Simulation of three-point bending test of titanium foam for biomedical applications

Using Titanium (Ti) foam as an implant material is a new approach for biomedical applications and it is important to understand the mechanical behaviors of this new foam material. In the present study, the bending of the Ti foam has been simulated and compared against recently published data [1]. FE Analysis has been performed by Abaqus software. Stiffness and Yield strength of foams between 50% (cortical bone) to 80% (cancellous bone) porosity range were considered. This study showed that crushable foam material model in Abaqus, which has developed primarily for Aluminum (Al) foam alloys, is also valid for Ti Foam before any crack or damage occurs in the sample.

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.

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.

Finding line of action of the force exerted on erect spine based on lateral bending test in personalization of scoliotic spine models

In multi-body models of scoliotic spine, personalization of mechanical properties of joints significantly improves reconstruction of the spine shape. In personalization methods based on lateral bending test, simulation of bending positions is an essential step. To simulate, a force is exerted on the spine model in the erect position. The line of action of the force affects the moment of the force about the joints and thus, if not correctly identified, causes over/underestimation of mechanical properties. Therefore, we aimed to identify the line of action, which has got little attention in previous studies. An in-depth analysis was performed on the scoliotic spine movement from the erect to four spine positions in the frontal plane by using pre-operative X-rays of 18 adolescent idiopathic scoliosis (AIS) patients. To study the movement, the spine curvature was considered as a 2D chain of micro-scale motion segments (MMSs) comprising rigid links and 1-degree-of-freedom (DOF) rotary joints. It was found that two MMSs representing the inflection points of the erect spine had almost no rotation (0.0028° ± 0.0021°) in the movement. The small rotation can be justified by weak moment of the force about these MMSs due to very small moment arm. Therefore, in the frontal plane, the line of action of the force to simulate the left/right bending position was defined as the line that passes through these MMSs in the left/right bending position. Through personalization of a 3D spine model for our patients, we demonstrated that our line of action could result in good estimates of the spine shape in the bending positions and other positions not included in the personalization, supporting our proposed line of action.

Effect of roller leveling on the bending behaviour of aged steel strip

The common grades of steel used in roll forming are: hot rolled carbon steel, high strength low alloy and recovery annealed cold rolled sheet. These steels are prone to ageing and are often skin passed and/or roller leveled to eliminate ageing as it can lead to problems in forming. In roll forming, shape defects such as bow, twist and camber are considered to be related to very small plastic strains in the longitudinal direction and hence knowledge of the material properties in the elastic plastic transition range is necessary if the process is to be modelled accurately. Previous studies with aluminium have indicated that skin pass rolling can lead to residual stresses in the strip. In this work, the study was extended to aged carbon steel and to the effect of roller leveling on both aged material and strip that had been given a light cold rolling to simulate a skin pass treatment. The results suggest that roller leveling reduced the magnitude of residual stresses resulting from skin pass rolling.

The significant differences observed between tensile and bending test results, at and near, the elastic plastic transition reinforces the need to consider bending properties when assessing the effect of prior processing on strip for roll forming.

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.

Cement composites reinforced with surface modified coir fibers

An experimental investigation of coir mesh reinforced mortar (CMRM) is conducted using nonwoven coir mesh matting. The main parameters in this study are the fiber volume fraction (number of mesh layers) and fiber surface treatment with a wetting agent. The composites are subjected to the four-point bending test. The short-term mechanical properties of CMRM are discussed. Scanning electron micrograph analysis is used to observe the fiber—matrix interfacial characteristics. The results indicate that the addition of coir mesh to mortar significantly improves the composite post-cracking flexural stress, toughness, ductility, and toughness index, compared to plain mortar materials. The Albatex © FFC wetting agent (2-ethylhexanol) can effectively improve water absorption of coir fiber and enhance the fiber—matrix bonding strength. These coir mesh reinforced composites may be useful in civil engineering applications.

On the definition of an kinematic hardening effect graph for sheet metal forming process simulations

The objective of this work is to develop a kinematic hardening effect graph (KHEG) which can be used to evaluate the effect of kinematic hardening on the model accuracy of numerical sheet metal forming simulations and this without the need of complex material characterisation. The virtual manufacturing process design and optimisation depends on the accuracy of the constitutive models used to represent material behaviour. Under reverse strain paths the Bauschinger effect phenomenon is modelled using kinematic hardening models. However, due to the complexity of the experimental testing required to characterise this phenomenon in this work the KHEG is presented as an indicator to evaluate the potential benefit of carrying out these tests. The tool is validated with the classic three point bending process and the U-channel width drawbead process. In the same way, the capability of the KHEG to identify effects in forming processes that do not include forming strain reversals is identified.

An enhanced method for determining the maximum strain a pipeline coating could tolerate

An enhanced mandrel bend testing method has been proposed for the evaluation of the maximum strain level that could be tolerated by an organic coating, and for the understanding of localised coating deformation and cracking behaviours under nonuniform mechanical strains. The aim is to develop a practical method that is suitable for selecting pipeline coatings in order to ensure that the selected coatings have sufficient flexibility to meet the high strain demand during the construction, hydrostatic testing and operation of high pressure pipelines. Two new mandrel bend testing setups have been designed by employing either centre or end clamps in order to improve the uniformity of strain distributions over coated steel coupons, and by using strain gauges to perform in situ measurements of local strains. A series of tests have been carried out to evaluate the new method for testing the flexibility of selected epoxy based pipeline industry coatings. Preliminary computational simulation has also been carried out for assisting the interpretation of mandrel bending test results.

An inverse routine to predict residual stress in sheet material

A method is presented to determine residual stress distribution in sheet material from data collected in a free bending test. It may be used where the residual stress distribution is symmetrical about the mid-surface as it is usually the case for frequently-used sheet metal post-processing techniques such as skin-pass or temper rolling, tension- and roller leveling. An existing inverse technique is used to obtain a residual stress profile and material constants that provide the best fit in a finite element analysis of bending with the experimentally derived moment-curvature relation. The method is verified for bending of a low-carbon stainless steel using measurement of residual stress by X-ray diffraction. The residual stresses were induced in the sheet by cold rolling. The technique described here can be used industrially as a rapid method of investigating residual stresses in incoming sheet. In processes where the deformation is principally one of bending, such as cold roll forming, it is known that residual stresses have an influence on shape defects and springback and the method presented here can be used to determine whether incoming sheet is suitable for further processing and also as a means of obtaining improved material data input for numerical simulation.

Application of bending under tension test to determine the effect of tool radius and the contact pressure on the coefficient of friction in sheet metal forming

To quantify the frictional behaviour in sheet forming operations, several laboratory experiments which simulate the real forming conditions are performed. The Bending Under Tension Test is one such experiment which is often used to represent the frictional flow of sheet material around a die or a punch radius. Different mathematical representations are used to determine the coefficient of friction in the Bending Under Tension Test. In general the change in the strip thickness in passing over the die radius is neglected and the radius of curvature to thickness ratio is assumed to be constant in these equations. However, the effect of roller radius, sheet thickness and the surface pressure are also omitted in some of these equations. This work quantitatively determined the effect of roller radius and the tooling pressure on the coefficient of friction. The Bending Under Tension Test was performed using rollers with different radii and also lubricants with different properties. The tool radii were found to have a direct influence in the contact pressure. The effect of roller radius on friction was considerable and it was observed that there is a clear relationship between the contact pressure and the coefficient of friction.

The effect of skin passing on the material behavior of metal strip in pure bending and tension

The metal strip used in roll forming has often been preprocessed by (tension or roller) leveling or by skin-pass rolling, and as a consequence, may contain residual stresses. These stresses are not well observed by the tensile test, but could have a significant effect on the bending and springback behavior. With the advent of improved process design techniques for roll forming, including advanced finite element techniques, the need for precise material property data has become important. The major deformation mode of roll forming is that of bending combined with unloading and reverse bending, and hence property data derived from bend tests could be more relevant than that from tensile testing.

This work presents a numerical study on the effect of skin passing on the material behavior of stainless steel strip in pure bending and tension. A two dimensional (2-D) numerical model was developed using Abaqus Explicit to analyze the affect of skin passing on the residual stress profile across a section for various working conditions. The deformed meshes and their final stress fields were then imported as pre-defined fields into Abaqus Standard, and the post-skin passing material behavior in pure bending was determined. The results show that a residual stress profile is introduced into the steel strip during skin passing, and that its shape and stress level depend on the overall thickness reduction as well as the number of rolling passes used in the skin passing process. The material behavior in bending and the amount of springback changed significantly depending on the skin pass condition.

Analytic study on pure bending of metal sheets

In this work, analytical models of pure bending are developed to simulate a particular type of bend test and to determine possible errors arising from approximations used in analyzing experimental data. Analytical models proposed for steels include a theoretical solution of pure bending and a series of finite element models, based on the von Mises yield function, are subjected to different stress and strain conditions. The results show that for steel sheets the difference between measured and calculated results of the moment-curvature behaviour is small and the numerical results from the finite element models indicate that experimental results obtained from the test are acceptable in the range of the pure bending operation. Further for magnesium alloys, which exhibit unsymmetrical yielding, the algorithm of the yield function with a linear isotropic hardening model is implemented by programming a user subroutine in Abaqus for bending simulations of magnesium. The simulations using the proposed user subroutine extract better results than those using the von Mises yield function.