Integrating effect of forming in fatigue life prediction: review of present scenario and challenges

doi:10.1177/0954405412437621

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Integrating effect of forming in fatigue life prediction: review of present scenario and challenges

Journal Article•DOI•

Integrating effect of forming in fatigue life prediction: review of present scenario and challenges

Krishnaswamy Hariharan¹, Krishnaswamy Hariharan², Raghu V. Prakash¹•Institutions (2)

Indian Institute of Technology Madras¹, Ashok Leyland²

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.

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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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Journal Article•DOI•

Ball-burnishing effect on deep residual stress on AISI 1038 and AA2017-T4

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A. A. Garcia-Granada, Giovanni Gómez-Gras, Ramón Jerez-Mesa¹, J. Antonio Travieso-Rodriguez¹, Guillermo Reyes - Show less +1 more•Institutions (1)

Polytechnic University of Catalonia¹

12 Apr 2017-Materials and Manufacturing Processes

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.

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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...

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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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Journal Article•DOI•

Determination of Anisotropic Yield Coefficients by a Data-Driven Multiobjective Evolutionary and Genetic Algorithm

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Krishnaswamy Hariharan¹, Ngoc-Trung Nguyen¹, Nirupam Chakraborti², Frédéric Barlat², Myoung-Gyu Lee³ - Show less +1 more•Institutions (3)

Indian Institute of Technology Delhi¹, Pohang University of Science and Technology², Korea University³

13 Feb 2015-Materials and Manufacturing Processes

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.

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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.

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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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Book Chapter•DOI•

Metal Forming Analysis: Finite Elements for Large Deformation

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R. H. Wagoner, J.-L. Chenot

01 Jan 2001

17 citations

Journal Article•DOI•

Influence of uniaxial and biaxial pre-straining on the high cycle fatigue performance of DP590 steel

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Puja Ghosal¹, Abhishek Raj², Surajit Kumar Paul¹•Institutions (2)

Indian Institute of Technology Patna¹, Tata Steel²

01 Aug 2021-International Journal of Fatigue

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.

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15 citations

Journal Article•DOI•

Fatigue life evaluation of tension‐compression asymmetric material using local stress–strain method

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Jiwei Chen¹, Weixing Yao¹, Daiyang Gao¹•Institutions (1)

Nanjing University of Aeronautics and Astronautics¹

01 Sep 2020-Fatigue & Fracture of Engineering Materials & Structures

8 citations

References

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Book Chapter•DOI•

Constitutive Modeling for Metals

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Frédéric Barlat¹, Frédéric Barlat²•Institutions (2)

Alcoa¹, University of Aveiro²

01 Jan 2007

TL;DR: In this paper, the authors review aspects of the plastic behavior common in metals and alloys, including macroscopic and microscopic phenomena occurring during plastic deformation, and present a model of plasticity at both micro-and macro-scales.

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Abstract: This paper reviews aspects of the plastic behavior common in metals and alloys. Macroscopic and microscopic phenomena occurring during plastic deformation are described succinctly. Constitutive models of plasticity at the micro- and macro-scales, suitable for applications to forming, are discussed in a very broad fashion. Approaches to plastic anisotropy are reviewed in a more detailed manner.

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17 citations

"Integrating effect of forming in fa..." refers background in this paper

...As discussed, the major application of sheet metal forming simulation is for the tooling industry(113,114) and as a result, formability of the component rather than the functionality of the component has gained primary importance.(82) 2....
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...In general, the structural finite element analyses of automobile components use isotropic material models assuming homogeneous material properties and zero residual stresses.(82) The material anisotropy, in addition to the residual stress distribution, influences the fatigue behaviour of materials....
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Book Chapter•DOI•

Metal Forming Analysis: Finite Elements for Large Deformation

[...]

R. H. Wagoner, J.-L. Chenot

01 Jan 2001

17 citations

"Integrating effect of forming in fa..." refers methods in this paper

...Some of the commonly used contact algorithms are discussed by Wagoner and Chenot.94 The Coloumb friction model, with constant friction coefficient, is used for sheet metal forming applications.3,89 Material models in sheet metal forming The accuracy of forming a prediction mainly depends on the choice of material model....
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...Some of the commonly used contact algorithms are discussed by Wagoner and Chenot.(94) The Coloumb friction model, with constant friction coefficient, is used for sheet metal forming applications....
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Proceedings Article•DOI•

Residual Forming Effects on Full Vehicle Frontal Impact and Body-in-White Durability Analyses

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Guofei Chen¹, S.-D. Liu¹, L. Knoerr², K. Sato, J. Liu - Show less +1 more•Institutions (2)

National Steel Corporation¹, General Motors²

04 Mar 2002

16 citations

Journal Article•DOI•

Observations on fatigue crack paths in the corners of cold-formed high-strength steel tubes

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S. Heinilä¹, Gary Marquis¹, Timo Björk¹•Institutions (1)

Lappeenranta University of Technology¹

01 Feb 2008-Engineering Fracture Mechanics

TL;DR: In this paper, the authors investigated fatigue crack propagation in cold-formed corners of high-strength structural steel plate-type structures and found that straight, zig-zag and "S" shaped cracks were observed depending on the material strength, range of cyclic loading, residual stress field and multi-axiality of the local stresses.

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14 citations

"Integrating effect of forming in fa..." refers background in this paper

...Heinilä et al.76 reported the adverse effect of through thickness residual stresses induced by cold forming on the fatigue failures of rectangular hollow cross section steel tubes....
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...Heinilä et al.(76) reported the adverse effect of through thickness residual stresses induced by cold forming on the fatigue failures of rectangular hollow cross section steel tubes....
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Journal Article•DOI•

A general framework for generating convex yield surfaces for anisotropic metals

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F. Mollica¹, Arun R. Srinivasa¹•Institutions (1)

Texas A&M University¹

01 Mar 2002-Acta Mechanica

TL;DR: In this article, Choi et al. developed a general procedure to create yield surfaces (both isotropic and anisotropic) for elastic plastic metals with particular reference to sheet metal forming operations.

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Abstract: The aim of this paper is to develop a general procedure to create yield surfaces (both isotropic and anisotropic) for elastic plastic metals with particular reference to sheet metal forming operations. Due to the fact that the forming limit of sheet metals requires a very accurate prediction of the yield limits and their normals, it is desirable to create yield functions that offer independent control of the yield points and the normal to the yield surface at a particular stress state without affecting its global convexity properties and the yield points at other states of stress. We achieve this by creating a class of yield surfaces that are obtained by the intersection of a number of elementary convex surfaces (such as planes and cylinders); the edges and corners that are a result of the intersection are smoothened by aL p-norm smoothing technique to give rounded corners. The yield surfaces generated by this procedure are centrosymmetric in nature and are thus limited in their applicability. We show that many of the standard yield surfaces can be recast into this form. We obtain a new yield surface that fits the experiments obtained for the 6022-T4 aluminum alloy as reported by Barlat et al. [1]. The same yield surface is also used to fit the results of the Taylor-Bishop-Hill polycrystal theory applied to a material with copper texture. The data were obtained from Choi et al. [2].

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14 citations