R&D UPDATE

Determining a flow stress curve with biaxial testing

The limiting dome height test handles larger strains
By Nimet Kardes Sever, Yurdaer Demiralp, and Taylan Altan

1,000 Effective Stress ( ) [MPa] 800 600 400 200 0 DP600 - to = 1 mm Bulge Test TensileTest 0 0.1 0.2 0.3 Effective Strain ( ) 0.4 0.5 0.15 0.49

Figure 1
Tensile and VPB tests were used to obtain flow stress curves for DP600.

ndustry uses the finite element method (FEM) widely for process design to predict metal flow and defects. The accuracy of the input data affects the accuracy of the results from FEM.

Uniaxial Tests
The true stress-strain curve, also known as the flow stress curve, is one of the critical input variables for process simulation. Valid for small strains, the flow stress curve often is obtained by a tensile test, which was explained in detail in the May/June and July/August issues of STAMPING Journal.
132.6 mm (5.22 in.) Groove 105.7 mm (4.16 in.) Die Blank Holder

In the tensile test, the deformation is uniaxial and does not fully represent the deformation strains seen in automotive stamping applications. In addition, because of early necking, flow stress data from a uniaxial tensile test is limited to low strains.

Biaxial Testing
Extrapolation, which can introduce errors, is necessary to cover the biaxial stress-strain conditions that occur in stamping and provide full curves for FE simulation in stamping die design. Viscous Pressure Bulge Test. A biaxial test, such as the viscous

pressure bulge (VPB) test, can offer advantages over a conventional tensile test: The formability of different materials and samples is compared quickly based on bulge height. Material properties, such as flow stress data points (usually fit to Hollomons law = Kn), can be determined in biaxial directions to the limiting strain level relevant to stamping. The VPB test allows biaxial flow stress curves to be measured during the test to strain levels that often are two times greater than the maximum strain of the corresponding uniaxial flow stress curves (see Figure 1).

Necking Moves With Increased COF Necking When COF = 0 Die

50.8 mm (2.0 in) Punch Lock Bead

Blank Holder

Punch Lock Bead

Figure 2
The biaxial LDH test can be used to determine flow stress curves for larger strains (from K.H. Grote and E.K. Antonsson eds., Springer Handbook of Mechanical Engineering XXVIII, 2009).
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Figure 3
As the coefficient of friction increases, the maximum thinning location moves from the apex of the dome toward the die corner radius.
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R&D UPDATE

Limiting Dome Height Test. Another biaxial test, the limiting dome height (LDH) test (see Figure 2), also can be used to determine flow stress curves for larger strains, similar to the VPB test. Rather than using a viscous medium, the LDH test uses a solid hemispherical punch to form the sheet. The LDH test is used widely in industry to evaluate lubricants and formability. Friction at the tool-workpiece interface affects formability and thinning distribution. As the coefficient of friction increases, the maximum thinning location moves from the apex of the dome toward the die corner radius (see Figure 3). To obtain an accurate flow stress curve, maximum thinning should occur at or very near the apex of the dome, as in the VPB test. A very good lubricant, such as Teflon, can be used to achieve maximum thinning at the apex of the dome. If excellent lubrication can be achieved, it is possible to determine flow stress curves from the LDH test using an FE-based inverse analysis. This is ongoing work at the Center for Precision Forming (CPF), with researchers using the following procedure: Perform LDH test. Record force and punch stroke during the LDH test. Conduct FE simulations under the same conditions for fictitious material. Calculate force and punch stroke curves for each FE simulation and generate a database. Compare force versus punch stroke curves from experiments and simulations. Select as the material property the FE simulation that results in minimum error. Since many companies use the LDH test, it will be easy for them to determine sheet material propan fma publication STAMPINGJOURNAL

erties in-house with the proposed approach.S

Nimet Kardes Sever and Yurdaer Demiralp are graduate research associates and Taylan Altan is

professor and director of the Center for Precision Forming (CPF), The Ohio State University, 339 Baker Systems, 1971 Neil Ave., Columbus, OH 43210-1271, 614-292-9267, www.cpforming.org.

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