An integrated finite element-based simulation framework: From hole piercing to hole expansion

X. H. Hu; X. Sun; S. F. Golovashchenko

doi:10.1016/j.finel.2015.09.005

An integrated finite element-based simulation framework: From hole piercing to hole expansion

X. H. Hu, X. Sun, S. F. Golovashchenko

Research output: Contribution to journal › Article › peer-review

19 Scopus citations

Abstract

An integrated finite element-based modeling framework is developed to predict the hole expansion ratio (HER) of AA6111-T4 sheet by considering the piercing-induced damages around the hole edge. Using damage models and parameters calibrated from previously reported tensile stretchability studies, the predicted HER correlates well with experimentally measured HER values for different hole piercing clearances. The hole piercing model shows burrs are not generated on the sheared surface for clearances less than 20%, which corresponds well with the experimental data on pierced holes cross-sections. Finite-element-calculated HER also is not especially sensitive to piercing clearances less than this value. However, as clearances increase to 30% and further to 40%, the HER values are predicted to be considerably smaller, also consistent with experimental measurements. Upon validation, the integrated modeling framework is used to examine the effects of different hole piercing and hole expansion conditions on the critical HERs for AA6111-T4.

Original language	English
Pages (from-to)	1-13
Number of pages	13
Journal	Finite Elements in Analysis and Design
Volume	109
DOIs	https://doi.org/10.1016/j.finel.2015.09.005
State	Published - Feb 1 2016
Externally published	Yes

Funding

Pacific Northwest National Laboratory is operated by Battelle for the U.S. Department of Energy (DOE) under Contract No. DE-AC05-76RL01830. This work was partially funded by the DOE’s Office of FreedomCAR and Vehicle Technologies under the Automotive Lightweighting Materials Program managed by Mr. William Joost. The authors would like to thank Nan Wang at Oakland University, who provided the cross-section pictures of hole-pierced samples. The authors also would like to thank Yevgeniya Katykova and Amir Hassannejadasl for providing the results of accumulated rolling and tension tests.

Funders	Funder number
Office of FreedomCar
U.S. Department of Energy	DE-AC05-76RL01830

Keywords

Aluminum alloys
Finite element simulations
Hole expansion ratio
Hole piercing

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10.1016/j.finel.2015.09.005

Cite this

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title = "An integrated finite element-based simulation framework: From hole piercing to hole expansion",

abstract = "An integrated finite element-based modeling framework is developed to predict the hole expansion ratio (HER) of AA6111-T4 sheet by considering the piercing-induced damages around the hole edge. Using damage models and parameters calibrated from previously reported tensile stretchability studies, the predicted HER correlates well with experimentally measured HER values for different hole piercing clearances. The hole piercing model shows burrs are not generated on the sheared surface for clearances less than 20%, which corresponds well with the experimental data on pierced holes cross-sections. Finite-element-calculated HER also is not especially sensitive to piercing clearances less than this value. However, as clearances increase to 30% and further to 40%, the HER values are predicted to be considerably smaller, also consistent with experimental measurements. Upon validation, the integrated modeling framework is used to examine the effects of different hole piercing and hole expansion conditions on the critical HERs for AA6111-T4.",

keywords = "Aluminum alloys, Finite element simulations, Hole expansion ratio, Hole piercing",

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AU - Hu, X. H.

AU - Sun, X.

AU - Golovashchenko, S. F.

PY - 2016/2/1

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N2 - An integrated finite element-based modeling framework is developed to predict the hole expansion ratio (HER) of AA6111-T4 sheet by considering the piercing-induced damages around the hole edge. Using damage models and parameters calibrated from previously reported tensile stretchability studies, the predicted HER correlates well with experimentally measured HER values for different hole piercing clearances. The hole piercing model shows burrs are not generated on the sheared surface for clearances less than 20%, which corresponds well with the experimental data on pierced holes cross-sections. Finite-element-calculated HER also is not especially sensitive to piercing clearances less than this value. However, as clearances increase to 30% and further to 40%, the HER values are predicted to be considerably smaller, also consistent with experimental measurements. Upon validation, the integrated modeling framework is used to examine the effects of different hole piercing and hole expansion conditions on the critical HERs for AA6111-T4.

AB - An integrated finite element-based modeling framework is developed to predict the hole expansion ratio (HER) of AA6111-T4 sheet by considering the piercing-induced damages around the hole edge. Using damage models and parameters calibrated from previously reported tensile stretchability studies, the predicted HER correlates well with experimentally measured HER values for different hole piercing clearances. The hole piercing model shows burrs are not generated on the sheared surface for clearances less than 20%, which corresponds well with the experimental data on pierced holes cross-sections. Finite-element-calculated HER also is not especially sensitive to piercing clearances less than this value. However, as clearances increase to 30% and further to 40%, the HER values are predicted to be considerably smaller, also consistent with experimental measurements. Upon validation, the integrated modeling framework is used to examine the effects of different hole piercing and hole expansion conditions on the critical HERs for AA6111-T4.

KW - Aluminum alloys

KW - Finite element simulations

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JO - Finite Elements in Analysis and Design

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ER -

An integrated finite element-based simulation framework: From hole piercing to hole expansion

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Keywords

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