Investigations of ductile damage during the process chains of toothed functional components manufactured by sheet-bulk metal forming

authored by: Kerim Isik, Gregory Gerstein, Thomas Schneider, Robert Schulte, Daniel Rosenbusch, Till Clausmeyer, Florian Nürnberger, Milan Vucetic, Sergej Koch, Sven Hübner, Bernd Arno Behrens, A. Erman Tekkaya, Marion Merklein
Abstract: Sheet-bulk metal forming processes combine conventional sheet forming processes with bulk forming of sheet semi-finished parts. In these processes the sheets undergo complex forming histories. Due to in- and out-of-plane material flow and large accumulated plastic strains, the conventional failure prediction methods for sheet metal forming such as forming limit curve fall short. As a remedy, damage models can be applied to model damage evolution during those processes. In this study, damage evolution during the production of two different toothed components from DC04 steel is investigated. In both setups, a deep drawn cup is upset to form a circumferential gearing. However, the two final products have different dimensions and forming histories. Due to combined deep drawing and upsetting processes, the material flow on the cup walls is three-dimensional and non-proportional. In this study, the numerical and experimental investigations for those parts are presented and compared. Damage evolution in the process chains is simulated with a Lemaitre damage criterion. Microstructural analysis by scanning electron microscopy is performed in the regions with high mechanical loading. It is observed that the evolution of voids in terms of void volume fraction is strongly dependent on the deformation path. The comparison of simulation results with microstructural data shows that the void volume fraction decreases in the upsetting stage after an initial increase in the drawing stage. Moreover, the concurrent numerical and microstructural analysis provides evidence that the void volume fraction decreases during compression in sheet-bulk metal forming.
Organisation(s): Institute of Materials Science
Institute of Metal Forming and Metal Forming Machines
External Organisation(s): TU Dortmund University
Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU Erlangen-Nürnberg)
Type: Article
Journal: Production Engineering
Volume: 10
Pages: 5-15
No. of pages: 11
ISSN: 0944-6524
Publication date: 14.01.2016
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Mechanical Engineering, Industrial and Manufacturing Engineering
Electronic version(s): https://doi.org/10.1007/s11740-016-0656-9 (Access: Closed)
: Details in the research portal "Research@Leibniz University"

BibTeX

@article{6fa066ec9a3d4abaa3afb00bd61555c7,
title = "Investigations of ductile damage during the process chains of toothed functional components manufactured by sheet-bulk metal forming",
abstract = "Sheet-bulk metal forming processes combine conventional sheet forming processes with bulk forming of sheet semi-finished parts. In these processes the sheets undergo complex forming histories. Due to in- and out-of-plane material flow and large accumulated plastic strains, the conventional failure prediction methods for sheet metal forming such as forming limit curve fall short. As a remedy, damage models can be applied to model damage evolution during those processes. In this study, damage evolution during the production of two different toothed components from DC04 steel is investigated. In both setups, a deep drawn cup is upset to form a circumferential gearing. However, the two final products have different dimensions and forming histories. Due to combined deep drawing and upsetting processes, the material flow on the cup walls is three-dimensional and non-proportional. In this study, the numerical and experimental investigations for those parts are presented and compared. Damage evolution in the process chains is simulated with a Lemaitre damage criterion. Microstructural analysis by scanning electron microscopy is performed in the regions with high mechanical loading. It is observed that the evolution of voids in terms of void volume fraction is strongly dependent on the deformation path. The comparison of simulation results with microstructural data shows that the void volume fraction decreases in the upsetting stage after an initial increase in the drawing stage. Moreover, the concurrent numerical and microstructural analysis provides evidence that the void volume fraction decreases during compression in sheet-bulk metal forming.",
keywords = "FE simulation, Lemaitre damage model, Sheet-bulk metal forming",
author = "Kerim Isik and Gregory Gerstein and Thomas Schneider and Robert Schulte and Daniel Rosenbusch and Till Clausmeyer and Florian N{\"u}rnberger and Milan Vucetic and Sergej Koch and Sven H{\"u}bner and Behrens, {Bernd Arno} and Tekkaya, {A. Erman} and Marion Merklein",
note = "Funding information: The authors gratefully acknowledge funding by the German Research Foundation (DFG) within the scope of the Transregional Collaborative Research Centre on sheet-bulk metal forming (SFB/TR 73) in the subprojects A1 “Process combination for manufacturing of teethed, thin-walled functional components out of tailored blanks”, A7 “Improvement of combined cutting and deep drawing processes by means of overlaying dynamic process forces”, C4 “Analysis of load history dependent evolution of damage and microstructure for the numerical design of sheet-bulk metal forming processes”.",
year = "2016",
month = jan,
day = "14",
doi = "10.1007/s11740-016-0656-9",
language = "English",
volume = "10",
pages = "5--15",
journal = "Production Engineering",
issn = "0944-6524",
publisher = "Springer Verlag",
number = "1",
}