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Material Selection For An Ultra High Strength Stee
Material Selection For An Ultra High Strength Stee
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Material Selection for an Ultra High Strength Steel Component Based on the
Failure Criteria of CrachFEM
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5 authors, including:
Helmut Gese
MATFEM Partnerschaft Dr. Gese & Oberhofer
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Abstract. An increasing use of combining more than one process step is noticed for coupling crash simulations with the
results of forming operations – mostly by inheriting the forming history like plastic strain and material hardening.
Introducing a continuous failure model allows a further benefit of these coupling processes; it sometimes can even be the
most attractive result of such a work. In this paper the algorithm CrachFEM for fracture prediction has been used to
generate more benefit of the successive forming and crash simulations – especially for ultra high strength steels. The
choice and selection of the material grade in combination with the component design can therefore be done far before
the prototyping might show an unsuccessful crash result; and in an industrial applicable manner.
CP778 Volume A, Numisheet 2005, edited by L. M. Smith, F. Pourboghrat, J.-W. Yoon, and T. B. Stoughton
© 2005 American Institute of Physics 0-7354-0265-5/05/$22.50
492
CHARACTERIZATION OF MATERIAL deformation of the sheet becomes concentrated in the
FOR A VIRTUAL COMPONENT necked region, the fracture strain is reached at once.
Because the localised neck has a width in the order of
DEVELOPMENT PROCESS the dimension of the sheet thickness, the necking
process and subsequent fracture cannot be modelled
Today, the usual material characterization process directly in industrial crash simulation (shell elements
is based on the tensile test and relatively similar for have a typical edge length of 3 to 10 times the sheet
stamping and crash processes. For stamping a yield
curve and r-values for the anisotropy are determined thickness). The instability strain ε eq
*
has to be used as
with tensile specimen. In addition to this a bulge test a fracture criterion instead of the local fracture strain
may be done to gather more detailed information about ε eq
**
inside the neck. From a numerical point of view, a
the yield locus shape - then quite often resulting in a
selection among the formulation of Hill ´48, Hill ´90 failure criterion based on the strain at onset of
or sometimes Barlat model. The most common failure instability, ε eq
*
, has the additional advantage that the
criteria is the strain based forming limit curve (FLC)
or a limitation of thinning. For crash simulations strain strain distribution is physically as well as numerically
rate dependent yield curves are used in combination homogeneous.
with an isotropic material formulation. Failure models
exist, but are in many cases limited and hardly able to The algorithm CRACH includes a refined description
include the results of forming operations. of material behaviour on a macroscopic level, in
conjunction with the effects of the material
To allow a powerful virtual component design microstructure. The mechanical problem is illustrated
process there exists a strong need of using the same in Figure 2. The basic concept is derived from the
failure model for stamping and crash, inheriting the Marciniak model [1]. In this model the localised neck
material “damage” from one process step to the is triggered by an initial imperfection of the sheet. The
following. sheet has an initial thickness of h0 . The thickness
inside the infinitely small imperfection is given in
equation (1).
Numerical Model for Instability (Localized
~
Necking) h0 = h0 (1 − δ ) (1)
Localised necking is the main mechanism leading
to fracture in ductile sheet metals. The classical δ is a very small number. Here and in the following
forming limit curve (FLC) generally used to predict chapters, all values inside the localised neck are
localised instabilities is not useful in case of coupled indicated with a tilde (∼). As the neck is infinitely
processes including forming and crash because of its small, the increase in strain parallel to the neck
assumption of linear strain paths in the material. In (defined as local y ' -direction in Figure 2) is identical
order to take the effects of nonlinear strain paths into inside and outside the neck according to equation (2).
account, which can develop during a crash event, a
theoretical model of the instability mechanism dε~y' = d ε y' (2)
(CRACH algorithm) is included in CrachFEM. This
approach has been validated in an industrial research
project using a set of multistage experiments at static This model is practicable for linear strain paths in
and dynamic strain rates using mild steel specimens the region of ε 2 < 0 ( ε 1 and ε 2 are the principal
[2].
strains in the plane of the sheet with ε 2 ≤ ε1 ), where
The relevant failure mechanisms in the sheet metal the neck width is very small. In the region ε 2 > 0 the
forming process are summarized in Figure 1. All neck can have a significant width. Therefore, the
forming operations are stable up to the instability CRACH algorithm uses an approximation of the neck
strain limit ε eq
*
, after which the instability causes the cross section according to equation (3).
formation of a localized thinning of the cross section –
a ‘neck’. ~ ⎡ ⎛ π x' ⎞⎤
h0 = h0 ⎢1 − d cos⎜ ⎟⎥ (3)
The state of stress in the neck area finally changes for ⎣ ⎝ l ⎠⎦
all strain paths to plane strain. As the plastic
493
x' indicates the local direction normal to the necking for anisotropic strain hardening according to Backhaus
[3] to account for the Bauschinger effect in the
line according to Figure 2. The initial thickness h0 has
CRACH algorithm.
no influence on the numerical problem and is fixed to
1. The ratio x' l changes from 0 (neck center) to 1/2 The global strain around the neck is increased
(region of the sheet with homogeneous deformation). incrementally as long as the force equilibrium is
d is the inhomogeneity parameter and its initial value fulfilled according to equations (5a) and (5b).
is calibrated from the limit strain out of one
~
experiment with the individual sheet. The parameter
σ~x′ h = σ x′ h (5a)
d increases with deformation in the CRACH ~
algorithm in order to account for the roughening of the σ~x′y′ h = σ x′y′ h ( 5b)
sheet during plastic deformation.
The first increment without equilibrium indicates the
instability with the start of the localised necking. This
mechanical problem has to be solved for different
orientation angles γ according to Figure 2 of the
initial neck relative to the rolling direction of the sheet.
The limit strain ε eq *
for one deformation path is
derived through optimisation according to equation
(6).
ε eq
*
= min{ε eq
γ
(γ )} (6)
494
**
ε eq
dε eq of fracture strain is small. Therefore the fracture model
∫ε
0
**
eq (η )
=1 (7) is used for the isotropic case in this study.
Shear Fracture
Integral criteria can account for nonlinear strain paths.
For shear fracture, it is assumed that the equivalent
However, in more severe cases of load path changes
(i.e. compression-tension reversal) even the integral strain at fracture ε eq
**
is a function of the variable θ
criteria are no longer valid. CrachFEM offers a given in equation (10).
tensorial criterion as an option for these cases. The
tensorial fracture criterion is not discussed here. 1 − k Sη
θ= ( 10 )
φ
The fracture criterion is calculated separately for the
risk of ductile fracture and shear fracture in
CrachFEM. It is assumed that there is no interaction where k S is a material parameter and φ is the ratio of
between both fracture mechanisms. the maximum shear stress and the equivalent stress
(von Mises) according to equation (11).
Ductile Fracture τ max
φ= ( 11 )
For ductile fracture, it is assumed that the equivalent σ eq
fracture strain ε eq
**
is a function of the stress triaxiality
η , defined in equation (8) by components in principal Analogous to equation (9), the equivalent plastic strain
stress space. for shear fracture with respect to θ is given in equation
(12).
3σ m σ1 + σ 2 + σ 3
η= = ε S+ sinh [ f (θ − θ − )] + ε S− sinh [ f (θ + − θ )] ( 12 )
σ eq σ + σ + σ 32 − σ 1σ 2 − σ 2 σ 3 − σ 3σ 1 ε eq
**
=
sinh [ f (θ + − θ − )]
2 2
1 2
(8)
where θ + and θ are the values of the parameter θ
−
The dependence of the equivalent fracture strain on the for equibiaxial tension und compression. Equation (12)
stress triaxiality is expressed in Equation (9). This
formulation includes a possible orthotropy of fracture. has two constant parameters ε S+ , ε S− and one
The equivalent fracture strain ε T+ for the equibiaxial orientation dependent parameter f . No significant
tension condition and ε for equibiaxial compression
− orthotropy of the shear fracture curve has been found
T
up to now for different sheets and extrusions.
(this value is usually very high) must not be
Therefore, it is assumed that f is a constant,
orientation dependent in this case.
independent of the orientation to rolling direction.
If η + is the stress triaxiality for equibiaxial tension and
η − indicates the stress triaxiality in equibiaxial Comprehensive Failure Model CrachFEM
compression (a material with isotropic plasticity yields
η + = 2 and η − = −2 ), the following boundary All three possible fracture modes (necking, ductile
conditions may be defined. fracture and shear fracture) have been combined into
the comprehensive failure model CrachFEM.
ε T+ sinh[c (η − − η )] + ε T− sinh[c (η − η + )] CrachFEM has been coupled to different FEM codes
ε eq
**
= ( 9)
sinh[c (η − − η + )]
with explicit-dynamic integration scheme for use with
shell elements. The results presented have been
obtained with the FEM codes PamStamp/PamCrash
An orientation dependent parameter c has been (CrachFEM coupled to material 128). A possible
introduced in equation (9) for the orthotropic case. fracture due to necking or shear fracture is checked
Therefore equation (9) has two constant against the membrane strains (both fracture modes
parameters, ε T+ , ε T− and one orientation dependent appear across the complete sheet thickness). A
parameter c . In the case of sheet steel the orthotropy possible failure due to ductile fracture is checked for
the upper and lower strains of the shell element. All
495
three fracture modes are uncoupled from each other. Additional experiments are needed to evaluate the
Also there is no coupling between the accumulated limit curves for ductile and shear fracture. Erichsen
damage and the elastoplastic material model in the FE test (equibiaxial stress with η = 2 ), three point
analysis. This is to avoid a localization of the strains bending of sheet coupons (width/thickness > 4 with
due to softening of the material.
plane strain tension and η = 3 ) and waisted tensile
specimens with fracture at the notch root (uniaxial
Material Specification tension with η = 1 ) have been used to obtain the
ductile fracture limit. The local fracture strains have
The material grades used in parts of this been derived from a grid on the surface of the
investigation were a multiphase steel, specified as specimens (Erichsen test and three point bending) or
Grade A, and a martensitic steel type, specified as from the sheet thickness in the fracture plane (waisted
grade B. The typical mechanical properties are given tensile specimens).
in table 1.
Tensile specimen with a groove (rectangular cross
TABLE 1. Properties of used material grades. section, groove depth = half sheet thickness) under 45°
Values in RD Grade A Grade B to loading direction ( θ = 1.469 ), specially shaped
YS (MPa) 725 1150 tensile specimens with a groove parallel to the loading
TS (MPa) 852 1350 direction (pure shear with θ = 1.732 ) and Erichsen
TE (%) 13,6 5
tests (biaxial tension with θ = 1.6 - some of these
specimens show shear fracture instead of ductile
Quasi-static uniaxial tensile tests have been fracture), have been used to determine the shear
performed in 0, 45 and 90 degree to rolling direction to fracture limit.
evaluate the orthotropy of yield strength and plastic
The ductile and shear fracture limits have been
anisotropy r. As the uniform elongation is
evaluated for quasi-static speed. It is assumed that
comparatively small for the steels cited above an
these fracture limits are not sensitive to strain rate for
additional experiment has been used to characterize
steels. All quasi-static fracture limits for steel Grade A
the strain hardening of the material at higher strains. In
are given in Figure 3.
this project the layered compression test has been used
for this purpose. Disk shaped specimens are cut from
2
the sheet and are laid on top of each other to form a
equivalent plastic strain [-]
Tensile tests with different strain rates have been A complete characterization of a steel quality for
used to characterize the strain rate sensitivity of the CrachFEM causes a significant increase in
flow stress. experimental effort compared to standard industrial
methods with simplified fracture criteria. However the
All material parameters for the algorithm Crach use of a comprehensive failure model is the only
(localized necking) can be derived from the sustainable technique to perform a full virtual
experiments cited above. development of components made from advanced high
strength and ultra high strength steels.
496
VIRTUAL COMPONENT DESIGN experiments have been done. Set A of experiments
PROCESS aimed on the general prediction of different material
grades and their behavior in component loading.
Set B focused on the possibility to cover possible
The aim of a virtual component design process is
material scatter within one material grade. Due to
the development of a robust component that fulfills all
complexity and space only Set A will be discussed in
demands. A result is thereby a virtual layout and
this paper.
testing that minimizes the existing risk of an
unforeseen event in real manufacturing or crash case. The overall design of the experiments was geared
If advanced failure criteria are used, they have to to the typical failure modes that can occur in a door
account for the possibility of interpreting all process intrusion beam – mainly instability and shear fracture.
steps of the component, typically the complete history In order to get the best reliability of the experiments
like “material grade selection – stamping – painting and simulations the selected and used steel grades
and finally crash”. The crash case is of cause were all fully characterized for the CrachFEM-model.
influenced by all prior process steps – leading to the
problem that the methods used in these different
process steps have to be compatible. With the above Set A: Material selection validation
mentioned CrachFEM model the complete evaluation
of the same safety definition values during all phases For these investigations the chosen material grades
in the virtual component design phase is now possible. A and B have been stamped in production tools and all
Even more there exists a chance to interpret the effect necessary data was gathered for the accompanying
of stamping method to the performance in the crash simulations tasks. Because in crash case the
case or the impact of the given geometrical component orientation of rolling direction in the blank is hardly
design on the predicted failure values. known in early concept phases, the blanks were
prepared in rolling direction and 90 degree to this. By
doing this the influence of orientation can be evaluated
Load Case Definition for Side Intrusion and reviewed.
Beams
In order to test the performance of the selected steel
The testing of side intrusion beams is defined by grades in three-point-bending, dynamic testing with
FMVSS 214. In general the specification aims on the speeds of up to 12.3 m/s and static testing with speeds
mean load value for given intrusion distance and a of 0.002 m/s have been arranged. Figure 5 shows the
maximum level of the peak load value. This leads to experimental results of dynamic and static tests for the
allowed force-deflection curves during crash. Compare two steel grades. It is quite obvious that grade A
Figure 4. generates a lower peak load but shows more ductility.
In comparison to this grade B shows a much higher
35 Peak load (0 .. 18 inch) peak load but is limited to lower punch travels because
of early fracture.
30
Acceptable force
25
Force (kN)
15
F (0 ... 6 inch)
10
Force (kN)
5
0
0 100 200 300 400 500
Displacement (mm)
497
Performing a crash simulation without an This can be included in the simulation by starting
appropriate failure model for these kinds of steels to eliminate elements but should not be discussed here.
would generate the force-displacement curves given in Inside the deformed areas the selected position A is
figure 6. It is obvious that grade B seams much more dominated by pure sheet instability risk, position B
favorable for the side intrusion beam application than and C show more shear and lower amounts of ductile
grade A. By introducing the CrachFEM-model with fracture effects and finally position D is again loaded
the specified material data for the three already by membrane tension. At around 60 mm punch travel
prescribed failure modes the engineer gets the the material grade B reaches a critical value for
capability to estimate possible failures in combination instability in position A. At a punch travel of around
with a specified load. 80 mm the shear value in position C gets to the limit.
In comparison to this grade A can go up to 100 mm
punch travel without reaching the limit value 1.0.
Grade B
1,1
1
0,9 Grade A
0,8 Experiment
0,7
0,6 C
74204
0,5
Force
A
74219 B
74205
0,4 D
74199
Start of failure. (Inst.)
0,3
0,2
0,1
0
40 60 80 100 40 60 80 100
Displacement (mm) Displacement (mm) Simulation
0
FIGURE 7. Simulation failure model results for selected 0 Displacement
positions in the critical areas during three-point-bending tests
of side intrusion beams made of different steel grades FIGURE 8. Experimental test results in comparison to
(results from deep drawing have been included) simulations results including component failure for the
complete history.
498
Experiment FEM (Instability) FEM (Ductile Frac.) as well. All by using standard shell element mesh size
of around 5 mm edge length and in an industrial
applicable manner. Even when the method itself can
be used for the isolated crash simulation the full
benefit is only available by coupling the results of
forming simulation with the crash load situation,
including the material history for the component. In
addition to plastic strain and thickness the results for
Necking ductile fracture the three failure models in CrachFEM have then to be
mapped on the final component structure. This can be
FIGURE 9. Comparison of failure positions for the final done by using the mapping algorithm inside PamSolid.
simulations. Clear limitations of this method can be seen in the
element elimination and crack propagation criterion.
This remains until now as a challenge for future
development work.
CONCLUSION
Summarizing the experimental and simulation
A correct representation of the plastic deformation work the presented method offers a clear and well
and failure of individual component parts is essential defined benefit for the virtual engineering process in
to obtaining accurate crashworthiness simulation the component development phase. By including
results. Especially for high strength steel materials the different failure models, continuous for the process
ductility in crash cases is an important and strong steps forming and crash, the engineer can realize a
influencing parameter for the component design in more realistic virtual testing and thereby has the
matter of thickness and shape. Therefore a opportunity to optimize the selected material grade in
comprehensive approach for predicting failure in combination with the shape and load condition of a
structural high strength steel components based on component. This is a clear support for gaining a full
macroscopic strains and stresses - using the CrachFEM benefit of light weight components made of high
code - has been presented. The shown comparison to strength steel grades in automotive applications.
experimental tests demonstrates the possibility of
predicting the mode of failure and the correct position
REFERENCES
1. Z Marciniak, K Kuczyński, and T Pokora, ‘Influence of
the plastic properties of a material on the forming limit
diagram for sheet metal in tension’, Int. J. of
Mechanical Sciences, 1973 15 789−805.
2. H Dell, H Gese, L Keßler, H Werner, and H Hooputra,
‘Continuous Failure Prediction Model for Nonlinear
Load Paths in Successive Stamping and Crash
499