This paper is dedicated to the presentation of an advanced 3D numerical methodology for virtual sheet and/or bulk metal forming simulation to predict the anisotropic ductile defects occurrence. First, the detailed formulation of thermodynamically-consistent fully coupled and fully anisotropic constitutive equations is given. The proposed constitutive equations account for the main material nonlinearities as the anisotropic plastic flow, the mixed isotropic and kinematic hardening and the anisotropic ductile damage under large inelastic strains. Second, the related numerical aspects required to solve the initial and boundary value problem (IBVP) are very briefly presented in the framework of the 3D finite element method. The global resolution schemes as well as the local integration schemes of the fully coupled constitutive equations are briefly discussed. Finally, some typical examples of sheet and bulk metal forming processes are numerically simulated using the proposed numerical methodology.
Accepté le :
Publié le :
@article{CRMECA_2016__344_4-5_296_0,
author = {Houssem Badreddine and Carl Laberg\`ere and Khemais Saanouni},
title = {Ductile damage prediction in sheet and bulk metal forming},
journal = {Comptes Rendus. M\'ecanique},
pages = {296--318},
publisher = {Elsevier},
volume = {344},
number = {4-5},
year = {2016},
doi = {10.1016/j.crme.2015.11.006},
language = {en},
}
TY - JOUR AU - Houssem Badreddine AU - Carl Labergère AU - Khemais Saanouni TI - Ductile damage prediction in sheet and bulk metal forming JO - Comptes Rendus. Mécanique PY - 2016 SP - 296 EP - 318 VL - 344 IS - 4-5 PB - Elsevier DO - 10.1016/j.crme.2015.11.006 LA - en ID - CRMECA_2016__344_4-5_296_0 ER -
Houssem Badreddine; Carl Labergère; Khemais Saanouni. Ductile damage prediction in sheet and bulk metal forming. Comptes Rendus. Mécanique, Volume 344 (2016) no. 4-5, pp. 296-318. doi : 10.1016/j.crme.2015.11.006. https://comptes-rendus.academie-sciences.fr/mecanique/articles/10.1016/j.crme.2015.11.006/
[1] Limit strain in the processes of stretch forming sheet steel, J. Mech. Phys. Solids, Volume 1 (1967), pp. 609-620
[2] Influence of the plastic properties of a material on the forming limit diagram for sheet metal in tension, Int. J. Mech. Sci., Volume 15 (1973), pp. 789-800
[3] Influence of strain-path changes on the formability of sheet steel, Metals Park, Ohio (ASM, ed.) (1977), pp. 167-178
[4] Determination of an intrinsic forming limit stress diagram for isotropic sheets, Proceedings of the 12th IDDRG Congress, 1982, pp. 61-71
[5] Determination of the forming limit stress curve for anisotropic sheets, CIRP Ann., Volume 36 (1987), pp. 195-198
[6] Calculations of forming limit, Metall. Trans. A, Phys. Metall. Mater. Sci., Volume 24 (1993), pp. 2497-2501
[7] Determination and use of the forming limit stress diagrams in sheet metal forming, J. Mater. Process. Technol., Volume 53 (1995), pp. 47-56
[8] Stress-based forming limits in sheet-metal forming, J. Eng. Mater. Technol., Volume 123 (2001), pp. 417-422
[9] A method for stress space forming limit diagram construction for aluminum alloys, J. Mater. Process. Technol., Volume 174 (2006), pp. 258-265
[10] A methodology for prediction of forming limit stress diagrams considering the strain path effect, Comput. Mater. Sci., Volume 45 (2009), pp. 195-204
[11] A combined necking and shear localization analysis for aluminum sheets under biaxial stretching conditions, Int. J. Plast., Volume 20 (2004), pp. 1953-1981
[12] Fracture limits of sheet metals under stretch bending, Int. J. Mech. Sci., Volume 47 (2005), pp. 1885-1896
[13] Effect of strain hardening behavior on forming limit stresses of steel tube subjected to nonproportional loading paths, Int. J. Plast., Volume 23 (2007), pp. 1260-1284
[14] Prediction of failure under complex 3D-stress conditions, ETH Zurich, IVP (2009), pp. 133-138
[15] Comparison of the work hardening of metallic sheets in bending–unbending and simple shear, Int. J. Mech. Sci., Volume 51 (2009), pp. 122-130
[16] Aluminum alloy damage evolution for different strain paths—application to hemming process, Eng. Fract. Mech., Volume 76 (2009), pp. 1202-1214
[17] Prediction of failure under complex 3D-stress conditions, 5–6 May, IVP, ETH Zurich (2009), pp. 133-138
[18] Plastic instability under plane stress, J. Mech. Phys. Solids, Volume 1 (1952), pp. 1-18
[19] Localized necking in thin sheets, J. Mech. Phys. Solids, Volume 23 (1975), pp. 421-441
[20] The use of a shear instability criterion to predict local necking in sheet metal deformation, Int. J. Mech. Sci., Volume 25 (1983), pp. 155-168
[21] Void growth and local necking in biaxially stretched sheets, J. Eng. Mater. Technol., Volume 100 (1978), pp. 164-169
[22] An analysis of localized necking in punch stretching, Int. J. Solids Struct., Volume 16 (1980), pp. 913-931
[23] Void nucleation effects in biaxially stretched sheets, J. Eng. Mater. Technol., Volume 102 (1980), pp. 249-256
[24] Experimental and analytical necking studies of anisotropic sheet metals, J. Mater. Process. Technol., Volume 112 (2001), pp. 214-226
[25] Modeling of Metal Forming and Machining Processes: By Finite Element and Soft Computing Methods, Springer Science & Business Media, 2008
[26] Modélisation et simulation numériques en formage virtuel, Lavoisier, 2012
[27] Damage Mechanics in Metal Forming: Advanced Modeling and Numerical Simulation, John Wiley & Sons, 2012
[28] An improved finite element method for the analysis of damage and ductile fracture in cold forming processes, CIRP Ann., Volume 34 (1985), pp. 209-213
[29] An anisotropic damage criterion for deformation instability and its application to forming limit analysis of metal plates, Eng. Fract. Mech., Volume 21 (1985), pp. 1031-1054
[30] Damage evolution modeling in bulk forming processes, Computational Methods for Predicting Material Processing Defects, 1987, pp. 251-262
[31] Plastic and viscoplastic flow of void-containing metals: applications to axisymmetric sheet forming problems, Int. J. Numer. Methods Eng., Volume 25 (1988), pp. 227-251
[32] The prediction of ductile fracture initiation in metalforming using a finite-element method and various fracture criteria, Res. Mech., Volume 28 (1989), pp. 269-293
[33] Finite element analysis of ductile fracture and defects formation in cold and hot forging, CIRP Ann., Volume 39 (1990), pp. 215-218
[34] Numerical investigation of the damage process in metal forming, Eng. Fract. Mech., Volume 40 (1991), pp. 387-393
[35] The finite element prediction of ductile fracture initiation in dynamic metalforming processes, J. Phys. IV, Volume 1 (1991) (C3-751–C753-757)
[36] The prediction of necking and failure in 3 D: sheet forming analysis using damage variable, J. Phys. IV, Volume 6 (1996) (C6-473–C476-482)
[37] Failure analysis of anisotropic sheet-metals using a non-local plastic damage model, J. Mater. Process. Technol., Volume 170 (2005), pp. 457-470
[38] A fully coupled elastoplastic damage modeling and fracture criteria in metalforming processes, J. Mater. Process. Technol., Volume 32 (1992), pp. 197-204
[39] A fully coupled elasto-visco-plastic damage theory for anisotropic materials, Int. J. Solids Struct., Volume 32 (1995), pp. 1607-1641
[40] Damage modeling in metal forming processes, Int. J. Damage Mech., Volume 9 (2000), pp. 196-240
[41] Numerical Simulation of Damage in Metal Forming Processes, Elsevier, New York, 2000
[42] Numerical aspects of finite elastoplasticity with isotropic ductile damage for metal forming, Rev. Eur. Éléments Finis, Volume 2-3-4 (2001), pp. 327-351
[43] Numerical aspects of finite elastoplasticity with damage for metal forming, Rev. Eur. Éléments Finis, Volume 10 (2001), p. 4
[44] Transfert de champs plastiquement admissibles, C. R. Mecanique, Volume 330 (2002), pp. 313-318
[45] Numerical improvement of thin tubes hydroforming with respect to ductile damage, Int. J. Mech. Sci., Volume 44 (2002), pp. 2427-2446
[46] Improvement of forging process of a 3D complex part with respect to damage occurrence, J. Mater. Process. Technol., Volume 142 (2003), pp. 307-317
[47] Numerical simulation of sheet metal blanking process using a coupled finite elastoplastic damage modelling, Int. J. Form. Process., Volume 6 (2003), pp. 7-32
[48] Computational damage mechanics: application to metal forming simulation (I. Milne; R.O. Ritchie; B. Karihaloo, eds.), Comprehensive Structural Integrity, Pergamon, Oxford, 2003, pp. 321-376
[49] Numerical prediction of ductile damage in metal forming processes including thermal effects, Int. J. Damage Mech., Volume 13 (2004), pp. 59-80
[50] Numerical prediction of discontinuous central bursting in axisymmetric forward extrusion by continuum damage mechanics, Comput. Struct., Volume 82 (2004), pp. 2309-2332
[51] Numerical simulation of an hexnut forming process including damage effect, Int. J. Form. Process., Volume 8 (2005), p. 291
[52] Simulation numérique de la coupe orthogonale par couplage thermique–comportement–endommagement en transformations finies, Méc. Ind., Volume 6 (2005), pp. 297-307
[53] Virtual metal forming including the ductile damage occurrence: actual state of the art and main perspectives, J. Mater. Process. Technol., Volume 177 (2006), pp. 19-25
[54] A CDM approach of ductile damage with plastic compressibility, Int. J. Fract., Volume 137 (2006), pp. 51-75
[55] Damage modelling in metal forming problems using an implicit non-local gradient model, Comput. Methods Appl. Mech. Eng., Volume 195 (2006), pp. 6646-6660
[56] Elastoplasticité anisotrope non normale en grandes deformations avec endommagement: application à la mise en forme des tôles minces, Eur. J. Comput. Mech., Volume 16 (2007), pp. 913-940
[57] On the numerical prediction of the ductile fracture in metal forming, Eng. Fract. Mech., Volume 75 (2008), pp. 3545-3559
[58] Advances in virtual metal forming including the ductile damage occurrence: application to 3D sheet metal deep drawing, J. Eng. Mater. Technol., Volume 130 (2008), pp. 02102201-02102211
[59] Application of continuum damage mechanics in discontinuous crack formation: forward extrusion chevron predictions, Z. Angew. Math. Mech., Volume 88 (2008), pp. 436-453
[60] A micromechanical model for inelastic ductile damage prediction in polycrystalline metals for metal forming, Int. J. Mech. Sci., Volume 51 (2009), pp. 453-464
[61] Finite element simulation of 3D sheet metal guillotining using advanced fully coupled elastoplastic–damage constitutive equations, Finite Elem. Anal. Des., Volume 46 (2010), pp. 535-550
[62] Modelling and numerical simulation of ductile damage in bulk metal forming, Steel Res. Int., Volume 80 (2009), pp. 645-657
[63] On non-associative anisotropic finite plasticity fully coupled with isotropic ductile damage for metal forming, Int. J. Plast., Volume 26 (2010), pp. 1541-1575
[64] Numerical prediction of thermomechanical field localization in orthogonal cutting, CIRP J. Manuf. Sci. Technol., Volume 5 (2012), pp. 175-195
[65] 2D adaptive FE simulations in finite thermo-elasto-viscoplasticity with ductile damage: application to orthogonal metal cutting by chip formation and breaking, Int. J. Damage Mech., Volume 20 (2011), pp. 23-61
[66] 2D adaptive mesh methodology for the simulation of metal forming processes with damage, Int. J. Mater. Forming, Volume 4 (2011), pp. 317-328
[67] About elastoplastic nonlocal formulations with damage gradients, Int. J. Damage Mech., Volume 20 (2011), pp. 845-875
[68] Identification of fully coupled anisotropic plasticity and damage constitutive equations using a hybrid experimental–numerical methodology with various triaxialities, Int. J. Damage Mech. (2014)
[69] Damage anisotropy and its effect on the plastic anisotropy evolution under finite strains, Int. J. Solids Struct., Volume 63 (2015), pp. 11-31
[70] Formability prediction of AL7020 with experimental and numerical failure criteria, J. Mater. Process. Technol., Volume 218 (2015), pp. 80-88
[71] Experimental characterization and numerical prediction of ductile damage in forming of AA1050-O sheets, Int. J. Mech. Sci., Volume 99 (2015), pp. 262-273
[72] On the anelastic flow with damage, Int. J. Damage Mech., Volume 3 (1994), pp. 140-169
[73] A Course on Damage Mechanics, Springer-Verlag, Berlin, 1992
[74] Numerical simulation of continuous damage and fracture in metal forming processes with 2D mesh adaptive methodology, Finite Elem. Anal. Des., Volume 82 (2014), pp. 46-61
[75] Numerical analysis and elastic–plastic deformation behavior of anisotropically damaged solids, Int. J. Plast., Volume 18 (2002), pp. 1237-1270
[76] An anisotropic ductile damage model based on irreversible thermodynamics, Int. J. Plast., Volume 19 (2003), pp. 1679-1713
[77] A continuum theory of creep and creep damage, Creep in Structures, Springer, 1981, pp. 422-444
[78] Anisotropic damage theory and its application to creep crack growth analysis, J. Soc. Mater. Sci. Jpn., Volume 37 (1988), pp. 278-282
[79] Continuum Damage Mechanics: A Continuum Mechanics Approach to the Analysis of Damage and Fracture, vol. 185, Springer Science & Business Media, 2012
[80] Anisotropic damage in elasticity and plasticity, J. Méc. Théor. Appl. (1982), pp. 45-60
[81] Anisotropie élastique induite par endommagement, Comportement mécanique des solides anisotropes, 1979, pp. 761-774
[82] Applications of tensor functions to the formulation of constitutive equations involving damage and initial anisotropy, Eng. Fract. Mech., Volume 25 (1986), pp. 573-584
[83] Damage induced anisotropy: on the difficulties associated with the active/passive unilateral condition, Int. J. Damage Mech., Volume 1 (1992), pp. 148-171
[84] Development of continuum damage mechanics for elastic solids sustaining anisotropic and unilateral damage, Int. J. Damage Mech., Volume 2 (1993), pp. 311-329
[85] A thermodynamically consistent framework for theories of elastoplasticity coupled with damage, Int. J. Solids Struct., Volume 31 (1994), pp. 359-389
[86] A plasticity–damage theory for large deformation of solids, I: theoretical formulation, Int. J. Eng. Sci., Volume 30 (1992), pp. 1089-1108
[87] Finite strain plasticity and damage in constitutive modeling of metals with spin tensors, Appl. Mech. Rev., Volume 45 (1992), p. S95-S109
[88] Theoretical formulation of a coupled elastic–plastic anisotropic damage model for concrete using the strain energy equivalence concept, Int. J. Damage Mech. (2009)
[89] Advances in Damage Mechanics: Metals and Metal Matrix Composites, Elsevier, 2012
[90] Anisotropic ductile damage effects on anisotropic plastic flow: modeling, numerical simulation and experimental validation, Int. J. Damage Mech., Volume 23 (2014), pp. 1211-1256
[91] On evolution laws of anisotropic damage, Eng. Fract. Mech., Volume 34 (1989), pp. 679-701
[92] Anisotropic damage law of evolution, Eur. J. Mech. A, Solids, Volume 19 (2000), pp. 187-208
[93] Engineering Damage Mechanics: Ductile, Creep, Fatigue and Brittle Failures, Springer Science & Business Media, 2005
[94] An anisotropic theory of continuum damage mechanics for ductile fracture, Eng. Fract. Mech., Volume 27 (1987), pp. 547-558
[95] Continuum thermodynamics, J. Appl. Mech., Volume 50 (1983), pp. 1010-1020
[96] Modelling of brittle and fatigue damage for elastic material by growth of microvoids, Eng. Fract. Mech., Volume 21 (1985), pp. 861-874
[97] A constitutive theory for the inelastic behavior of concrete, Mech. Mater., Volume 4 (1985), pp. 67-93
[98] A model of unilateral elastic damageable material and its application to concrete, Fracture Toughness and Fracture Energy of Concrete, Elsevier, New York, 1986
[99] On energy-based coupled elastoplastic damage theories: constitutive modeling and computational aspects, Int. J. Solids Struct., Volume 25 (1989), pp. 803-833
[100] The unilateral behaviour of damaged concrete, Eng. Fract. Mech., Volume 35 (1990), pp. 629-635
[101] J. Chaboche, P. Lesne, J. Maire, Continuum damage mechanics, anisotropy and damage deactivation for brittle materials like concrete and ceramic composites, 1995.
[102] Mécanique des matériaux solides, Dunod, Paris, 2009
[103] Quasi-unilateral conditions in anisotropic elasticity, C. R. Acad. Sci., Sér. 2, Méc. Phys. Chim. Astron., Volume 328 (2000), pp. 445-450
[104] Modeling microdefects closure effect with isotropic/anisotropic damage, Int. J. Damage Mech. (2007)
[105] On an anisotropic damage theory (J.P. Boehler, ed.), Failure Criteria of Structured Media, Balkema, Rotterdam, 1993, pp. 355-363
[106] The Finite Element Method: Linear Static and Dynamic Finite Element Analysis, Courier Corporation, 2012
[107] Finite Element Procedures, Prentice Hall, Upper Saddle River, 1996
[108] Nonlinear Finite Elements for Continua and Structures, Wiley, 2000
[109] Computational Inelasticity, Springer-Verlag Inc., New York, 1998
[110] Computational Methods for Plasticity: Theory and Applications, John Wiley & Sons, 2011
[111] Analysis of the effect of strain hardening on central bursting defects in drawing and extrusion, J. Eng. Ind., Volume 92 (1970), pp. 135-145
[112] The analysis of void growth that leads to central bursts during extrusion, J. Mech. Phys. Solids, Volume 34 (1986), pp. 55-79
[113] Microcontinuum Field Theories, I: Foundations and Solids, Springer Verlag, New York, 1999
[114] Nonlocal Continuum Field Theories, Springer Science & Business Media, 2002
[115] Elastoviscoplastic constitutive frameworks for generalized continua, Acta Mech., Volume 160 (2003), pp. 71-111
[116] Milieux continus généralisés et matériaux hétérogènes, Presses des MINES, 2006
[117] Micromorphic approach for gradient elasticity, viscoplasticity, and damage, J. Eng. Mech., Volume 135 (2009), pp. 117-131
[118] Micromorphic approach for finite gradient-elastoplasticity fully coupled with ductile damage: formulation and computational aspects, Int. J. Solids Struct., Volume 50 (2013), pp. 2289-2309
Cité par Sources :
Commentaires - Politique
Strain localization analysis for planar polycrystals based on bifurcation theory
Mohamed Ben Bettaieb; Farid Abed-Meraim
C. R. Méca (2018)
Effect of the kinematic hardening on the plastic anisotropy parameters for metallic sheets
Houssem Badreddine; Khemais Saanouni; Carl Labergère; ...
C. R. Méca (2018)
Qi-zhi Zhu; Jian-fu Shao; Djimedo Kondo
C. R. Méca (2008)