Integrating effect of forming in fatigue life prediction: review of present scenario and challenges
22 Feb 2012-Vol. 226, Iss: 6, pp 967-979
TL;DR: In this article, the residual stresses of sheet metal deformation during forming induces complex residual stresses in the component owing to its geometry and material anisotropy, which affect the durability of the component.
Abstract: Plastic deformation of sheet metals during forming induces complex residual stresses in the component owing to its geometry and material anisotropy. The residual stresses affect the durability of t...
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TL;DR: In this article, the incremental hole drilling (IHD) technique is tested to measure residual stresses, being able to reach a 2-mm measuring depth, and a commercial strain gage is used and calibrated using finite element model simulations.
Abstract: Ball-burnishing induces compressive residual stresses on treated materials by the effect of plastic deformation. The result is an increase in the fatigue life of the treated part, retarding the initiation of cracks on the surface. Compressive residual stresses have been previously measured by X-ray diffraction near the surface, revealing considerably high values at the maximum analyzed depth, in relation to other finishing processes such as shot peening. However, the maximum analyzed depth is very limited by using this technique. In this paper, the incremental hole drilling (IHD) technique is tested to measure residual stresses, being able to reach a 2-mm measuring depth. To that objective, a commercial strain gage is used and calibrated using finite element model simulations. A second Finite Element Model based on material removal rate is developed to obtain the equations to calculate the strain release through IHD. Finally, residual stresses are measured experimentally with that technique on two...
35 citations
Cites background from "Integrating effect of forming in fa..."
...) [7], and a longer lifespan of industrial components can be expected, as explained by Hariharan and Prakash [8]....
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...[7], and a longer lifespan of industrial components can be expected, as explained by Hariharan and Prakash [8]....
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TL;DR: In this article, a robust multiobjective optimization based on evolutionary algorithm is proposed to minimize the error in yield stress and plastic strain ratio simultaneously and thereby overcomes the limitations in the approaches used before.
Abstract: The texture induced anisotropy of yield strength in cold rolled sheet metals is modeled using anisotropic yield criteria. The classical and other optimization methods used so far to determine the yield coefficients are limited by fixed set of experimental data, initial guess values, and pre-determined weight factors. A robust multiobjective optimization based on evolutionary algorithm proposed in this paper minimizes the error in yield stress and plastic strain ratio simultaneously and thereby overcomes the limitations in the approaches used before. The new approach is tested using Hill48 and Barlat89 yield criteria for five different materials from literature. The new approach is observed to improve the prediction capability of yield coefficients when compared to earlier approaches. The Pareto frontier obtained in the new approach can serve as a comparative tool to evaluate the accuracy of different yield criteria.
19 citations
Cites background from "Integrating effect of forming in fa..."
...The complex mechanical behavior of different materials [5] and the demand for accurate modeling of forming process [2, 6, 7] have led to the development of several advanced yield functions [1, 8– 10]....
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...Assuming orthotropic symmetry, several phenomenological models have been proposed in the past to describe the anisotropy of yield strength [1, 2]....
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01 Jan 2001
17 citations
TL;DR: In this paper, the authors assess tensile and high cycle fatigue performance of dual-phase (DP590) steel subjected to uniaxial and equi-biaxial pre-strain.
15 citations
References
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TL;DR: In this article, the effect of prestrain on the fatigue limit of 0.1% and 0.5% carbon steels was investigated and the precrack, variation of surface hardness and surface residual stress were considered to be parameters applicable in formulas for predicting the prestrained carbon steel.
34 citations
"Integrating effect of forming in fa..." refers background or methods in this paper
...Ideally, residual stress should be used to validate the material models for sheet metal forming and spring back.(74) 3....
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...The manufacturing process variables and heat treatment have considerable influence on the fatigue behaviour under pre-strain.(74) Laser formed HSLA steels exhibited superior fatigue behaviour owing to surface hardening by laser irradiation....
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TL;DR: In this article, the influence of yield strength gradient on the increase of residual stress in a hardened material when it is subject to a bending fatigue load was investigated. But the authors focused on the residual stress evolution in cold-rolled steels.
33 citations
"Integrating effect of forming in fa..." refers background in this paper
...The fatigue behaviour is highly sensitive to the level of prior cold working; a 25% cold rolled AISI 301 steel exhibited stress relaxation under bending fatigue load, whereas an increase in stress amplitude was observed in 50% cold rolled condition.(77) This indicates a complex interaction of prior cold working and fatigue....
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TL;DR: In this article, the suitability of interstitial free (IF) steel sheets of thickness 0.6, 0.9, 1.2, and 1.6mm for press forming operations were examined by obtaining the forming limit diagrams.
31 citations
15 Jun 2005-Materials Science and Engineering A-structural Materials Properties Microstructure and Processing
TL;DR: In this article, the residual stresses created by deep drawing of AISI-1010 cups were investigated by means of neutron diffraction, and it was found that axial, and tangential stress profiles are similar to what is expected from a bending-unbending operation, but it also exhibits a strong dependence on the axial and to a minor extent, on the circumferential position.
Abstract: The residual stresses created by deep drawing of AISI-1010 cups were investigated by means of neutron diffraction. The wall thickness of the cups was below 3.0 mm, for which 8–10 through-thickness measurements were conducted. It was found that the axial, and tangential stress profiles are similar to what is expected from a bending–unbending operation, but it also exhibits a strong dependence on the axial and, to a minor extent, on the circumferential position. The strong axial stress dependence reflects the effect of stretching while the weaker circumferential stress variations are due to sheet anisotropy. We also found that the thermal relief of cold work in the initial AISI-1010 cold rolled blank has no discernable effect both on the residual stresses and the springback.
29 citations
TL;DR: In this paper, an elastoplastic constitutive model which accounts for combined isotropic-kinematic hardening for complex strain-path changes in a dual-phase steel, DP800, was evaluated through numerical simulations of sequential uniaxial tension and notched tension/shear tests.
Abstract: This paper aims at evaluating an elastoplastic constitutive model which accounts for combined isotropic-kinematic hardening for complex strain-path changes in a dual-phase steel, DP800. The capability of the model to reproduce the transient hardening phenomena under two-stage non-proportional loading has been assessed through numerical simulations of sequential uniaxial tension and notched tension/shear tests. Finite element simulations with shell elements were performed using the explicit non-linear FE code LS-DYNA. Numerical predictions of the stress–strain response were compared to the corresponding experimental data. The results from the experiments demonstrated that prior plastic deformation has certainly influenced the subsequent work-hardening behaviour of the material under biaxial or shear deformation modes. Furthermore, the numerical simulations from the two-stage uniaxial tension–notched tension and uniaxial tension–shear tests predicted the general trends of the experimental results such as transitory hardening and overall work hardening. However, some discrepancies were found in accurately describing the transient hardening behaviour subsequent to strain path changes between the experiments and numerical simulations.
29 citations
"Integrating effect of forming in fa..." refers methods in this paper
...Mixed hardening models, to account for stress reversals, are under research.(122,123) 5....
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