Professional Documents
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1)
Atılım University, Department of Manufacturing Engineering, 06836, Ankara, Turkey
2)
Middle East Technical University, Department of Civil Engineering, 06531, Ankara, Turkey
3)
University of Dortmund, Institute of Forming Technology and Lightweight Construction, 44227, Dortmund, Germany
In the context of forward bulk extrusion, where product defects are frequently observed, the effect of counter pressure on damage
accumulation materializing a Continuum Damage Mechanics (CDM) approach is presented. A Lemaitre variant damage model accounting
for unilateral damage evolution coupled with a multiplicative finite plasticity is utilized for this purpose. After a presentation of the crack
governing mechanism, it is demonstrated that application of counter pressure introduces a marked decrease in the central damage
accumulation, which in turn increases the formability of the material through keeping the tensile triaxiality in tolerable limits. It is also shown
that, for a crack involving process, through systematic increase of the counter pressure, the crack sizes diminish; and at a certain level of
counter pressure chevron cracks can be completely avoided.
Keywords: forward extrusion; counter pressure; chevron cracks; ductile damage; finite elements.
Introduction
Micro-based Damage Mechanics (MDM), Fracture process and thus has certain limits governed by the
Mechanics (FM) and CDM. Attempts to simulate discrete allowable punch and die stresses. Counter pressure
crack formations are also made, utilizing several methods application is also employed as a precision extrusion
such as Element Deletion (ED), Node Separation (NS) and method where the under-filling defects are eliminated,
Stiffness Degradation (SD). Among those, the simplest Osakada et al. [20]. However, this type of utilization falls
and most frequently utilized one seems to be the ED out of the context of this study.
method where the Gauss points with accumulated damage To the authors’ knowledge, there exist no numerical
values violating the critical damage threshold are studies on the use of counter pressure to give account for
eliminated from the computational stack. A chronological defect-free extrusion. Accordingly, in this follow up work
summary of the numerical studies that investigates damage of Soyarslan et al. [16], the aim is to investigate what
formation in cold forward extrusion is listed in Table 1. finite element suggests on the role of counter pressure in
These studies prove that central crack formation in suppressing crack formations in axi-symmetric forward
extrusion is due to the local positive triaxial stress state at extrusion. For this purpose, utilizing the thermodynamics
the area reduction zone where plastic flow occurs. This of internal variables, a Lemaitre variant damage model
positive triaxiality when met with plastic flow promotes which relies on the effective stress concept of Kachanov
the nucleation, growth and coalescence of micro-voids to [21] and Rabotnov [22] and the strain equivalence
produce macro-cracks. Besides, it is shown that low area principle of Lemaitre [23] is coupled with a finite
reductions combined with high semi-cone angles enhance multiplicative plasticity. To this end, the derived
central damage accumulation whereas friction motivates framework is implemented as VUMAT user defined
surface damage accumulation rather then central damage. material subroutine for ABAQUS/Explicit and used in an
Accordingly, for a crack including simulation, the increase extensive set of simulations in which damage
of friction in turn decreases the frequency of internal accumulation and crack growth are monitored. It is shown
cracks. In the extremes surface defects may emerge. It is that proper application of counter pressure suppresses
notable that in most of these studies rate hardening and the central crack formation completely, by keeping the
thermal softening effects are assumed to cancel each other. forming zone hydrostatic stress levels in tolerable limits.
Since, in avoiding cracks, the main motivation is to The deviations of crack morphologies and sizes with
obtain a hydrostatic compression at the forming zone, at counter pressure application are also examined.
fixed die geometry and process parameters one could
supply additional central compression by means of
employing counter pressure at the extruded nose part of Modelling Damage
the workpiece. The experimental studies of Wagener et al.
[17], Wagener and Wolf [18], Wagener and Haats [19] Construction of the constitutive model follows along the
show that the application of counter pressure promotes same lines with Soyarslan et al. [16] to which the reader is
material formability in extrusion so that it becomes referred for a detailed treatment. Assuming a, b and c as
neighbourhood of every X ∈ B, a
being its Jacobian. Within the
Table 1. Numerical investigation of damage formation in cold forward extrusion.
q = − Kα − (τ ∞ − τ 0 ) (1 − exp[− δα ]) (3)
Y=
1
2
H tr ε e [ ] 2
[ ]
+ G dev ε e : dev ε e [ ] (4)
γ&
micro-mechanical entities which are dislocation pile ups
b e = −2 N • be
(1 − D )
for α and density of micro-voids and micro-cracks for D. o
(5)
A simple 1D observation is helpful to gain a geometrical
insight into the problem. With reference to Figure 2, two
α& = γ&
process spaces are constructed, one of which is the
2 (6)
physical space and the other is the so-called effective
space. The physical space refers to the actual space where 3
γ&
D& = −a
the effects of micro-voids persist and at the plane of
(1 − D )
interest nominal material cross sectional area, A, is due. Y (7)
The effective space stands for the fictitious one which is
carried out by removing existing micro-voids and micro- o
~ = / (1 − D )
damage conjugate variable in the principal effective stress
(1) space where contributions of tensile and compressive
principal stresses are separated. Accordingly, one may
[ ]− 29νE ~p
like variables will preserve their structure as far as the
stress is used in terms of effective measures, assuming following,
[ + − τ~ ]−
logarithmic strains, εe, one has,
2 2 2 2
h(1 + ν )
[ ] [ ]
2E
9 hν
(8)
~ = H tr ε e 1 + 2G dev ε e + − τ~1 + − τ~2 −~
2 2 2 2
(2) 3 p
2E 2E
Figure 8. Central line a) hydrostatic stress, b) damage rate values, for different counter pressure levels, μ = 0.
Figure 9. Mean crack dimensions and crack patterns for various Figure 10. Punch force demand curves for different counter
counter pressure levels, μ = 0. pressure levels, μ = 0.
forces and thus become impractical. In addition, die and compared to those with smaller cracks. The expected
punch stress limitations act as the main obstacles against increase in the punch force demand with increasing
excessive amplification of counter pressures. Figure 9 also counter pressure values reminds one that in the actual
illustrates the effect of the counter pressure intensity on applications reasonable counter pressure values should be
crack morphologies. Accordingly, the outputs suggest that selected for feasibility.
the crack opening and the crack half width, measured as Once a friction of µ = 0.04 is applied at the die-
the mean of the first three cracks, show a monotonic workpiece interface, crack patterns for different counter
decrease with increased counter pressure, which is pressure values take the form demonstrated in Figure 11.
physically reasonable, thus expected. It is notable that, A remarkable point is that, in the presence of friction, the
unlike friction, counter pressure does not seem to have an counter pressure required for the crack-free simulations
effect on the periodicity of the cracks. decreases considerably from 200 MPa to 125 MPa. This is
For frictionless simulations, the curves of punch force due to the fact that both friction and counter pressure act
versus normalized process time are given in Figure 10 for analogically similar, as a counter force which works in
the analyses without counter pressure and with counter opposite direction with respect to the applied external
pressure of 100 and 200 MPa. Crack involving simulations pressure by the punch. Another point, as will be shown
experience an oscillatory behaviour. In contrast, in the later, is that with friction the damage accumulation zones
simulation without any cracks, no oscillations are observed are carried over to the surface rather than the centre. Thus
and a steady trend is captured in the absence of friction. under frictional conditions, cracks can be healed with
Moreover, the extent of the oscillations is strictly employment of a reduced counter pressure. The change of
dependent on the internal crack size. In the simulations the crack sizes as a function of the applied counter pres-
with larger cracks, oscillations become more dominant sure follows a similar trend in the frictionless simulations.
Figure 14. Damage contours, a) counter pressure = 100 MPa, μ = 0; b) counter pressure = 200 MPa, μ = 0;
c) counter pressure =100 MPa, μ = 0.04; d) counter pressure = 200 MPa, μ = 0.04.
Figure 15. Radial damage distribution for different counter pressure levels (steady state), a) μ = 0, b) μ = 0.04.
Figure 16. Radial equivalent plastic strain distribution for different counter pressure levels (steady state), a) μ = 0, b) μ = 0.04.
chevron crack formations can be prevented at the expense [10] Gelin, J. C.: Modelling of damage in metal forming simulations, J.
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Acknowledgement 109–120.
[14] Saanouni, K., Mariage, J. F., Cherout, A., Lestriez, P.: Numerical
The authors wish to thank Miss Burcu Anık for her prediction of discontinuous central bursting in axisymmetric forward
extrusion by continuum damage mechanics, Computers and
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