Advanced material modeling based on biaxial tensile test using a cruciform specimen Toshihiko Kuwabara

Professor, Division of Advanced Mechanical Systems Engineering, Institute of Engineering Category: Advanced Manufacturing Technology Keywords: plasticity, sheet metal, anisotropy, yield function, constitutive equations URLhttp://www.tuat.ac.jp/~kuwabara/

Point A biaxial tensile testing method using a cruciform specimen has been established. This testing method enables the accurate identification of material models for anisotropic sheet metals. The stress measurement error is estimated to be less than 2% according to finite element analysis. The author is now working on the standardization of the testing method for JIS and ISO.
1. Summary of Research (Technology and Development) Why a Biaxial Tensile Test? Recently, efforts to make transportation equipment more sophisticated and lighter are accelerating from the viewpoint of preserving the global environment. This has been followed by a surge in applications involving difficult-to-process materials such as high-tensile strength steels, aluminum alloys, magnesium alloys and titanium alloys. However, this has led to a sudden increase in press forming defects such as cracks and springback and additional man-hours are required to modify the dies, which has resulted in increased production costs. To resolve this problem and expand application involving lighter materials, it is critical to predict forming defects at an early stage by computer simulation and eliminate trial-and-error manufacturing (Fig. 1).
wrinkle

wrinkle

overlapping

Material selection

fracture

fracture

Material modeling

X High cost due to trytry-and -error manufacturing

Die design

Biaxial tensile test using cruciform specimen

Accurate numerical simulation

Computer simulation

TryTry-less manufacturing

Fig. 1 Biaxial tensile test improves the accuracy of material modeling for sheet metals and enhances trial-and-error-less manufacturing

To predict forming defects with high precision by computer simulation, it is crucial that the constitutive model for the material that is build into the software be made more sophisticated; in other words precision enhancement of the material model is crucial. To accomplish this, the conventional uniaxial tensile test is not adequate. It is crucial to conduct material tests based on the biaxial tensile testing method. Outline of the Test Method: A servo-controlled biaxial tensile testing machine (Fig. 2a) can apply an arbitrary biaxial tensile stress to a cruciform (cross-shaped) specimen (Fig. 2b). It is possible to precisely

measure the elasto-plastic deformation behavior and yield surfaces of sheet metal under biaxial tensile stress. The measurement values are used for selecting and developing optimal material models (yield functions).
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Gauge area arm
t0 Corner radius R :R Slit widthw :w Ss L

BS x

B L
Slit B

x
Rolling direction

BS y

B /( N + 1)

Thickness: t0

(a)

(b)

Fig.2 (a) biaxial tensile testing machine and (b) cruciform specimen1) 2. Originality of Research (Technology and Development) This test method enables the measurement of the yield surfaces of sheet metals (Fig. 3), which enhance the accuracy of material modeling and forming simulation.2, 3)
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Von Mises
Experimental (0 =0.04)
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1.0

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Detailed finite element analysis (FEA) of a cruciform specimen under biaxial tensile stress has revealed that the error in stress measurement is less than 2%.4) Fig. 3 Yield functions for 590MPa steel sheet =>

0.8

Hill'48

0.6 Yld2000-2d(M=8)
(M=6)

0.4 0.2

(M=4)

3. Future Prospects

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Through joint research with Kokusai Co., Ltd. (Chofu-shi, Tokyo), our servo-controlled biaxial tensile testing machine has been commercialized and sold in and outside Japan. We are currently working towards international standardization of the biaxial tensile testing method. We intend to construct a database of material models for various difficult-to-process materials.

x / 0

4. Resources, Bibliography and References 1) T. Kuwabara, S. Ikeda and T. Kuroda, Measurement and Analysis of Differential Work Hardening in Cold-Rolled Steel Sheet under Biaxial Tension, J. Mater. Process. Technol., 80/81 (1998), 517-523. 2) T. Kuwabara, K. Hashimoto, E. Iizuka and J.W. Yoon, Effect of anisotropic yield functions on the accuracy of hole expansion simulations, J. Mater. Processing Technol., 211 (2011), 475481 3) T. Moriya, T. Kuwabara, S. Kimura, and S. Takahashi. Effect of anisotropic yield function on the predictive accuracy of surface deflection of automotive outer panels, Steel Research Int., 81-9 (2010), 1384-1387.omotive Outer Panels, Journal of the Japan Society for Technology of Plasticity, 51-588 (2010), 43-49 4) Y. Hanabusa, H. Takizawa, and T. Kuwabara. Evaluation of accuracy of stress measurements determined in biaxial stress tests with cruciform specimen using numerical method, Steel Research Int., 81-9 (2010), 1376-1379.