TJ965 : Analytical and Numerical Investigation of Through-thickness Compressive Stress Effect on The Springback of a mextallic Sheet with Plastic Anisotropy
Thesis > Central Library of Shahrood University > Mechanical Engineering > PhD > 2024
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In contemporary sheet mextal forming processes such as electromagnetic forming, the sheet is subjected to significant out-of-plane compression stress. In this dissertation, springback estimation in the bending process with the application of compressive stress normal to the sheet surface is addressed. An analytical approach was employed to calculate the longitudinal stress distribution across the sheet thickness, by utilizing equilibrium equations and applying the flow rule in incremental plasticity baxsed on the von Mises yield criterion (in isotropic analysis) and the Hill 48 yield criterion (in anisotropic analysis). The power hardening model is utilized in this approach. The reverse bending moment was then obtained from these calculations. During unloading, the springback was estimated by assuming linear elastic behavior and neglecting the Bauschinger effect through a superposition method. A case study was conducted on an aluminum alloy sheet with varying compressive stresses and bend curvatures. The analytical results demonstrated that by increasing the compressive stress normal to the surface to 326 MPa (120% of the material's yield stress), the bending moment and springback are reduced by 51%. In complementing the analytical method, a three-dimensional analytical solution for the bending of anisotropic plastic sheets was presented, considering the sheet's angle relative to the rolling direction and examining the simultaneous effects of compressive normal stress and sheet rotation on springback. The results of springback angle under different compressive stresses were compared with the numerical modeling outcomes obtained using Abaqus software. The finite element modeling results in Abaqus under the conditions of P=0 and P=0.75Y corresponded with the analytical results, with errors of 3.1% and 4.4%, respectively. To evaluate the validity of the proposed analytical model, four-point bending tests were conducted under conditions without applied pressure. The results obtained from these experiments showed a 9.2% deviation from the analytical solution. Additionally, the closed-die-bending tests were designed to apply variable normal pressure to the sheet surface using polyurethane pads. The results of this experiment under pressures of P=0, P=0.4Y, and P=0.8Y corresponded with the analytical method, showing errors of 2.6%, 2.6%, and 3.8%, respectively
Keywords:
#Bending #Springback #Through-thickness stress #Plastic anisotropy #Four-point bending test Keeping place: Central Library of Shahrood University
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