Fracture Characterisation and Modelling of AHSS Using Acoustic Emission Analysis for Deep Drawing

authored by: Eugen Stockburger, Hendrik Wester, Bernd Arno Behrens
Abstract: Driven by high energy prices, AHSS are still gaining importance in the automotive industry regarding electric vehicles and their battery range. Simulation-based design of forming processes can contribute to exploiting their potential for lightweight design. Fracture models are frequently used to predict the material’s failure and are often parametrised using different tensile tests with optical measurements. Hereby, the fracture is determined by a surface crack. However, for many steels, the fracture initiation already occurs inside the specimen prior to a crack on the surface. This leads to inaccuracies and more imprecise fracture models. Using a method that detects the fracture initiation within the specimen, such as acoustic emission analysis, has a high potential to improve the modelling accuracy. In the presented paper, tests for fracture characterisation with two AHSS were performed for a wide range of stress states and measured with a conventional optical as well as a new acoustical measurement system. The tests were analysed regarding the fracture initiation using both measurement systems. Numerical models of the tests were created, and the EMC fracture model was parametrised based on the two evaluation areas: a surface crack as usual and a fracture from the inside as a novelty. The two fracture models were used in a deep drawing simulation for analysis, comparison and validation with deep drawing experiments. It was shown that the evaluation area for the fracture initiation had a significant impact on the fracture model. Hence, the failure prediction of the EMC fracture model from the acoustic evaluation method showed a higher agreement in the numerical simulations with the experiments than the model from the optical evaluation.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
Type: Article
Journal: Journal of Manufacturing and Materials Processing
Volume: 7
Publication date: 05.07.2023
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Mechanics of Materials, Mechanical Engineering, Industrial and Manufacturing Engineering
Electronic version(s): https://doi.org/10.3390/jmmp7040127 (Access: Open)
: Details in the research portal "Research@Leibniz University"

BibTeX

@article{982154756e9e42c39300545fc5ee1285,
title = "Fracture Characterisation and Modelling of AHSS Using Acoustic Emission Analysis for Deep Drawing",
abstract = "Driven by high energy prices, AHSS are still gaining importance in the automotive industry regarding electric vehicles and their battery range. Simulation-based design of forming processes can contribute to exploiting their potential for lightweight design. Fracture models are frequently used to predict the material{\textquoteright}s failure and are often parametrised using different tensile tests with optical measurements. Hereby, the fracture is determined by a surface crack. However, for many steels, the fracture initiation already occurs inside the specimen prior to a crack on the surface. This leads to inaccuracies and more imprecise fracture models. Using a method that detects the fracture initiation within the specimen, such as acoustic emission analysis, has a high potential to improve the modelling accuracy. In the presented paper, tests for fracture characterisation with two AHSS were performed for a wide range of stress states and measured with a conventional optical as well as a new acoustical measurement system. The tests were analysed regarding the fracture initiation using both measurement systems. Numerical models of the tests were created, and the EMC fracture model was parametrised based on the two evaluation areas: a surface crack as usual and a fracture from the inside as a novelty. The two fracture models were used in a deep drawing simulation for analysis, comparison and validation with deep drawing experiments. It was shown that the evaluation area for the fracture initiation had a significant impact on the fracture model. Hence, the failure prediction of the EMC fracture model from the acoustic evaluation method showed a higher agreement in the numerical simulations with the experiments than the model from the optical evaluation.",
keywords = "butterfly specimen, enhanced Mohr–Coulomb fracture model, HCT780C, HCT980X",
author = "Eugen Stockburger and Hendrik Wester and Behrens, {Bernd Arno}",
note = "Funding Information: This research was funded by the German Research Foundation (Deutsche Forschungsgemeinschaft, DFG) within the project “Improving the fracture characterisation of advanced high-strength steel sheets by coupling measuring systems for optical forming analysis with acoustic emission technology” with the grant number “385276585”. ",
year = "2023",
month = jul,
day = "5",
doi = "10.3390/jmmp7040127",
language = "English",
volume = "7",
journal = "Journal of Manufacturing and Materials Processing",
issn = "2504-4494",
publisher = "MDPI Multidisciplinary Digital Publishing Institute",
number = "4",
}