Fracture limit prediction for a double safety structure in cylindrical-type lithium secondary batteries

In this study, a double safety structure used for cylindrical-type lithium secondary batteries is newly introduced. The structure is necessary to prevent users and the cylindrical-type secondary batteries from unpredictable explosions due to a temporary increase in the inner pressure of the batteries. The double safety structure consists of a primary safety component as micro half-blanked component, and a secondary safety device as V-notched part. For the double safety device, both the mentioned components are considered by the micro half-blanking and the V-notch forming processes with numerical and experimental predictions for the fracture limit. The mechanical properties are investigated with both a raw and an annealed thin sheet material of 1050-H16 aluminum alloy. The main process parameters are considered to be the clearance and punch-die corner radius for the micro half-blanking process, and the remaining thickness, tip radius, and shape angle of the V-notch. In this study, finite element simulations are carried out to verify the manufacturing process with the mentioned process parameters. The ductile fracture criterion is also adopted to predict the fracture limit for each component. Furthermore, experimental investigations are included to verify the fracture limit predicted from the numerical approach. From the systematic approaches, it is confirmed that the fracture limit for the double safety structure is well predicted, and satisfies the required fracture limit.     

An investigation on the damage of AISI-1045 and AISI-1025 steels in fine-blanking with negative clearance

The technical process of fine-blanking with negative clearance is introduced in this paper. Under the guidance of the Cockcroft and Latham fracture criteria, possible damage and fracture in the blanking process are simulated with FEM code DEFORM-2D. The quality differences between the conventional blanking and negative clearance blanking are discovered by computer simulation of AISI-1045 steel, as well as the effects caused by the material plasticity on blanking quality. The punch and die radii influence the blanking damage, and the appropriate values of the punch and die radii are determined. In addition, the following conclusions are obtained: the quality of negative clearance blanking is better than that of conventional blanking; and the better material plasticity, the better blanking quality. Final results of the FEM simulation agree with experimental data, which will provide reference for the engineering practice.     

台阶盒形件起皱和开裂改善

目的 改善台阶盒形件拉深成形时凸缘区起皱和圆角区开裂的缺陷。方法 理论分析了起皱和开裂产生的原因,利用有限元模拟分析了压边力大小、凹模运行方式和板料形状对台阶盒形件拉深成形的影响,采用实验验证了有限元模拟结果的准确性。结果 长方形板料拉深成形时,4个角部相比直边部位流动阻力更大,直边部位材料过度向模具型腔内流动,造成凸缘区周向压应力过大,进而引起起皱,当零件拉深深度较大时,圆角部位材料变形剧烈且材料流动不均匀,极易产生开裂;采用20 kN的压边力、梯形的凹模向下运行方式和类椭圆形板料的工艺参数可以控制材料流动,使板料变形均匀并改善凸缘区起皱和圆角区开裂缺陷。结论 有限元模拟可为冲裁工艺参数的选取提供理论指导。     

铝合金薄板冲压成形过程中的侧壁起皱及有限元模拟

针对铝合金薄板的侧壁起皱问题,本文通过有限元软件分析工艺参数对成形质量的影响,提出了一种基于数值模拟与智能算法相结合的优化方法。首先,利用最优拉丁超立方抽样进行实验设计,并依据数值模拟获取实验值;其次,基于BP神经网络拟合工艺参数与成形质量之间的关系,预测结果的平均相对误差为2.69%,建立了准确的预测模型;最后,用遗传算法极值寻优获取了一组最优的工艺参数组合,起皱幅值的预测值和仿真值相对误差仅为4.03%,实验结果与仿真分析结果相近,验证了该优化方法的合理性和有效性。研究表明:以料厚、摩擦系数和压边力作为优化变量,以最大起皱幅值最小化为优化目标,建立几何模型,并利用有限元软件Autoform进行仿真分析;依据起皱轮廓线径向位移的实验和数值模拟对比,验证了有限元模型的正确性,表明利用神经网络和遗传算法极值寻优可以有效解决铝合金侧壁起皱缺陷。     

The application of the formability utilization indicator for finite element modeling the ductile fracture during the material blanking process

The purpose of researches presented in the paper was to achieve the numerical model of material blanking process for engineering purposes. The beginning and course of the ductile fracture phase has been modeled using so called “formability utilization indicator”. For this reason, the specialized subroutine for MSC MARC/Mentat software has been developed and implemented to calculate the formability utilization indicator, which functions also as a ductile fracture criterion. The original experimental and numerical methodology to determine the formability limit function has been developed. This methodology enables determining the function course based on the tension test and shearing of the original plane specimen with notch. FEM simulation for blanking has been performed for specimens made of sheet steel S355JR (thickness 3.5 mm) for clearance Lj = 0.5 mm and 0.05 mm. The fracture progress has been modeled by step-by-step deleting the segments, where the formability utilization indicator’s critical value has been exceeded. The results of modeling have been compared with experimental results, in particular attention to the cross-cut section shape.     

Discrete ductile fracture modelling for the metal blanking process

 Design and realisation of a metal blanking process in current industrial practice are mainly based on empirical knowledge. For more sophisticated applications, involving high accuracy geometry specifications, or non-standard materials and product shapes, this empirical approach often fails. This paper presents a set of interrelated numerical techniques resulting in a finite element model of the metal blanking process, focusing on the prediction of the shape of the cut edge of a blanked product. The large, localised deformations are handled by an Operator Split Arbitrary Lagrange Euler (OS-ALE) method supplemented by full remeshing. Transport of the state variables between subsequent meshes for the OS-ALE and remeshing methods is accomplished by the Discontinous Galerkin (DG) method and an interpolation procedure, respectively. Ductile fracture is incorporated using a discrete cracking approach, which is shown to generate mesh independent results. Received 4 February 2000     

Effect of hardening models on different ductile fracture criteria in sheet metal forming

Prediction of the fracture is one of the challenging issues which gains attention in sheet metal forming as numerical analyses are being extensively used to simulate the process. To have better results in predicting the sheet metal fracture, appropriate ductile fracture criterion (DFC), yield criterion and hardening rule should be chosen. In this study, the effects of different hardening models namely isotropic, kinematic and combined hardening rules on the various uncoupled ductile fracture criteria are investigated using experimental and numerical methods. Five different ductile fracture criteria are implemented to a finite element code by the user subroutines. The criterion constants of DFCs are obtained by the related experimental tests. The in-plane principle strains obtained by the finite element analyses for different DFCs are compared with the experimental results. Also, the experimental results are used to evaluate the principle strain values calculated by the finite element analysis for different combinations of DFCs and hardening rules. It is shown that some DFCs give better predictions if the appropriate hardening model is employed.     

精冲压边与间隙的有限元模拟优化研究

运用DEFORM-2D软件对板料精冲过程中压边与间隙进行了数值模拟分析.将NormalC＆L断裂准则应用于预测精冲韧性断裂,分析了不同压边力、压边方式、反顶力以及冲裁间隙对材料涡流流动特性、冲裁断面圆角和撕裂带的影响;根据模拟结果提出了新的工艺建议.     

Phase‐field material point method for brittle fracture

The material point method for the analysis of deformable bodies is revisited and originally upgraded to simulate crack propagation in brittle media. In this setting, phase‐field modelling is introduced to resolve the crack path geometry. Following a particle in cell approach, the coupled continuum/phase‐field governing equations are defined at a set of material points and interpolated at the nodal points of an Eulerian, ie, non‐evolving, mesh. The accuracy of the simulated crack path is thus decoupled from the quality of the underlying finite element mesh and relieved from corresponding mesh‐distortion errors. A staggered incremental procedure is implemented for the solution of the discrete coupled governing equations of the phase‐field brittle fracture problem. The proposed method is verified through a series of benchmark tests while comparisons are made between the proposed scheme, the corresponding finite element implementation, and experimental results.     

紧缩场蜂窝夹层反射面板材料参数优化反求

紧缩场高精度蜂窝夹层结构反射面板由经特殊工艺处理的铝蜂窝芯和表层铝板胶接而成 , 解析计算和材料力学性能试验很难准确获得该夹层板的材料性能参数。本文中采用数值2试验混合模型方法对该种夹层板的等效材料性能参数进行了优化反求。正向分析采用有限元方法 , 逆向分析采用遗传算法和梯度法组合优化算法。正、 逆分析过程的无缝集成和组合优化算法策略使反求效率明显提高。试验验证表明 , 采用反求方法获得的材料性能参数能够精确反应该夹层板的弹性本构关系 , 建立在该材料参数基础上的有限元模型具有理想的精度。     

Ductile fracture of commercial purity titanium at room temperature

An experimental and numerical program was carried out to examine and assess the deformation and fracture behaviour of alloys of commercial purity (CP) titanium. The material rate-dependent deformation under constant displacement rates and under sustained loads was directly simulated in finite element analyses using an implemented unified material model. The simulations predicted the fracture of compact tension specimens subjected to J – R tests and sustained load tests employing a dimensional analysis and strain-hardening approach. Differences between two batches with different oxygen contents were examined and the limitation of the material model was investigated.     

Experimental and numerical evaluation of forming limit diagram for Ti6Al4V titanium and Al6061-T6 aluminum alloys sheets

The forming limit diagram (FLD) is a useful concept for characterizing the formability of sheet metal. In this work, the formability, fracture mode and strain distribution during forming of Ti6Al4V titanium alloy and Al6061-T6 aluminum alloy sheets has been investigated experimentally using a special process of hydroforming deep drawing assisted by floating disc. The selected sheet material has been photo-girded for strain measurements. The effects of process parameters on FLD have been evaluated and simulated using ABAQUS/Standard. Hill-swift and NADDRG theoretical forming limit diagram models are used to specify fracture initiation in the finite element model (FEM) and it is shown that the Hill-swift model gives a better prediction. The simulated results are in good agreement with the experiment.     

304不锈钢板冷冲及其冲裁质量研究

为提高冲裁件质量,降低废品率,研究不锈钢板冷冲过程及冲裁间隙对冲裁件质量的影响规律.本文采用板料冲孔试验:以2 mm厚的同一规格304不锈钢板为试验材料,以凸模直径为冲孔公称尺寸,通过更换不同直径的凹模改变冲裁间隙,完成在不同冲裁间隙下的冲裁试验.试验采集了冲裁力随冲裁行程的变化曲线,分析了冲孔件断面形貌,测量了断面光亮带的孔径和高度、毛刺高度以及断裂带的孔径,并拟合各参数与冲裁间隙之间的关系曲线,研究不锈钢板冷冲过程中冲裁力的变化及冲裁间隙对尺寸精度、断面质量的影响.试验结果表明:不同冲裁间隙下冲裁力-冲裁行程曲线变化趋势基本一致,与冲裁3个变形阶段互相对应,冲裁力达到最大值时光亮带结束;冲裁间隙对冲孔件质量影响显著,冲裁间隙较小时,断裂带形貌呈韧窝状,而较大时断裂带形貌呈台阶状.研究表明:在试验给定大冲裁间隙条件下,当冲裁间隙为15%t左右时,冲孔件尺寸精度最高且断面质量最好,即冲孔件质量最好.     

The plastic flow and finite element simulation of plastic fine blanking

An idea of fine blanking is put forward where negative clearance affects plastic shearing and the plastic state of material in the shearing zone is examined under the condition of negative clearance. By analyzing of blanking force and stress, the paper brings forward a method of setting up the three-directions pressed stress. The method determines if the material of deformation field enters the plasticity regime. Some parameters that control when the material of blanked zone enters into the plastic state are given. The analysis indicates that the material stays in the plastic regime, when the specific energy of elastic deformation for common carbon steel Q235 reaches 8.34 MPa. The status of plastic flowing in the shearing zone is simulated.     

On the numerical implementation of a shear modified GTN damage model and its application to small punch test

Gurson-type models have been widely used to predict failure during sheet metal forming process. However, a significant limitation of the original GTN model is that it is unable to capture fracture under relatively low stress triaxiality. This paper focused on the fracture prediction under this circumstance, which means shear-dominated stress state. Recently, a phenomenological modification to the Gurson model that incorporates damage accumulation under shearing has been proposed by Nahshon and Hutchinson. We further calibrated new parameters based on this model in 22MnB5 tensile process and developed the corresponding numerical implementation method. Lower stress triaxiality were realized by new-designed specimens. Subsequently, the related shear parameters were calibrated by means of reverse finite element method and the influences of new introduced parameters were also discussed. Finally, this shear modified model was utilized to model the small punch test (SPT) on 22MnB5 high strength steel. It is shown that the shear modification of GTN model is able to predict failure of sheet metal forming under wide range of stress state.     

Numerical simulation and experimental validation of a multi-step deep drawing process

This paper presents the numerical simulation of an industrial multi-step deep drawing process. A large strain finite element formulation including a hyperelastic elastoplastic constitutive model and a contact-friction law is used to this end where the steel sheet material parameters considered in the analysis are previously derived through a characterization procedure of its mechanical response. The numerical predictions of the final shape and thickness distribution of the blank are compared and discussed with available experimental values measured at the end of three successive drawing steps. In addition, a plastic work-based damage index is used to assess failure occurrence during the process. The damage values computed at the end of the drawing process are found to be lower than that corresponding to rupture in the tensile test, considered here as the threshold of failure, confirming, as observed experimentally, that neither fracture nor necking is developed in the blank during the whole drawing process. Finally, the possibility to carry out a reduced two-step drawing process, obtained by merging the second and third steps of the three-step process, is precluded since the damage criterion predicts in this case excessively large values that indicate that failure may occur in specific zones of the sheet.     

Relationships Between Blanking Force and Part Geometry vs. Clearance, Tool Wear, and Sheet Thickness

The blanking of metal parts for electronic components is subjected to a variety of process parameters. In this paper, an experimental investigation into the blanking process was carried out using tools with four different wear states and four different clearances. The aim was to study the effects of the interaction between the clearance, the wear state of the tool, and the sheet metal thickness on the evolution of the blanking force and the geometry of the sheared profile.

Designed experiments are an efficient and cost-effective way to model and analyze the relationships that describe process variations.

The results of the proposed experimental investigation show the strong dependence between the geometrical quality of the blanked part and the magnitude of the force applied on the tool as well as the variations in the process factors.     

Parameter identification of a mechanical ductile damage using Artificial Neural Networks in sheet metal forming

In this paper, we report on the developed and used of finite element methods, have been developed and used for sheet forming simulations since the 1970s, and have immensely contributed to ensure the success of concurrent design in the manufacturing process of sheets metal. During the forming operation, the Gurson–Tvergaard–Needleman (GTN) model was often employed to evaluate the ductile damage and fracture phenomena. GTN represents one of the most widely used ductile damage model. In this investigation, many experimental tests and finite element model computation are performed to predict the damage evolution in notched tensile specimen of sheet metal using the GTN model. The parameters in the GTN model are calibrated using an Artificial Neural Networks system and the results of the tensile test. In the experimental part, we used an optical measurement instruments in two phases: firstly during the tensile test, a digital image correlation method is applied to determinate the full-field displacements in the specimen surface. Secondly a profile projector is employed to evaluate the localization of deformation (formation of shear band) just before the specimen’s fracture. In the validation parts of this investigation, the experimental results of hydroforming part and Erichsen test are compared with their numerical finite element model taking into account the GTN model. A good correlation was observed between the two approaches.     

Numerical study of strengths of spot-welded joints of steel

A resistance spot-welding (RSW) joint consists of several material zones with different microstructure and properties as a result of the thermal, metallurgical and mechanical deformation process. Detailed material properties are essential to accurately simulate the mechanical behavior of a joint and its dependency on some key structural parameters (e.g. nugget size, sheet thickness etc.). The work presented in this paper utilises an inverse modelling methodology combining numerical modelling and indentation tests with a standard hardness test to characterise the detailed properties of different weld zones of spot-welded joints. The yield and strain hardening parameters of the three zones (nugget zone, HAZ: heat-affected zone and base zone) were determined and the predicted stress–strain curves for base zone were compared with standard tensile tests results. A 3-D finite element model based on the predicted constitutive material laws for different zones coupled with a fracture model was developed to predict the deformation of spot-welded joints beyond the onset of initial yield under tensile-shear loading. The deformation mode and force–displacement result showed good agreements with experimental data. The effect of nugget size and sheet thickness on the tensile-shear strength of welded joints was further systematically studied using a high performance computing system.