Effect of tensile pre-strain on bending and unloading of automotive steels

In recent years, advanced high strength steels (AHSS) have been used in a wide range of automotive applications; they may have property variations through the thickness and the properties may also be dependent of prior processing including pre-straining. In order to model forming processes precisely using, for example, finite element analysis, it is important that material input data should adequately reflect these effects. It is known that shape defects in roll forming are related to small strains in material that has undergone prior deformation in a different strain path. Much research has already been performed on the change in the Young’s Modulus once a steel sheet has been plastically deformed,however many of these tests have only been conducted using tensile testing, and therefore may not take into account differences in compressive and tensile unloading. This research investigates the effect of tensile pre-straining on bending behaviour for various types of material;in bending, one half of the sheet will load and unload in compression and hence experience deformation under a reversed stress. Four different materials were pre-strained in tension with 1%, 3%, 7%, 11% and 25% elongation. Using a free bending test, moment curvature diagrams were obtained for bending and unloading. The results showed that the characteristics of the moment curvature diagram depended on the degree of pre-straining; more highly strained samples showed an earlier elastic-plastic transformation and a decreased Young's Modulus during unloading. This was compared to previous literature results using only tensile tests. Our results could influence the modeling of springback in low tension sheet operations, such as roll forming.

Development of an inverse routine to predict residual stresses in the material based on a bending test

Bending and reverse bending are the dominant material deformations in roll forming, and hence property data derived from bend tests could be more relevant than tensile test data for numerical simulation of a roll forming process. Recent investigations have shown that residual stresses change the material behavior close to the yield in a bending test. So, residual stresses introduced during prior steel processing operations may affect the roll forming process, and therefore they need to be included in roll forming simulations to achieve improved model accuracy. Measuring the residual stress profile experimentally is time consuming and has limited accuracy while analytical models that are available require detailed information about the pre-processing conditions that is generally not available for roll forming materials. The main goal of this study is to develop an inverse routine that determines a residual stress profile through the material thickness based on experimental pure bend test data. A numerical model of the skin passing (temper rolling) process is performed to introduce a residual stress profile in DP780 steel sheet. The skin passed strips are used in a pure bending simulation to record moment-curvature data and this data is then applied in an inverse analysis to predict the residual stress profile in the material. Comparison of the residual stress profile predicted by the inverse routine with that calculated by finite element analysis (FEA) indicates an inverse approach combined with pure bend test may present an alternative to predict residual stresses in sheet metals.

Bending behaviour of step-wise graded carbon nanofiber/polymer nanocomposites

In this study, a finite element-based model was developed to investigate the mechanical behavior of step-wise graded carbon nanofibre/phenolic nanocomposites. Four step-wise graded nanocomposites (FGNs), a non-graded nanocomposite (NGN), and a pure phenolic with the same geometry and total carbon nanofiber content were designed, fabricated and analyzed. Flexural tests were conducted to validate the finite element model. Close agreement was obtained between experimental results and numerical predictions. The results showed that flexural modulus was highly influenced by the compositional gradients.

A study on bending behaviours of aluminium foam-filled tubes

In the study, the strengthening effect of aluminium foam in thin-walled aluminium tubes subject to bending load in investigated experimentally and numerically. Bending tests are conducted on foam filler, hollow tube and foam-filled tube. The finite element method is used as well to get deeper insight into the crush failure modes via focusing on the influence from wall thickness of the tube. The obtained information is useful to optimally design foam-filled tubes as energy absorbing devices in automotive engineering. The optimisation results can be implemented to find an optimum foam-filled tube that absorbs the same energy as the optimal hollow tube but with much less weight. © (2014) Trans Tech Publications, Switzerland.

Analysis of backward congestion notification with delay for enhanced Ethernet networks

At present, companies and standards organizations are enhancing Ethernet as the unified switch fabric for all of the TCP/IP traffic, the storage traffic and the high performance computing traffic in data centers. Backward congestion notification (BCN) is the basic mechanism for the end-to-end congestion management enhancement of Ethernet. To fulfill the special requirements of the unified switch fabric, i.e., losslessness and low transmission delay, BCN should hold the buffer occupancy around a target point tightly. Thus, the stability of the control loop and the buffer size are critical to BCN. Currently, the impacts of delay on the performance of BCN are unidentified. When the speed of Ethernet increases to 40 Gbps or 100 Gbps in the near future, the number of on-the-fly packets becomes the same order with the buffer size of switch. Accordingly, the impacts of delay will become significant. In this paper, we analyze BCN, paying special attention on the delay. We model the BCN system with a set of segmented delayed differential equations, and then deduce sufficient condition for the uniformly asymptotic stability of BCN. Subsequently, the bounds of buffer occupancy are estimated, which provides direct guidelines on setting buffer size. Finally, numerical analysis and experiments on the NetFPGA platform verify our theoretical analysis.

Numerical modeling and analysis for forming process of dual-phase 980 steel exposed to infrared local heating

A recent experiment confirmed that the infrared (IR) local heating method drastically reduces springback of dual-phase (DP) 980 sheets. In the experiment, only the plastic deformation zone of the sheets was locally heated using condensed IR heating. The heated sheets were then deformed by V-bending or 2D-draw bending. Although the experimental observation proved the merit of using the IR local heating to reduce springback, numerical modeling has not been reported. Numerical modeling has been required to predict springback and improve the understanding of the forming process. This paper presents a numerical modeling for V-bending and 2D-draw bending of DP 980 sheets exposed to the IR local heating with the finite element method (FEM). For describing the thermo-mechanical behavior of the DP 980 sheet, a flow stress model which includes a function of temperature and effective plastic strain was newly implemented into Euler-backward stress integration method. The numerical analysis shows that the IR local heating reduces the level of stress in the deformation zone, although it heats only the limited areas, and then it reduces the springback. The simulation also provides a support that the local heating method has an advantage of shape accuracy over the method to heat the material as a whole in V-bending. The simulated results of the springback in both V-bending and 2D-draw bending also show good predictions.

Micromechanical modelling of bending under tension forming behaviour of dual phase steel 600

A micromechanical modelling based approach by means of a Representative Volume Element (RVE) was employed to predict the flow behaviour and plastic strain of DP600 steel, produced by WISCO. Macroscopic modelling of a classical Bending-Under-Tension (BUT) experiment was employed to acquire strain deformation, and thus the following microscopic modelling was implemented by considering the realistic microstructure morphology. Comparisons between macroscopic behaviour and microscopic behaviour, including strain distribution and stress distribution, were extracted for different boundary conditions of the BUT set-up. The micro-macro modelling approach increases the understanding of the steel microstructure, which will enable this microstructure to be tailored for different applications in automobile industry in the future.

Improvement of accuracy in a free bending test for material characterization

The effect of secondary (anticlastic) curvature and the stress state on the measurement of material properties in a free bending test is studied in order to improve the accuracy of the test. Experiments and numerical analysis are conducted on a medium strength 304L stainless steel and high strength dual-phase steels, DP780 and DP1000. The dependence of the secondary curvature on sample geometry is analysed and correction factors are introduced to improve the accuracy of the calculation of material properties when using plane strain or uniaxial stress two-dimensional assumptions. A free bending test procedure is proposed to characterize material behaviour close to yield. This will allow the quick and simple analysis of material properties for bending-dominated forming processes such as roll forming.