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Abd El-Aty A, Xu Y, Hou Y, Zhang SH, Ha S, Xia L, Alzahrani B, Ali A, Ahmed MMZ, Shokry A. Modelling the Flow Behaviour of Al Alloy Sheets at Elevated Temperatures Using a Modified Zerilli-Armstrong Model and Phenomenological-Based Constitutive Models. Materials (Basel) 2024; 17:1584. [PMID: 38612098 PMCID: PMC11012879 DOI: 10.3390/ma17071584] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 04/13/2023] [Revised: 03/17/2024] [Accepted: 03/26/2024] [Indexed: 04/14/2024]
Abstract
The flow behaviour of AA2060 Al alloy under warm/hot deformation conditions is complicated because of its dependency on strain rates (ε˙), strain (ε), and deformation modes. Thus, it is crucial to reveal and predict the flow behaviours of this alloy at a wide range of temperatures (T) and ε˙ using different constitutive models. Firstly, the isothermal tensile tests were carried out via a Gleeble-3800 thermomechanical simulator at a T range of 100, 200, 300, 400, and 500 °C and ε˙ range of 0.01, 0.1, 1, and 10 s-1 to reveal the warm/hot flow behaviours of AA2060 alloy sheet. Consequently, three phenomenological-based constitutive models (L-MJC, S1-MJC, S2-MJC) and a modified Zerilli-Armstrong (MZA) model representing physically based constitutive models were developed to precisely predict the flow behaviour of AA2060 alloy sheet under a wide range of T and ε˙. The predictability of the developed constitutive models was assessed and compared using various statistical parameters, including the correlation coefficient (R), average absolute relative error (AARE), and root mean square error (RMSE). By comparing the results determined from these models and those obtained from experimentations, and confirmed by R, AARE, and RMSE values, it is concluded that the predicted stresses determined from the S2-MJC model align closely with the experimental stresses, demonstrating a remarkable fit compared to the S1-MJC, L-MJC, and MZA models. This is because of the linking impact between softening, the strain rate, and strain hardening in the S2-MJC model. It is widely known that the dislocation process is affected by softening and strain rates. This is attributed to the interactions that occurred between ε and ε˙ from one side and between ε, ε˙, and T from the other side using an extensive set of constants correlating the constitutive components of dynamic recovery and softening mechanisms.
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Affiliation(s)
- Ali Abd El-Aty
- Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al-Kharj 11942, Saudi Arabia (M.M.Z.A.)
- Mechanical Engineering Department, Faculty of Engineering, Helwan University, Cairo 11795, Egypt
| | - Yong Xu
- Shi-Changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
| | - Yong Hou
- Department of Materials Science and Engineering & RIAM, Seoul National University, Seoul 08826, Republic of Korea
| | - Shi-Hong Zhang
- Shi-Changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
| | - Sangyul Ha
- Department of Semiconductor Engineering, Myongji University, Yongin 17058, Republic of Korea;
| | - Liangliang Xia
- School of Transportation, Ludong University, Yantai 264025, China
| | - Bandar Alzahrani
- Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al-Kharj 11942, Saudi Arabia (M.M.Z.A.)
| | - Alamry Ali
- Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al-Kharj 11942, Saudi Arabia (M.M.Z.A.)
| | - Mohamed M. Z. Ahmed
- Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al-Kharj 11942, Saudi Arabia (M.M.Z.A.)
| | - Abdallah Shokry
- Department of Mechanical Engineering, Faculty of Engineering, Fayoum University, Fayoum 63514, Egypt
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El-Aty AA, Xu Y, Xie W, Xia LL, Hou Y, Zhang S, Ahmed MMZ, Alzahrani B, Ali A, Huang X, Sobh AS. Finite Element Analysis and Experimental Study of Manufacturing Thin-Walled Five-Branched AISI 304 Stainless Steel Tubes with Different Diameters Using a Hydroforming Process. Materials (Basel) 2023; 17:104. [PMID: 38203958 PMCID: PMC10779626 DOI: 10.3390/ma17010104] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 11/13/2023] [Revised: 12/11/2023] [Accepted: 12/18/2023] [Indexed: 01/12/2024]
Abstract
This study aims to investigate the feasibility of hydroforming (HF) technology coupled with response surface optimization for producing high-quality five-branched AISI 304 stainless steel tubes with different diameters, addressing the shortcomings of traditional manufacturing processes. Conventional techniques often result in issues with multiple consumables, low precision, and subpar performance. The research focuses on finding optimal forming parameters for a more effective process. Initial attempts at a five-branched tube proved unfeasible. Instead, a multi-step forming approach was adopted, starting with the formation of the upper branch tube followed by the two reducing lower branch tubes, a strategy termed "first three, then five". This method, enhanced by a subsequent solid solution treatment, yielded promising results: the combined height of the upper and lower branches was 141.1 mm, with a maximum thinning rate of 26.67%, reduced to 25.33% after trimming. These outcomes met the product usage requirements. Additionally, the study involved designing and developing dies for manufacturing five-branched tubes with different diameters using servo HF equipment. The effectiveness of the multi-step forming process and parameter combinations was confirmed through experimental validation, aligning closely with the FE simulation results. The maximum thinning rate observed in the experiments was 27.60%, indicating that FE simulation and response surface methodology can effectively guide the production of high-quality parts with superior performance.
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Affiliation(s)
- Ali Abd El-Aty
- Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 11942, Saudi Arabia
- Mechanical Engineering Department, Faculty of Engineering, Helwan University, Cairo 11795, Egypt
| | - Yong Xu
- Shi-Changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
| | - Wenlong Xie
- Shi-Changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
| | - Liang-Liang Xia
- School of Transportation, Ludong University, Yantai 264025, China
| | - Yong Hou
- Department of Materials Science and Engineering & RIAM, Seoul National University, 1-Gwanak-ro, Gwanak-gu, Seoul 08826, Republic of Korea
| | - Shihong Zhang
- Shi-Changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
| | - Mohamed M. Z. Ahmed
- Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 11942, Saudi Arabia
| | - Bandar Alzahrani
- Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 11942, Saudi Arabia
| | - Alamry Ali
- Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 11942, Saudi Arabia
| | - Xinyue Huang
- Shenyang Duoyuan Mechanical & Electrical Equipment Co., Ltd., Shenyang 110000, China
| | - Arafa S. Sobh
- Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 11942, Saudi Arabia
- School of Engineering and Applied Sciences, Nile University, Cairo 12566, Egypt
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Gao X, Wang S, Xu Z, Zhou J, Wan X, Rayhan HMA, Lou Y. Plastic Evolution Characterization for 304 Stainless Steel by CQN_Chen Model under the Proportional Loading. Materials (Basel) 2023; 16:6828. [PMID: 37959425 PMCID: PMC10649071 DOI: 10.3390/ma16216828] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 09/16/2023] [Revised: 10/16/2023] [Accepted: 10/18/2023] [Indexed: 11/15/2023]
Abstract
In this paper, the CQN_Chen function is used to characterize the plastic anisotropic evolution of 304 stainless steel (SS304). The uniaxial tensile tests along different loading directions are conducted to experimentally investigate the anisotropic hardening behavior for SS304. The experimental data indicates that the anisotropy of SS304 is weak. The convexity analysis is carried out by the geometry-inspired numerical convex analysis method for the CQN_Chen yield locus during plastic deformation. The Hill48, SY2009 and CQN functions are used as the comparison to evaluate the accuracy of the CQN_Chen function in characterizing plastic evolution. The predicted values are compared with the experimental data. The comparison demonstrates that the CQN_Chen function can accurately characterize anisotropic hardening behavior under uniaxial tension along distinct loading directions and equibiaxial tension. Simultaneously, the CQN_Chen model has the capacity to adjust the yield surface shape between uniaxial tension and equibiaxial tension. The CQN_Chen model is recommended to characterize plastic evolving behavior under uniaxial tension along different directions and equibiaxial tension.
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Affiliation(s)
- Xiang Gao
- College of Mechanical and Vehicle Engineering, Chongqing University, Chongqing 400044, China; (X.G.)
- China Automotive Engineering Research Institute Co., Ltd., Chongqing 401122, China
| | - Songchen Wang
- School of Mechanical Engineering, Xi’an Jiaotong University, 28 Xianning West Rd, Xi’an 710049, China; (S.W.)
| | - Zhongming Xu
- College of Mechanical and Vehicle Engineering, Chongqing University, Chongqing 400044, China; (X.G.)
| | - Jia Zhou
- China Automotive Engineering Research Institute Co., Ltd., Chongqing 401122, China
| | - Xinming Wan
- China Automotive Engineering Research Institute Co., Ltd., Chongqing 401122, China
| | - Hasib Md Abu Rayhan
- School of Mechanical Engineering, Xi’an Jiaotong University, 28 Xianning West Rd, Xi’an 710049, China; (S.W.)
| | - Yanshan Lou
- School of Mechanical Engineering, Xi’an Jiaotong University, 28 Xianning West Rd, Xi’an 710049, China; (S.W.)
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Du K, Dong L, Zhang H, Mu Z, Dong H, Wang H, Ren Y, Sun L, Zhang L, Yuan X. Modeling of Eyld2000-2d Anisotropic Yield Criterion Considering Strength Differential Effect and Analysis of Optimal Calibration Strategy. Materials (Basel) 2023; 16:6445. [PMID: 37834581 PMCID: PMC10573253 DOI: 10.3390/ma16196445] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 08/31/2023] [Revised: 09/19/2023] [Accepted: 09/22/2023] [Indexed: 10/15/2023]
Abstract
Sheet metals usually experience various loading paths such as uniaxial tension, uniaxial compression, biaxial tension, and simple shear during the forming process. However, the existing constitutive models cannot always accurately describe blanks' anisotropic yield and plastic flow behavior of blanks under all typical stress states. Given this, this paper improves the Eyld2000-2d yield criterion by introducing hydrostatic pressure to the A-Eyld2000-2d yield criterion that can describe the strength differential effect of materials. Meanwhile, to control the curvature of the yield surface more effectively, the near-plane strain yield stresses were added in the parameter identification process to calibrate the exponent m, so that the exponent is no longer considered as a constant value. Taking the widely used AA6016-T4, AA5754-O, DP980, and QP980 blanks in the automotive stamping industry as an example, the effectiveness of the new model and different parameter identification methods was verified by predicting experimental data under various simple and complex loading paths. Subsequently, the new model employing the optimal parameter identification strategy was compared with four widely used asymmetric yield criteria under associated and non-associated flow rules, including CPB06, LHY2013, S-Y2004, and Hu & Yoon2021, to further verify the accuracy of the proposed constitutive model. The results indicate that parameter identification strategy with variable exponent can significantly improve the flexibility of the yield criterion in describing the plastic anisotropy of blanks. Compared to the other yield criteria examined in this work, the new model provides the best prediction accuracy for the yield stresses and plastic flows of all blanks, especially in the near-plane strain and simple shear stress states. Modeling under the concept of anisotropic hardening can more accurately capture the evolving plastic behavior of blanks than isotropic hardening.
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Affiliation(s)
- Kai Du
- School of Materials Science and Engineering, Shenyang University of Technology, Shenyang 110870, China (L.S.)
- State Key Laboratory of Light Alloy Casting Technology for High-End Equipment, Shenyang 110022, China
| | - Li Dong
- School of Materials Science and Engineering, Shenyang University of Technology, Shenyang 110870, China (L.S.)
| | - Hao Zhang
- School of Materials Science and Engineering, Shenyang University of Technology, Shenyang 110870, China (L.S.)
| | - Zhenkai Mu
- Hebei Key Laboratory of Material Near-Net Forming Technology, Hebei University of Science and Technology, Shijiazhuang 050018, China;
| | - Hongrui Dong
- School of Materials Science and Engineering, Beihang University, Beijing 100191, China;
| | - Haibo Wang
- School of Mechanical and Materials Engineering, North China University of Technology, Beijing 100144, China;
| | - Yanqiang Ren
- School of Materials Science and Engineering, Shenyang University of Technology, Shenyang 110870, China (L.S.)
| | - Liang Sun
- School of Materials Science and Engineering, Shenyang University of Technology, Shenyang 110870, China (L.S.)
| | - Liang Zhang
- School of Materials Science and Engineering, Shenyang University of Technology, Shenyang 110870, China (L.S.)
| | - Xiaoguang Yuan
- School of Materials Science and Engineering, Shenyang University of Technology, Shenyang 110870, China (L.S.)
- State Key Laboratory of Light Alloy Casting Technology for High-End Equipment, Shenyang 110022, China
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Hou Y, Min J, El-Aty AA, Han HN, Lee MG. A new anisotropic-asymmetric yield criterion covering wider stress states in sheet metal forming. International Journal of Plasticity 2023; 166:103653. [DOI: 10.1016/j.ijplas.2023.103653] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 09/02/2023]
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Abd El-Aty A, Ha S, Xu Y, Hou Y, Zhang SH, Alzahrani B, Ali A, Ahmed MMZ. Coupling Computational Homogenization with Crystal Plasticity Modelling for Predicting the Warm Deformation Behaviour of AA2060-T8 Al-Li Alloy. Materials (Basel) 2023; 16:ma16114069. [PMID: 37297204 DOI: 10.3390/ma16114069] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 03/20/2023] [Revised: 05/16/2023] [Accepted: 05/23/2023] [Indexed: 06/12/2023]
Abstract
This study aimed to propose a new approach for predicting the warm deformation behaviour of AA2060-T8 sheets by coupling computational homogenization (CH) with crystal plasticity (CP) modeling. Firstly, to reveal the warm deformation behaviour of the AA2060-T8 sheet, isothermal warm tensile testing was accomplished using a Gleeble-3800 thermomechanical simulator at the temperatures and strain rates that varied from 373 to 573 K and 0.001 to 0.1 s-1. Then, a novel crystal plasticity model was proposed for describing the grains' behaviour and reflecting the crystals' actual deformation mechanism under warm forming conditions. Afterward, to clarify the in-grain deformation and link the mechanical behaviour of AA2060-T8 with its microstructural state, RVE elements were created to represent the microstructure of AA2060-T8, where several finite elements discretized every grain. A remarkable accordance was observed between the predicted results and their experimental counterparts for all testing conditions. This signifies that coupling CH with CP modelling can successfully determine the warm deformation behaviour of AA2060-T8 (polycrystalline metals) under different working conditions.
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Affiliation(s)
- Ali Abd El-Aty
- Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 11942, Saudi Arabia
- Mechanical Engineering Department, Faculty of Engineering-Helwan, Helwan University, Cairo 11795, Egypt
| | - Sangyul Ha
- PKG Simulation, SK Hynix Inc., Icheon 17336, Gyeonggi, Republic of Korea
| | - Yong Xu
- Shi-Changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
- School of Materials Science and Engineering, University of Science and Technology of China, Shenyang 110016, China
| | - Yong Hou
- Department of Materials Science and Engineering & RIAM, Seoul National University, Seoul 08826, Republic of Korea
| | - Shi-Hong Zhang
- Shi-Changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
- School of Materials Science and Engineering, University of Science and Technology of China, Shenyang 110016, China
| | - Bandar Alzahrani
- Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 11942, Saudi Arabia
| | - Alamry Ali
- Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 11942, Saudi Arabia
| | - Mohamed M Z Ahmed
- Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 11942, Saudi Arabia
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