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  • 1.
    Deng, Liang
    et al.
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Mozgovoy, Sergej
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Machine Elements.
    Hardell, Jens
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Machine Elements.
    Prakash, Braham
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Machine Elements.
    Oldenburg, Mats
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Numerical study of contact conditions in press hardening for tool wear simulation2017In: International Journal of Material Forming, ISSN 1960-6206, E-ISSN 1960-6214, Vol. 10, no 5, p. 717-727Article in journal (Refereed)
    Abstract [en]

    In the press hardening industry, industrial and academic efforts are being directed toward predicting tool wear to realize an economical manufacturing process. Tool wear in press hardening is a tribological response to contact conditions such as pressure and sliding motion. However, these contact conditions are difficult to measure in-situ. Furthermore, press hardening involves high temperatures, and this increases the complexity of the tribo system. The present work investigated the contact conditions of press hardening with a commercial FE code (LS-DYNA) as a base for tool wear simulation. A press hardening experiment was established in industrial environments and evaluated through FE simulations. The numerical model was set up so as to approximate the manufacturing conditions as closely as possible, and the sensitivity with respect to the friction coefficients was examined. The influence of numerical factors such as the penalty value and mesh size on the contact conditions is discussed. The implementation of a modified Archard’s wear model in the FE simulation proved the possibility of tool wear simulation in press hardening. Finally, a comparison between the tool wear simulation and the measured wear depth is presented. 

  • 2.
    Kalhori, Vahid
    et al.
    AB Sandvik Coromant, Sandviken.
    Wedberg, Dan
    AB Sandvik Coromant, Sandviken.
    Lindgren, Lars-Erik
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Simulation of mechanical cutting using a physical based material model2010In: International Journal of Material Forming, ISSN 1960-6206, E-ISSN 1960-6214, Vol. 3, no Suppl. 1, p. 511-514Article in journal (Refereed)
    Abstract [en]

    A dislocation density material model based on model-based-phenomenology has been used to predict orthogonal cutting of stainless steel Sanmac 316L. The chip morphology and the cutting forces are used to validate the model. The simulated cutting forces and the chip morphology showed good conformity with practical measurements. Furthermore, simulation of cutting process utilizing the dislocation density based material model improved understanding regarding material behaviour such as strain hardening and shear localization at the process zone.

  • 3.
    Odenberger, Eva-Lis
    et al.
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Hertzman, J.
    Forming Group, OSAS, Industrial Development Centre in Olofström AB.
    Thilderkvist, P.
    Forming Group, OSAS, Industrial Development Centre in Olofström AB.
    Merklein, M.
    Manufacturing Technology, University of Erlangen-Nuremberg.
    Kuppert, A.
    Manufacturing Technology, University of Erlangen-Nuremberg.
    Stöhr, B.
    Manufacturing Technology, University of Erlangen-Nuremberg.
    Lechler, J.
    Manufacturing Technology, University of Erlangen-Nuremberg.
    Oldenburg, Mats
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Thermo-mechanical sheet metal forming of aero engine components in Ti-6Al-4V: Part 1: Material characterisation2013In: International Journal of Material Forming, ISSN 1960-6206, E-ISSN 1960-6214, Vol. 6, no 3, p. 391-402Article in journal (Refereed)
    Abstract [en]

    Ti-6Al-4V is one of the most frequently used titanium alloy in aerospace applications such as for load carrying engine structures, due to their high strength to weight ratio in combination with favourable creep resistance at moderate operating temperatures. In the virtual development process of designing suitable thermo-mechanical forming processes for titanium sheet metal components in aero engine applications numerical finite element (FE) simulations are desirable to perform. The benefit is related to the ability of securing forming concepts with respect to shape deviation, thinning and strain localisation. The reliability of the numerical simulations depends on both models and methods used as well as on the accuracy and applicability of the material input data. The material model and related property data need to be consistent with the conditions of the material in the studied thermo-mechanical forming process. In the present work a set of material tests are performed on Ti-6Al-4V at temperatures ranging from room temperature up to 560°C. The purpose is to study the mechanical properties of the specific batch of alloy but foremost to identify necessary material model requirements and generate experimental reference data for model calibration in order to perform FE-analyses of sheet metal forming at elevated temperatures in Ti-6Al-4V.

  • 4.
    Odenberger, Eva-Lis
    et al.
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Schill, M.
    DYNAmore Nordic AB.
    Oldenburg, Mats
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Thermo-mechanical sheet metal forming of aero engine components in Ti-6Al-4V: Part 2 : Constitutive modelling and validation2013In: International Journal of Material Forming, ISSN 1960-6206, E-ISSN 1960-6214, Vol. 6, no 3, p. 403-416Article in journal (Refereed)
    Abstract [en]

    In this work constitutive models suitable for thermo-mechanical forming of the titanium alloy Ti-6Al-4V are evaluated. A tool concept for thermo-mechanical forming of a double-curved sheet metal component in Ti-6Al-4V is proposed. The virtual tool design is based on finite element (FE) analyses of thermo-mechanical sheet metal forming in which two different anisotropic yield criteria are evaluated and compared with an isotropic assumption to predict global forming force, draw-in, springback and strain localisation. The shape of the yield surface has been found important and the accuracy of the predicted shape deviation could be slightly improved by including the cooling procedure. The predicted responses show promising agreement with the corresponding experimental observations when the anisotropic properties of the material are considered

  • 5.
    Pérez Caro, Lluís
    et al.
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials. RISE IVF AB.
    Schill, Mikael
    DYNAmore Nordic AB.
    Haller, Kristian
    AcousticAgree AB.
    Odenberger, Eva-Lis
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials. RISE IVF AB.
    Oldenburg, Mats
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Damage and fracture during sheet-metal forming of alloy 7182019In: International Journal of Material Forming, ISSN 1960-6206, E-ISSN 1960-6214Article in journal (Refereed)
    Abstract [en]

    Forming nickel-based superalloy aero-engine components is a challenging process, largely because of the risk of high degree of springback and issues with formability. In the forming tests conducted on alloy 718 at room temperature, open fractures are observed in the drawbead regions, which are not predicted while evaluating the formability using the traditional forming-limit diagram(FLD). This highlights the importance of an accurate prediction of failure during forming as, in some cases, may severely influence the springback and thereby the accuracy of the predicted shape distortions, leading the final shape of the formed component out of tolerance. In this study, the generalised incremental stress-state dependent damage model (GISSMO) is coupled with the isotropic von Mises and the anisotropic Barlat Yld2000-2D yield criteria to predict the material failure in the forming simulations conducted on alloy 718 using LS-DYNA. Their effect on the predicted effective plastic strains and shape deviations is discussed. The failure and instability strains needed to calibrate the GISSMO are directly obtained from digital image correlation (DIC) measurements in four different specimen geometries i.e. tensile, plane strain, shear, and biaxial. The damage distribution over the drawbeads is measured using a non-linear acoustic technique for validation purposes. The numerical simulations accurately predict failure at the same regions as those observed in the experimental forming tests. The expected distribution of the damage over the drawbeads is in accordance with the experimental measurements. The results highlight the potential of considering DIC to calibrate the GISSMO in combination with an anisotropic material model for forming simulations in alloy 718.

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