)
Excellent EMI shielding
9/13/2012
15
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
Room temperature 5
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
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
9/13/2012
16
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
Accurate modeling of reverse loading behavior Large springback
y y g y g
Correlation between measured stress-strain
responses and calculated ones
Hardening behavior (2)
@RT 150
o
C
@RT 150
o
C
9/13/2012
17
Yielding asymmetry + unusual hardening behavior:
Sophisticated yield function:
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.
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
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
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
9/13/2012
18
Isotropic hardening rule:
stress-strain relation is generalized with the S-shaped curve
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
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
s

o
. tens
o
. comp
o
. re tens
o

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
compression following tension (twin)
tension following compression (untwin)
various prestrain cases
Output: material card
9/13/2012
19
User-defined material (UDM):
Input data:
Method 1: GUI
Method 1: GUI
User-defined material (UDM):
Input data:
Method 2: User-defined attributes
Method 2: User defined attributes
9/13/2012
20
User defined material (UDM):
Input data:
Method 3: Curves (Lookup table data)
Method 3: Curves (Lookup table data)
(to appear soon)
Room temperature 150
o
C
Verification
u
e

s
t
r
e
s
s

(
M
P
a
)
u
e

s
t
r
e
s
s

(
M
P
a
)
True strain True strain
T
r
u
T
r
u
9/13/2012
21
Results
Room temperature 150
o
C
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.
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.
9/13/2012
22
1 Background
2. -
1. Background
3.
4.
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-
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
September 13, 2012

Copyright ESI Group, 2012 All rights reserved. Copyright ESI Group, 2012. All rights reserved.
p
NGOC-TRUNG NGUYEN
ntnguyen@kangwon.ac.kr
9/13/2012
24
Copyright ESI Group, 2012 All rights reserved.

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9/13/2012

September 13, 2012

WPM (World Premier Materials) project

Y : Inner surface size

' ' '

(Isotropic & Kinematic hardening)

September 13, 2012

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