Abstract
A combined physico-mechanical approach to research and modeling of forming processes for metals with predictable properties is developed. The constitutive equations describing large plastic deformations under complex loading are based on both plastic flow theory and continuum damage mechanics. The model which is developed in order to study strongly plastically deformed materials represents their mechanical behavior by taking micro-structural damage induced by strain micro-defects into account. The symmetric second-rank order tensor of damage is applied for the estimation of the material damage connected with volume, shape, and orientation of micro-defects. The definition offered for this tensor is physically motivated since its hydrostatic and deviatoric parts describe the evolution of damage connected with a change in volume and shape of micro-defects, respectively. Such a representation of damage kinetics allows us to use two integral measures for the calculation of damage in deformed materials. The first measure determines plastic dilatation related to an increase in void volume. A critical amount of plastic dilatation enables a quantitative assessment of the risk of fracture of the deformed metal. By means of an experimental analysis we can determine the function of plastic dilatation which depends on the strain accumulated by material particles under various stress and temperature-rate conditions of forming. The second measure accounts for the deviatoric strain of voids which is connected with a change in their shape. The critical deformation of ellipsoidal voids corresponds to their intense coalescence and to formation of large cavernous defects. These two damage measures are important for the prediction of the meso-structure quality of metalware produced by metal forming techniques. Experimental results of various previous investigations are used during modeling of the damage process.
Similar content being viewed by others
References
Armero F., Oller S.: A general framework for continuum damage models. I. Infinitesimal plastic damage models in stress space. Int. J. Solids Struct. 37, 7409–7436 (2000)
Bernstein, M.L.: Micro-structure of Deformed Metals. Metallurgy, Moscow (1977) (in Russian)
Bogatov, A.A., Mizhiritskiy, O.I., Smirnov, S.V.: Resource of Metals Plasticity during Forming. Metallurgy, Moscow (1984) (in Russian)
Briottet L., Klöcker H., Montheillet F.: Damage in a viscoplastic material. Part II. Overall behaviour. Int. J. Plast. 14, 453–471 (1998)
Brunig M.: An anisotropic ductile damage model based on irreversible thermodynamics. Int. J. Plast. 19, 1679–1713 (2003)
Butuc M.C., Gracio J.J., Baratada Rocha A.: An experimental and theoretical analysis on the application of stress-based forming limit criterion. Int. J. Mech. Sci. 48, 414–429 (2006)
Chen B., Li W.G., Peng X.H.: A microvoid evolution law involving change of void shape and micro/macroscopic analysis for damaged materials. J. Mater. Process. Technol. 122, 189–195 (2002)
Demir I., Zbib H.M.: A mesoscopic model for inelastic deformation and damage. Int. J. Eng. Sci. 39, 1597–1615 (2001)
Dung N.L.: Plasticity theory of ductile fracture by void growth and coalescence. Forsch. Ingenieurw. 58, 135–140 (1992)
Fan J., Zhang J.: An endochronic constitutive equation for damaged materials. Chin. Sci. (Ser. A) 32, 246–256 (1989)
Fleck N.A., Hutchinson J.W.: Void growth in shear. Proc. R. Soc. Lond. Ser. A 407, 435–458 (1986)
Gelin J.C.: Modelling of damage in metal forming processes. J. Mater. Process. Technol. 80–81, 24–32 (1998)
Glazoff M.V., Barlat F., Weiland H.: Continuum physics of phase and defect microstructures: bridging the gap between physical metallurgy and plasticity of aluminum alloys. Int. J. Plast. 20, 363–402 (2004)
Gurson L.: Continuum theory of ductile rupture by void nucleation and growth. J. Eng. Mater. Technol. Trans. ASME 99, 2–15 (1977)
Hill R.: The mathematical theory of plasticity. Clarendon Press, Oxford (1983)
Horstemeyer M.F., Matalanis M.M., Sieber A.M., Botos M.L.: Micromechanical finite element calculations of temperature and void configuration effects on void growth and coalescence. Int. J. Plast. 16, 979–1015 (2000)
Il’iushin, A.A.: Plasticity: Fundamentals of the General Mathematical Theory. Nauka, Moscow (1963) (in Russian)
Kachanov L.M.: Introduction to Continuum Damage Mechanics. Kluewer, Dordrecht (1986)
Khraishi T.A., Khaleel M.A., Zbib H.M.: A parametric-experimental study of void growth in superplastic deformation Int. J. Plast. 17, 297–315 (2001)
Klöcker H., Tvergaard V.: Growth and coalescence of non-spherical voids in metals deformed at elevated temperature. Int. J. Mech. Sci. 45, 1283–1308 (2003)
Kolmogorov, V.L., Bogatov, A.A., Migachev, B.A.: Plasticity and Fracture. Metallurgy, Moscow (1977) (in Russian)
Korn G.A., Korn T.M.: Mathematical Handbook for Scientists and Engineers: Definitions, Theorems, and Formulas for Reference and Review. 2nd revised edn. Dover Publications, New York (2000)
Krajcinovic D.: Damage mechanics: accomplishments, trends and needs. Int. J. Solids Struct. 37, 267–277 (2000)
Lemaitre J., Desmorat R., Sauzay M.: Anisotropic damage law of evolution. Eur. J. Mech. A/Solids 19, 187–208 (2000)
Maire E., Bordreuil C., Babout L., Boyer J.-C.: Damage initiation and growth in metals. Comparison between modelling and tomography experiments. J. Mech. Phys. Solids 53, 2411–2434 (2005)
Makarov, E.S., Tutyshkin, N.D., Gvozdev, A.E., Tregubov, V.I., Zapara, M.A.: Technological Mechanics of Dilating Materials. 3rd rev. and add. edn. Tul’skiy Polygraphist Publ., Tula (2007) (in Russian)
McClintock F.A.: A criterion for ductile fracture by the growth of holes. J. Appl. Mech. 90, 363–371 (1968)
Menzel A., Steinmann P.: A theoretical and computational framework for anisotropic continuum damage mechanics at large strains. Int. J. Solids Struct. 38, 9505–9523 (2001)
Panin V.E.: Physical Mesomechanics of Heterogeneous Media and Computer-Aided Design of Materials. Cambridge Publishing, Cambridge (1998)
Pirondi A., Bonora N., Steglich D., Brocks W., Hellmann D.: Simulation of failure under cyclic plastic loading by damage models. Int. J. Plast. 22, 2146–2170 (2006)
Rice J., Tracey D.: On ductile enlargement of voids in triaxial stress field. J. Mech. Phys. Solids 17, 201–217 (1969)
Sedov, L.I.: Continuum Mechanics, vol. 1. Nauka, Moscow (1983) (in Russian)
Tang C.Y., Shen W., Lee T.C.: A damage-based criterion for fracture prediction in metal forming processes: a case study in Al 2024T3 sheet. J. Mater. Process. Technol. 89–90, 79–83 (1999)
Thomson C.I.A., Worswick M.J., Pilkey A.K., Lloyd D.J.: Void coalescence within periodic clusters of particles. J. Mech. Phys. Solids 51, 127–146 (2003)
Tutyshkin, N.D., Zapara, M.A.: The advanced method of definition of stress and velocity fields in the processes of axisymmetric plastic yielding. In: WSEAS Trans. on Heat and Mass Transfer vol. 2, pp. 150–156
Tutyshkin, N.D., Gvozdev, A.E., Tregubov, V.I.: Complex Problems of Plasticity Theory. Tul’skiy Polygraphist Publ., Tula (2001) (in Russian)
Voyiadjis G.Z., Venson A.R., Kattan P.I.: Experimental determination of damage parameters in uniaxially-loaded metal-matrix composites using the overall approach. Int. J. Plast. 11, 895–926 (1995)
Weinberg K., Mota A., Ortiz M.: A variational constitutive model for porous metal plasticity. Int. J. Comput. Mech. 37, 142–152 (2006)
Xiang Y., Wu S.: Numerical simulation of cavity damage evolution in superplastic bulging process. J. Mater. Process. Technol. 116, 224–230 (2001)
Yokobori T.: An Interdisciplinary Approach to Fracture and Strength of Solids. Wolters-Noordhoff Scientific Publications Ltd., Groningen (1966)
Zaikov M.A.: Strength of carbon steels at high temperatures. J. Tech. Phys. 19, 684–695 (1949) (in Russian)
Zhu, M., Jin, Q.L.: A constitutive relation for materials containing voids and application in closing of voids. In: Fan, J., Murakami, S. (eds.) Proceedings of the ICCLEM, Chongqing, pp. 542–545 (1989)
Author information
Authors and Affiliations
Corresponding author
Additional information
Communicated by S. Roux
Rights and permissions
About this article
Cite this article
Zapara, M.A., Tutyshkin, N.D., Müller, W.H. et al. A physico-mechanical approach to modeling of metal forming processes—part I: theoretical framework. Continuum Mech. Thermodyn. 20, 231–254 (2008). https://doi.org/10.1007/s00161-008-0080-2
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00161-008-0080-2
Keywords
- Plasticity
- Continuum damage mechanics
- Metal fracture
- Plastic flow
- Damage kinetics
- Deformation
- Stress
- Temperature
- Micro-structure
- Strain micro-defect
- Void
- Modeling
- Constitutive equation