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  • 1.
    Gonçalves, L. A.
    et al.
    Centre Internacional de Mètodes Numèrics en Enginyeria (CIMNE), Campus Norte UPC, 08034 Barcelona, Spain.
    Jiménez, S.
    Centre Internacional de Mètodes Numèrics en Enginyeria (CIMNE), Campus Norte UPC, 08034 Barcelona, Spain; Universitat Politècnica de Catalunya (UPC), Campus Norte UPC, 08034 Barcelona, Spain.
    Cornejo, A.
    Centre Internacional de Mètodes Numèrics en Enginyeria (CIMNE), Campus Norte UPC, 08034 Barcelona, Spain; Universitat Politècnica de Catalunya (UPC), Campus Norte UPC, 08034 Barcelona, Spain.
    Barbu, L. G.
    Centre Internacional de Mètodes Numèrics en Enginyeria (CIMNE), Campus Norte UPC, 08034 Barcelona, Spain; Universitat Politècnica de Catalunya (UPC), Campus Norte UPC, 08034 Barcelona, Spain.
    Parareda, S.
    Eurecat, Centre Tecnològic de Catalunya, Unit of Metallic and Ceramic Materials, 08243 Manresa, Spain.
    Casellas, Daniel
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Solid Mechanics. Eurecat, Centre Tecnològic de Catalunya, Unit of Metallic and Ceramic Materials, 08243 Manresa, Spain.
    Numerical simulation of a rapid fatigue test of high Mn-TWIP steel via a high cycle fatigue constitutive law2023In: International Journal of Fatigue, ISSN 0142-1123, E-ISSN 1879-3452, Vol. 168, article id 107444Article in journal (Refereed)
    Abstract [en]

    The generation of reliable data in the high cycle fatigue domain is crucial to support further metallurgic developments of fatigue optimized steel grades. Commonly employed for this aim, traditional standardized characterization methods are expensive and time-consuming. Thus, to circumvent these limitations, different accelerated fatigue testing methodologies have been proposed. In this work, the rapid fatigue test based on stiffness evolution is numerically reproduced using the finite element method for a specific grade of twinning-induced plasticity steel. A high cycle fatigue constitutive law grounded on the continuum damage mechanics framework is employed for this purpose. To adequately capture the material non-linear behavior observed in the experiments, a novel hardening–softening stress–strain curve for damage is proposed. The entire load history in the fatigue domain is modeled. A cycle-jump algorithm is used to improve the computational efficiency of the simulations. It is shown that a reduction of about 55% in the analysis elapsed time is reached by using this algorithm, while the result accuracy is maintained. Finally, the good agreement between numerical and experimental results, revealed by a maximum relative error smaller than 6.0%, evidences the potential of the present constitutive formulation to model the behavior of metals in the high cycle fatigue domain.

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  • 2.
    Gustafsson, David
    et al.
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Solid Mechanics.
    Parareda, Sergi
    Eurecat, Plaça de la ciència 2, 08242 Manresa; CIEFMA, EEBE, Universitat Politècnica de Catalunya-BarcelonaTech, 08019 Barcelona, Spain.
    Jonsén, Pär
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Solid Mechanics.
    Kajberg, Jörgen
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Solid Mechanics.
    Olsson, Erik
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Solid Mechanics.
    Effect of cutting clearance and sandblasting on fatigue of thick CP800 steel sheets for heavy-duty vehicles2022In: Hot Sheet Metal Forming of High-Performance Steel: proceedings / [ed] Mats Oldenburg; Jens Hardell; Daniel Casellas, Wissenschaftliche Scripten , 2022, p. 315-322Conference paper (Refereed)
    Abstract [en]

    Effect from manufacturing processes on fatigue properties of high-strength thick steel sheets have gained increased attention the recent years, due to new demands on the heavy-duty vehicle (HDV) industry to reduce the carbon footprint. The aim of this study is to add knowledge of the effect of shear cutting clearance on the fatigue behaviour of complex phase CP800 thick steel sheets. In addition, sandblasting and its effect on the fatigue properties are studied. Service loads are fluctuating loads acting on chassis component making fatigue an important failure mode. The fatigue strength usually follows the yield strength of the material and hence weight could in theory be saved by using steels of higher strength. However, in the presence of edge defects this relation does not necessarily hold, this leads to large safety factors of the design and under-utilization of the high-strength material. Thus, an increased knowledge about the effect from manufacturing processes on fatigue properties is important for the quest to achieve weight reduction. This is particularly true for thick sheets which, to the best of our knowledge, are less investigated than their thinner counterparts, but of high importance for the HDV development.

     

    In this paper, empirical results from fatigue testing of complex phase steel CP800, subjected to punching and trimming, are presented. Results for different cutting clearances are compared as well as the effect of sandblasting. A fast fatigue testing method called Rapid fatigue test based on stiffness evolution is utilized. The results show the improvement obtained by using sandblasting as well as illustrating the effect of different cutting clearances. These results can be used as a guidance for design and production of HDV components, where cutting clearance is set. Furthermore, the results can be used as an input for discussions whether the extra costs associated with sandblasting is motivated or not for components made from high strength, thick steel sheets.

  • 3.
    Gustafsson, David
    et al.
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Solid Mechanics.
    Parareda, Sergi
    Eurecat, Centre Tecnològic de Catalunya, Unit of Metallic and Ceramic Materials, Manresa, 08243, Spain; Eurecat, Centre Tecnològic de Catalunya, Unit of Metallic and Ceramic Materials, Manresa, 08243, Spain.
    Ortiz-Membrado, Laia
    CIEFMA, Universitat Politècnica de Catalunya, Barcelona, 08019, Spain.
    Mateo, Antonio
    CIEFMA, Universitat Politècnica de Catalunya, Barcelona, 08019, Spain.
    Jiménez-Piqué, Emilio
    CIEFMA, Universitat Politècnica de Catalunya, Barcelona, 08019, Spain.
    Olsson, Erik
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Solid Mechanics.
    Simulation of metal punching and trimming using minimal experimental characterization2023In: Journal of Materials Processing Technology, ISSN 0924-0136, E-ISSN 1873-4774, Vol. 321, article id 118148Article in journal (Refereed)
    Abstract [en]

    This paper presents a validated finite element modeling approach for simulating shear cutting, needing a minimal amount of experimental characterization. Only one uniaxial tensile test and one force–displacement relationship from a punching experiment are needed for calibration, with maintained prediction accuracy compared to more experimentally demanding approaches. A key ingredient is the observation that the Lode angle parameter is close to zero in the fracture region, postulating that the fracture strain only depends on stress triaxiality, with one free calibration parameter. The true stress–strain behavior is provided from inverse modeling of the tensile test, whereas the fracture model is calibrated using the punching test. The model is verified for different materials by comparing force–displacement curves for punching experiments not used in the calibration. The prediction error for the intrusion is below 4%. A validation is made for two setups. The local residual stresses are measured using Focused Ion-Beam Digital Image Correlation (FIB-DIC). The simulated values are within the experimental bounds. Cut edge morphology and plastic strains obtained by nano-indentation mappings are compared to simulation results, showing a decent agreement. For trimming, the cut edge morphology prediction performance decreases at 17% cutting clearance while it is maintained over the whole range for punching. The predicted hardness values have a mean absolute percentage error below 7.5%. Finally, the effect of element size and remeshing is discussed and quantified. The minimal experimental characterization and simulation effort needed, enables an efficient optimization of the cutting process in the industry.

  • 4.
    Parareda, Sergi
    et al.
    Eurecat, Centre Tecnològic de Catalunya, Unit of Metallic and Ceramic Materials, 08243 Manresa, Spain; CIEFMA – Department of Materials Science and Metallurgical Engineering, EEBE, Universitat Politècnica de Catalunya-BarcelonaTech, 08019 Barcelona, Spain.
    Casellas, Daniel
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Solid Mechanics. Eurecat, Centre Tecnològic de Catalunya, Unit of Metallic and Ceramic Materials, 08243 Manresa, Spain.
    Lara, Antoni
    Eurecat, Centre Tecnològic de Catalunya, Unit of Metallic and Ceramic Materials, 08243 Manresa, Spain.
    Mateo, Antonio
    CIEFMA – Department of Materials Science and Metallurgical Engineering, EEBE, Universitat Politècnica de Catalunya-BarcelonaTech, 08019 Barcelona, Spain.
    Fatigue resistance evaluation of high Mn-TWIP steel through damage mechanics: a new method based on stiffness evolution2022In: International Journal of Fatigue, ISSN 0142-1123, E-ISSN 1879-3452, Vol. 156, article id 106643Article in journal (Refereed)
    Abstract [en]

    The work presented here deals with the implementation of a new methodology that allows fast and reliable determination of the fatigue strength. It is based on monitoring the specimen stiffness changes at different stress levels, as an indicator of the evolution of fatigue damage. This new rapid fatigue test uses techniques available in many laboratories, as the DIC (Digital Image Correlation) technique and common extensometers. Moreover, the obtained data are easier to handle than infrared cameras or acoustic emission systems data, and the experimental procedure to determine the fatigue limit is more evident than in the self-heating method.

    Experiments have been conducted in TWIP (Twinning Induced Plasticity) steel, a material used for lightweighting the structural parts of vehicles. With their excellent energy absorption capacity, TWIP steels can satisfy the part requirements in terms of crash performance, while their high tensile strength can deal with the cyclic loads acting on chassis parts. Therefore, many efforts focus on improving the fatigue strength of TWIP steels through pre-straining and/or surface treatments. However, finding the best way to improve the fatigue resistance requires time and resources that often hinder the development of the material. For this reason, a TWIP steel has been selected to check the new rapid fatigue test. The prediction made using the proposed approach is validated by comparison with conventional staircase results and fatigue crack growth standardised tests. The good agreement allows proposing the new method as a fast and efficient way to determine the fatigue resistance in metals.

  • 5.
    Parareda, Sergi
    et al.
    Eurecat, Centre Tecnològic de Catalunya, Unit of Metallic and Ceramic Materials, 08243 Manresa, Spain; CIEFMA – Department of Materials Science and Engineering, EEBE, Universitat Politècnica de Catalunya-BarcelonaTech, 08019 Barcelona, Spain.
    Casellas, Daniel
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials. Eurecat, Centre Tecnològic de Catalunya, Unit of Metallic and Ceramic Materials, 08243 Manresa, Spain.
    Mares, Marc
    Eurecat, Centre Tecnològic de Catalunya, Unit of Metallic and Ceramic Materials, 08243 Manresa, Spain.
    Mateo, Antonio
    CIEFMA – Department of Materials Science and Engineering, EEBE, Universitat Politècnica de Catalunya-BarcelonaTech, 08019 Barcelona, Spain.
    A damage-based uniaxial fatigue life prediction method for metallic materials2023In: Materials & design, ISSN 0264-1275, E-ISSN 1873-4197, Vol. 231, article id 112056Article in journal (Refereed)
    Abstract [en]

    Determining the fatigue behaviour of metallic materials using standardised testing methods is costly and time-consuming. Therefore, several methods have been proposed to shorten the testing time and improve the fatigue optimisation of materials and components. This work presents a new fatigue testing method based on fatigue damage monitoring that allows determining the fatigue resistance in a short time and with few specimens. The presented method, named as the stiffness method, monitors the inelastic strains as an indicator of fatigue damage evolution. Strain measurements were carried out by digital image correlation techniques and showed to effectively follow damage evolution during fatigue tests. Results are convincing and more evident to obtain and discuss than other monitoring techniques, like temperature dissipation. In addition, the method overcomes the main limitations of the existing fast testing methods by avoiding the utilisation of complex apparatus, like infrared cameras or acoustic emission sensors. The approach has been validated in ten different metallic materials, as titanium and aluminium alloys, carbon steels, and stainless steels. The estimated fatigue limit was compared with values obtained following standardised tests, showing excellent agreement. Results allow pointing out the stiffness method as an efficient and effective tool for rapidly determining the fatigue behaviour of metallic materials.

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  • 6.
    Sandin, Olle
    et al.
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Solid Mechanics.
    Hammarberg, Samuel
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Solid Mechanics.
    Larour, Patrick
    voestalpine Stahl GmbH, Linz, Austria.
    Hinterdorfer, Josef
    voestalpine Stahl GmbH, Linz, Austria.
    Parareda, Sergi
    Eurecat, Centre Tecnològic de Catalunya, Unit of Metallic and Ceramic Materials, Plaça de la Ciència, 2, Manresa 08243, Spain.
    Frómeta, David
    Eurecat, Centre Tecnològic de Catalunya, Unit of Metallic and Ceramic Materials, Plaça de la Ciència, 2, Manresa 08243, Spain.
    Jonsén, Pär
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Solid Mechanics.
    Casellas, Daniel
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Solid Mechanics. Eurecat, Centre Tecnològic de Catalunya, Unit of Metallic and Ceramic Materials, Plaça de la Ciència, 2, Manresa 08243, Spain.
    A numerical approach for predicting cut edge morphology in high strength sheetsManuscript (preprint) (Other academic)
  • 7.
    Sandin, Olle
    et al.
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Solid Mechanics.
    Hammarberg, Samuel
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Solid Mechanics.
    Parareda, S.
    Eurecat, Centre Tecnològic de Catalunya, Unit of Metallic and Ceramic Materials, Plaça de la Ciència, 2, Manresa 08243, Spain.
    Frómeta, D.
    Eurecat, Centre Tecnològic de Catalunya, Unit of Metallic and Ceramic Materials, Plaça de la Ciència, 2, Manresa 08243, Spain.
    Casellas, Daniel
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Solid Mechanics. Eurecat, Centre Tecnològic de Catalunya, Unit of Metallic and Ceramic Materials, Plaça de la Ciència, 2, Manresa 08243, Spain.
    Jonsén, Pär
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Solid Mechanics.
    Prediction of sheared edge characteristics of advanced high strength steel2022In: IOP Conference Series: Materials Science and Engineering / [ed] Sandrine Thuillier, Vincent Grolleau, Hervé Laurent, Institute of Physics (IOP), 2022, Vol. 1238, article id 012034Conference paper (Refereed)
    Abstract [en]

    In the present work, numerical models are developed for the shearing and cutting process of advanced high strength steel-blanks which can predict the edge morphology in the shear effected zone. A damage model, based on the modified Mohr-Coulomb fracture surface, is calibrated. To increase the predictability of the numerical models, the fracture surface is fine-tuned in areas corresponding to the stress-state of cutting, a methodology called Local calibration of Fracture Surface (LCFS). Four cutting cases with varying clearance are simulated and verified with experimental tests, showing good agreement. It is thus found that the suggested methodology can simulate cutting with adequate accuracy. Furthermore, it is found that solely using plane-stress tensile specimens for calibrating the fracture surface is not enough to obtain numerical models with adequate accuracy.

  • 8.
    Sandin, Olle
    et al.
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Solid Mechanics.
    Rodriguez, Juan Manuel
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Solid Mechanics. School of Applied Sciences and Engineering, EAFIT University, Carrera 49 No. 7 South-50, Medellín, Colombia.
    Larour, Patrick
    voestalpine Stahl GmbH, voestalpine-Straße 3, 4020, Linz, Austria.
    Parareda, Sergi
    Unit of Metallic and Ceramic Materials, Eurecat, Centre Tecnològic de Catalunya, Plaça de la Ciència, 2, 08243, Manresa, Spain.
    Frómeta, David
    Unit of Metallic and Ceramic Materials, Eurecat, Centre Tecnològic de Catalunya, Plaça de la Ciència, 2, 08243, Manresa, Spain.
    Hammarberg, Samuel
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Solid Mechanics.
    Kajberg, Jörgen
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Solid Mechanics.
    Casellas, Daniel
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Solid Mechanics. Unit of Metallic and Ceramic Materials, Eurecat, Centre Tecnològic de Catalunya, Plaça de la Ciència, 2, 08243 Manresa, Spain.
    A particle finite element method approach to model shear cutting of high-strength steel sheets2024In: Computational Particle Mechanics, ISSN 2196-4378Article in journal (Refereed)
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