Accessible Requires Authentication Published by De Gruyter June 30, 2021

Influence of various procedures for the determination of flow curves on the predictive accuracy of numerical simulations for mechanical joining processes

Max Böhnke, Fabian Kappe, Mathias Bobbert and Gerson Meschut
From the journal Materials Testing

Abstract

The predictive quality of numerical simulations for mechanical joining processes depends on the implemented material model, especially regarding the plasticity of the joining parts. Therefore, experimental material characterization processes are conducted to determine the material properties of sheet metal and generate flow curves. In this regard, there are a number of procedures which are accompanied by varying experimental efforts. This paper presents various methods of determining flow curves for HCT590X as well as EN AW-6014, including varying specimen geometries and diverse hardening laws for extrapolation procedures. The flow curves thus generated are compared considering the variety of plastic strains occurring in mechanical joining processes. The material data generated are implemented in simulation models for the joining technologies, clinching and self-piercing riveting. The influence of the varied methods on the predictive accuracy of the simulation model is analysed. The evaluation of the differing flow curves is achieved by comparing the geometric formation of the joints and the required joining forces of the processes with experimentally investigated joints.


MSc Max Böhnke Laboratory for Material and Joining Technology (LWF) Paderborn University Pohlweg 47-49, 33098 Paderborn Germany

Acknowledgement

Funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation) – TRR 285 – Project-ID 418701707. In particular, the authors wish to express their most sincere gratitude to Mr. Christian R. Bielak for his valuable assistance in building up the simulation models and evaluating the results.

References

1 A. Zweck, D. Holtmannspötter, M. Braun, M. Hirt, S. Kimpeler, P. Warnke: Social changes 2030, Results Volume 1 of the Search Phase of BMBF Foresight Cycle II, Future Technologies No. 100, VDI Technology Center, Düsseldorf, Germany (2015) (in German) Search in Google Scholar

2 U. Klasfauseweh: Contribution to the Simulation of Non-Cutting Clinching Processes, Dissertation, University of Paderborn, Germany (1994) (in German) Search in Google Scholar

3 O. Hahn, N. Dölle: Numerical Simulation of the Joining Process During Self-Piercing Riveting with Semi-Tubular Rivet of Ductile Sheet Metal Materials, Shaker, Aachen, Germany (2001) (in German) Search in Google Scholar

4 M. Carandente, R. J. Dashwood, I. G. Masters, L. Han: Improvements in numerical simulation of the SPR process using a thermo-mechanical finite element analysis, Journal of Materials Processing Technology 236 (2016), pp. 148-161 DOI:10.1016/j.jmatprotec.2016.05.001 Search in Google Scholar

5 S. Busse, M. Merklein, K. Roll: Numerical and experimental investigations of an innovative clinching process, Proc. Of the 10th International Conference on the Technology of Plasticity, Aachen (2011), pp. 736-741 Search in Google Scholar

6 S. Coppieters: Experimental and Numerical Study of Clinched Connection, Dissertation, KU Leuven, Belgium (2012) Search in Google Scholar

7 C. Chermette, K. Unruh, I. Peshekhodov: A new analytical method for determination of the flow curve for high-strength sheet steels using the plane strain compression test, International Journal of Material Forming (2019), pp. 269-292 DOI:10.1007/s12289-019-01485-4 Search in Google Scholar

8 B.-A. Behrens, R. Rolfes, M. Vucetic, I. Peshekhodov, J. Reinoso, M. Vogler, N. Grbic: Material characterization for FEA of the clinching process of short fiber reinforced thermoplastics with an aluminum sheet, Advanced Materials Research 966-967 (2014), pp. 557-568 DOI:10.4028/www.scientific.net/AMR.966-967.557 Search in Google Scholar

9 H. Traphöner, T. Clausmeyer, A. E. Tekkaya: Material characterization for plane and curved sheets using the in-plane torsion test – An overview, Procedia Engineering 207 (2017), pp. 1934-1939 DOI:10.1016/j.proeng.2017.10.964 Search in Google Scholar

10 B. Mülders: Modeling of Strain Hardening of Technical Aluminum Alloys, Dissertation, RWTH Aachen, Germany (2001) (in German) Search in Google Scholar

11 A. Kahrimanidis, M. Lechner, J. Degner, D. Wortberg, M. Merklein: Process Design of Aluminum Tailor Heat Treated Blanks, MDPI Materials, Basel, Switzerland (2015) DOI:10.3390/ma8125476 Search in Google Scholar

12 A. Werber, M. Liewald, W. Nester, M. Grünbaum, K. Wiegand, J. Simon, J. Timm, W, Hotz: Assessment of forming limit stress curves as failure criterion for non-proportional forming processes, German Academic Society for Production Engineering, Stuttgart (2013), pp. 213-221 DOI:10.1007/s11740-013-0446-6 Search in Google Scholar

13 Y. Chen, A. H. Clausen, O. S. Hopperstad, M. Langseth: Stress–strain behavior of aluminum alloys at a wide range of strain rates, International Journal of Solids and Structures 46 (2009), pp. 3825-3835 DOI:10.1016/j.ijsolstr.2009.07.013 Search in Google Scholar

14 S. Liu, A. Kouadri-Henni, A. Gavrus. Numerical simulation and experimental investigation on the residual stresses in a laser beam welded dual phase DP600 steel plate: Thermomechanical material plasticity model, International Journal of Mechanical Sciences 122 (2017), pp. 235-343, DOI:10.1016/j.ijmecsci.2017.01.006 Search in Google Scholar

15 W. Wu-rong, H. Chang-wei, Z. Zhong-hua, W. Xi-cheng: The limit drawing ratio and formability prediction of advanced high strength dual-phase steels, Materials and Design 32 (2011), pp. 3320-3327 DOI:10.1016/j.matdes.2011.02.021 Search in Google Scholar

16 M. Jäckel, S. Coppieters, N. Vandermeiren, C. Kraus, W.-G Drossel, N. Miyake, T. Kuwabara, K. Unruh, H. Traphöner, A. E. Tekkaya, T. Balan: Process-oriented flow curve determination in mechanical joining, Proc. of the 23rd International ESAFORM Conference on Material Forming (2020), pp. 368-374, DOI:10.1016/j.promfg.2020.04.289 Search in Google Scholar

17 M. Merklein, A. Kuppert: A method for the layer compression test considering the anisotropic material behavior, International Journal of Material Forming 2 (2009), pp. 483-486 DOI:10.1007/s12289-009-0592-8 Search in Google Scholar

18 P. K. C. Wood, C. A. Schley, M. A. Williams, A. Rusinek: A model to describe the high rate performance of self-piercing riveted joints in sheet aluminum, Materials and Design 32 (2011), pp. 2246-2259 DOI:10.1016/j.matdes.2010.11.018 Search in Google Scholar

19 DIN EN ISO 50125: Testing of Metallic Materials – Tensile Specimens, Beuth, Berlin, Germany (2003) Search in Google Scholar

20 W. Böhme, M. Luke, J. G. Blauel, S. Dong-Zhi, I. Rohr, W. Harwick: Dynamic Material Characteristics for Crash Simulation, FAT-Publications 211, Frankfurt, Germany (2007) (in German) Search in Google Scholar

21 Y. H. Wang, J. H. Jiang, C. Wanintrudal, C. Du, D. Zhou, L. M. Smith, L. X. Yang: Whole field sheet-metal tensile test using digital image correlation, Experimental Techniques 34 (2010), pp. 54-59 DOI:10.1111/j.1747-1567.2009.00483.x Search in Google Scholar

22 B. Xu, J. Xia, R. Ma, J. Wang, X. Chen, H. Chang, L. Zhang: Investigation on true stress-strain curves of flat and corner regions of cold-formed section using 3D digital image correlation method, Hindawi Advances in Civil Engineering 2019, Article ID 3138176 DOI:10.1155/2019/3138176 Search in Google Scholar

23 DVS-EFB 3420: Clinching – Basics, German Welding Society (DVS)/European Research Association for Sheet Metal Working (EFB), DVS-Verlag, Düsseldorf, Germany (2012) (in German) Search in Google Scholar

24 DVS-EFB 3410: Self-Piercing Riveting – Basics, German Welding Society (DVS)/ European Research Association for Sheet Metal Working (EFB), DVS-Verlag, Düsseldorf, Germany (2014) (in German) Search in Google Scholar

25 N. N.: HCT590X, Material Data Sheet, Salzgitter Flachstahl, Salzgitter, Germany (2019) Search in Google Scholar

26 EN AW-6014 T4, Material Data Sheet Novelis Advanz™ 6F – e170, Novelis Global Automotive, Atlanta, Georgia, USA (2019) Search in Google Scholar

27 DIN EN ISO 50106: Testing of Metallic Materials – Compression Test at Room Temperature, Beuth, Berlin, Germany (2016) Search in Google Scholar

Published Online: 2021-06-30
Published in Print: 2021-06-30

© 2021 Walter de Gruyter GmbH, Berlin/Boston, Germany