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Lecture 4: Contents: Constitutive Modeling of Large-Strain Cyclic Plasticity For Anisotropic Metals

This document summarizes material constitutive modeling and applications to springback simulation. It discusses: 1) Models for anisotropic cyclic plasticity and the Yoshida-Uemori model for accurate springback prediction. 2) Examples of springback simulation for various automotive parts using the Yoshida-Uemori model. 3) Optimization techniques to compensate for springback by modifying drawbeads or die shapes.

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167 views18 pages

Lecture 4: Contents: Constitutive Modeling of Large-Strain Cyclic Plasticity For Anisotropic Metals

This document summarizes material constitutive modeling and applications to springback simulation. It discusses: 1) Models for anisotropic cyclic plasticity and the Yoshida-Uemori model for accurate springback prediction. 2) Examples of springback simulation for various automotive parts using the Yoshida-Uemori model. 3) Optimization techniques to compensate for springback by modifying drawbeads or die shapes.

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Constitutive modeling of large-strain cyclic plasticity for anisotropic metals

1: Basic framework of modeling 2: Models of orthotropic anisotropy 3: Cyclic plasticity Kinematic hardening model 4: Applications to sheet metal forming and some topics on material modeling

Fusahito Yoshida
Department of Mechanical Science and Engineering Hiroshima University, JAPAN

Lecture 4: Contents
1. Springback simulation 2. Springback compensation based on optimization technique 3. Some topics on material modeling - Modeling of yield point phenomena - Multi-scale modeling - Material database

Springback Simulation
Hat-type draw bending S-rail forming Bumper beam B-pillar etc.

Accuracy of springback analysis strongly depends on material models.

CASE 1: Hat draw-bending

Experiment

Experiment on 980HSS sheet

Isotropic hardening

Isotropic hardening model

Yoshida-Uemori

Accurate description of the Bauschinger effect

Yoshida Uemori model

by LS-DYNA

CASE 2: S-rail forming


X= 0

by PAM-Stamp 2G
with Yoshida model
980MPa HSS

X= 115

X= 115 X=115 X=0 X=115

CASE 3: Bumper beam Selection of a material model is of vital importance for accurate simulation of springback Yoshida-Uemori model

IH model by PAM-STAMP 2G
Bumper beam

Yoshida-Uemori model by PAM-STAMP 2G


Experiment

CASE 4: Application of Yoshida model for massmass-production parts

MAZDA-5(2005 model)s B-pillar rein

Real (Red line)

Yoshida (Blue line)

Material; SPHN590R-DS t1.6(Red) SPCN780Y-N-E t1.8(Green) SPCN590R-N t1.4(Blue)

Section cut

Blank

1st forming (completed)

CASE 5: B-pillar (780+980 MPa HSS tailored blank) Comparison between FE simulation (Pam-Stamp2G) and experimental results
Isotropic hardening Yoshida-Uemori Kinematic hardening

75.81%

91.53%

Simulation error less than 1.0mm

CASE 6: L-shaped beam


Initial Blank After Holding Process After Stamping Process After Trimming Process

Holding Process Calculation Stamping Process Calculation

1st Springback Calculation

2ndSpringback Calculation

Trimming

980HSS sheet

Simulation of wrinkles by PAM-STAMP 2G: Yoshida-Uemori Model


No drawbead 2-mm drawbeads 4-mm drawbeads

Photos

D measurement

Simulation

Springback Compensation based on Optimization Technique

Drawbeads for S-rail forming Tool shape design for bumper beam

Optimum Drawbead Setting for Springback Compensation in S-rail Forming

Optimum drawbead Twisting springback

Effect of Drawbead on Springback


Full drawbead setting Clockwise direction
sec-2 sec-1 sec-1 sec-2

Partial drawbead setting


sec-1 sec-2

sec-2

Counterclockwise direction

sec-1 Remove a part of draw bead line

sec-1

sec-2

12

Springback Control by Drawbead as a Problem of Optimization Design variables x = Drawead heights


Where design variables x = x1, x2, x3, x4 are 0.0 1 2.0 0.0 2 2.0 -0.4 3 0.4 -0.4 4 0.4
No. No. No.2 No.3 No.4 No.5 No.6 No.7 No.8 Drawbead height mm

H1 = x1 H2 = x2 H3 = x3 +H1 H4 = x4 +H2 H5 = ( H1 + H7 ) / 2 H6 = ( H2 + H8 ) / 2 H7 = 2.0 H8 = 2.0

Objective function to be minimized F(x)= twising angle

Drawbead height Hi

Result of FE simulation based Optimization


No drawbead
Tortional angle
Section-1

Section-2

3.5 degree
Section-1 Section-2

Optimum drawbeads

0.4 degree
Section-1 Section-2

Torsional springback is successfully suppressed by optimum drawbead setting

Experimental Verification

Optimum drawbead

Blank holding

Drawing

Triminng

Experimental Verification
No drawbead
Tortional angle
Section-1

Section-2

4.0 degree
Section-1 Section-2

Optimum drawbeads

0.5 degree
Section-1 Section-2

Torsional springback is successfully suppressed by optimum drawbead setting Verified!

Determination of optimum tool shapes for bumper beam


A. Cross-section opening springback

B.Longitudinal springback

Springback compensation for A (cross section) and B (longitudinal) types were treated separately.

Die design as an optimization problem (Cross section) Minimize objective function f(x) -Subject to
g1 ( x ) C1 , g 2 ( x ) C2 , g3 ( x ) C3
Objective function FE simulation Result after springback calculation Target shape

Design variables Punch

Die

Z Y

x1

x2
Pad

x3 d2d1
Constraints

g1(x) g2(x)

di

Z Y

f(x) = di

Z Y

g3(x)=min di

Die design as an optimization problem (Longitudinal direction)


Objective function

Z X

After springback

Target shape

Before springback
Design variable

8.1mm

x=r

Result of optimization (Final shape of the beam after springback)

28.4

53.4

Some topics on material modeling

Yield-point phenomena Multi-scale modeling

Rate-dependent Yield-Point Phenomena


..
500 400

Yield point

Workhardening

Stress (MPa)

300 200 100 0 0 0.02 0.04 0.06 0.08 0.1

Yield plateau
Crosshead speed 0.5(mm/s) Crosshead speed 0.005(mm/s) Crosshead speed 0.0005(mm/s)

Strain

Non-uniform plastic deformation .. due to Luders band propagation

Modeling and Simulations of Yield-Point Phenomena (Overview)


Metal physics: Cottrell & Bibly (1949); Lomer (1952); ;Stein and Low (1966); ; Fujita & Miyazaki (1978); ; Neuhauser & Hampel (1993) Constitutive modeling: Jhonston & Gilman (1959); Hahn (1962); Shioya & Shioiri (1976); Yoshida (IJP 16 (2000) 359)

Model of cyclic plasticity


FE simulation of Luders-band propagation: Itoh-Yoshida et al. (1992); Tsukahara (1998); Kyriakides (2001); Sun-Yoshida et al. (2003) .. Polycrystal plasticity simulation: Ghosh et al. (2004)

Framework of Constitutive Modeling (1) Single crystal


& p = b m
& p = b m c
D
n

eff

D = c

eff

m eff

: Burgers Vector : mobile dislocation density : effective resolved shear stress : interaction stress acting on moving dislocations : velocity of dislocations : drag stress

Yield-point phenomena result from rapid dislocation multiplication and the stress-dependence of dislocation velocity.

Framework of Constitutive Modeling (2) Polycrystals


& = b m ( Y + R ) M D
n

&p =

3( s ) & 2
Y +R

3 (s ) : (s ) 2

&p

s : stress deviator,

: backstress deviator,
R : isotropic hardening stress, Y : initial yield stress, M : Taylor factor

s
Yield surface

Yoshida, F, Int. J. Plasticity 16 (2000) 359-380

A Model of Yield Point Phenomena .. deformation Plastic at Luders-band front:


&LBF = b m Y M DLBF
n

, =

3 s:s 2

Plastic deformaton at workhardening region: n b m (Y + R) & WH = , M DWH

=
Yoshida, F.: Int. J. Plasticity 16 (2000) ,359 Yoshida, F. et al.: Int. J. Plasticity 24 (2008),1792

3 (s - ) : (s - ) 2

Rapid dislocation multipication


m = f = 0 + C a
m : mobile dislocation density

: total dislocation density

(Hahn 1962; Kohda 1973; Hull & Bacon 1984)

f = f 0 + ( f asy f 0 ) {1 exp( )}

Initial value of mobile dislocation density is very small because of the Cottrell atmosphere.

Model of rapid dislocation multiplication


m = f = 0 + C a
m : mobile dislocation density

: total dislocation density

(Hahn 1962; Kohda 1973; Hull & Bacon 1984)

f = f 0 + ( f asy f 0 ) {1 exp( )}

A sharp yield point and the subsequent abrupt yield drop is a consequence of rapid dislocation multiplication and strong stress dependency of dislocation velocity.

Very low mobile dislocation density because of Cottrell locking

Uniaxial tension Experiment


500
500

Simulation
400

400

Stress(MPa)

300

Stress(MPa)

300

200

200 Crosshead speed 0.5(mm/s) Crosshead speed 0.005(mm/s) Crosshead speed 0.0005(mm/s)

100

Crosshead speed 0.5(mm/s) Crosshead speed 0.005(mm/s) Crosshead speed 0.0005(mm/s) 0 0.02 0.04 0.06 0.08 0.1

100

0 0 0.02 0.04 0.06 0.08 0.1

Strain

Strain

F. Yoshida, Int. J. Plasticity, 16 (2000), pp.359-380

Elimination of Yield-Point by temper rolling

FE simulation of temper rolling


Stress (MPa)

500 400 300 200 100

Before skin-pass rolled

0.5% 1.0% 2.0% rolled


0 0 0.05 0.1 0.15 0.2

Strain

FE simulation

Experiment

Yoshida, F. et al.: A plasticity model describing yield-point phenomena of steels and its application to FE simulation of temper rolling, Int J. Plasticity 24 (2008) pp.1792-1818.

model for -Ti (Ti-20V-4Al-1Sn) at elevated temperature


Furnace Extensometer Laser displacement

specimen

&p =

b m Y0 Riso Q exp M D RT & = B (Q R ) & p aR R iso iso iso iso


n

Servo-controlled testing machine

Strain hardening

Dynamic recovery

X.T. Wang, F. Yoshida et al.: Mat Trans 50-9 (2009), pp.1576

Multi-scale modeling for prediction of macro elasto-plasticity behavior of materials


FE forming simulation

Homogenization
Macro modeling Material parameters associated with micro structures Dislocation motion, accumulation and Dstructure formation Models of obstacles (Gboundaries, precipitates, etc.)

Modeling for multi-phase & polycrystal materials

Modeling of single crystal for each phase

Volume fraction of each phase and texture

Continuum mechanics

Crystal plasticity

DDMD

Material tests & Parameter identification Material Database

SPCN780Y

Cyclic plasticity Material parameter identification

Yield function, material parameters

Database
Automatic idetification software

Sheet metal forming simulation

Forming limit criteria & material parameters

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