Advanced material modeling for large strain using a tube hydro-bulging test apparatus Toshihiko Kuwabara

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

Point A servo-controlled tension-internal pressure testing machine for metal tubes is developed. This testing machine is capable of applying arbitrary stress or strain paths to a tubular specimen and measuring stress-strain curves from initial yielding up to fracture, as well as forming limit strains and stresses. The testing machine can be applied to sheet metals by making a tubular specimen from it.
1. Summary of Research (Technology and Development) The servo-controlled tube hydro-bulging test apparatus we have developed is shown in Fig. 1.1). It measures the elasto-plastic deformation behavior and forming limit of a tubular specimen by applying an axial force T and internal pressure P simultaneously under feedback control to give arbitrary stress or strain paths (Fig. 2).1-8) There are two methods for measuring the strain of a tubular specimen: a method using a regular strain gauge1-7) and a method using a strain gauge dedicated to measuring large strain deformation of tubular specimens.8) True stress components and in the axial and circumferential directions of a tubular specimen, respectively, can be calculated as values at the thickness center by formula (1) based on the equilibrium equations for an small material element at the center of the tube:

( R t )( D 2t ) P ( D / 2 t ) 2 + T Dt = P (D t) t (2 R t ) t 2 R t

(1)

where D, t, and R are the outer diameter, thickness, and radius of curvature along the tube axis respectively.

Fig. 1

Tension-internal pressure tube hydro-bulging test apparatus1)

400

/ MPa

0.8
Yld2000-2d (M=8)

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1:10 1:4

Experimental

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1:2 3:4 1:1.1

1:1.03 1:1

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-0.2

/ MPa
0 100 200 300 400
-0.4 -0.4 -0.2 0.0 0.2 0.4 0.6

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(a)

Fig. 2 (a) Contours of plastic work for aluminum alloy tube2) and (b) forming limit strain for steel tube5)

2. Originality of Research (Technology and Development) Cruciform specimens are suitable for the precise measurement of the material properties in a strain range of several percent or smaller. On the other hand, this test apparatus is amenable to evaluating the material properties in a large strain range from two to three percent up to rupture (Fig. 2a). One of the distinctive features of this apparatus is that it can directly measure the forming limit strain and forming limit stress of the raw material along arbitrary loading path (Fig. 2b). It is also possible to test sheet material by bending it and welding the edges together to form a tubular specimen.7, 8) 3. Future Prospects We intend to create tubular specimens from lightweight and difficult-to-process sheet materials such as titanium alloys, magnesium alloys, and high-intensity aluminum alloys that are hard to handle as cruciform specimens, and construct a database of their material models. We are developing a tube hydro-bulging test apparatus that can measure stress-strain curves at arbitrary stress/strain rate ratio in a quasi-high strain range of 0.1/s. 4. Resources, Bibliography and References 1) Kuwabara T., Ishiki M., Kuroda M., Takahashi S. Yield Locus and Work-Hardening Behavior of a Thin-Walled Steel Tube Subjected to Combined Tension-Internal Pressure, Journal de Physique IV, 105 (2003), 347-354 2) Kuwabara, T., Yoshida, K., Narihara, K., Takahashi, S. Anisotropic plastic deformation of extruded aluminum alloy tube under axial forces and internal pressure, Int. J. Plasticity, 21-1 (2005), 101-117 3) Yoshida, K, Kuwabara, T., Narihara, K. and Takahashi, S.: Experimental verification of the path-independence of forming limit stresses, International Journal of Forming Processes, 8-SI (2005), 283-2988 4) Yoshida, K, Kuwabara, T., Kuroda, M. : Path-dependence of the forming limit stresses in a sheet metal, Int. J. Plasticity, 23-3 (2007), 361-384. 5) Yoshida, K., Kuwabara, T., Effect of strain hardening behavior on forming limit stresses of steel tube subjected to nonproportional loading paths, Int. J. Plasticity, 23-7 (2007), 1260-1284.5 6) Kuwabara T, Inoue H., Hanabusa Y., Takizawa H., Ito R. Measurement of Anisotropy in Deformation and Fracture Strength of Aluminum Beverage Can using Biaxial Stress Tests, Journal of Japan Institute of Light Metals, 58-9 (2008), 449-455 7) Ishiki M., Kuwabara T., Yamaguchi M., Maeda Y., Hayashida Y., Itsumi Y. Differential Work Hardening Behavior of Pure Titanium Sheet under Biaxial Loading, Transactions of the Japan Society of Mechanical Engineers. A, 75-752 ( 2009), 491-500 8) Yamagishi S., Kuwabara T., Enatsu R. Plastic Deformation Behavior of Cold-rolled IF Steel Plates along Large Strain Nonlinear Biaxial Stress Paths, The Proceedings of the 61st Japanese Joint Conference for the Technology of Plasticity, (2010), 439-440