An extension of the stress-based forming limit curve (FLC) advanced by Stoughton (2000, “A General Forming Limit Criterion for Sheet Metal Forming,” Int. J. Mech. Sci., 42, pp. 1–27) is presented in this work. With the as-received strain-based FLCs and stress-strain curves for -thick AA5754 and -thick AA5182 aluminum alloy, stress-based FLCs are obtained. These curves are then transformed into extended stress-based forming limit curves (XSFLCs), which consist of the invariants, effective stress, and mean stress. By way of application, stretch flange forming of these aluminum alloy sheets is considered. The AA5754 stretch flange displays a circumferential crack during failure, whereas the AA5182 stretch flange fails through a radial crack at the edge of the cutout. It is shown that the necking predictions obtained using the strain- and stress-based FLCs in conjunction with shell element computations are inconsistent when compared with the experimental results. By comparing the results of the shell element computations with those in which the mesh comprises eight-noded solid elements, it is demonstrated that the plane stress approximation is not valid. The XSFLC is then used with results from the solid-element computations to predict the punch depths at the onset of necking. Furthermore, it is shown that the predictions of failure location and failure mode obtained using the XSFLC are in accord with the differences observed between the two alloys/gauges.
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e-mail: simha@lagavulin.uwaterloo.ca
e-mail: worswick@lagavulin.uwaterloo.ca
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October 2008
Research Papers
Application of an Extended Stress-Based Forming Limit Curve to Predict Necking in Stretch Flange Forming
C. Hari Manoj Simha,
C. Hari Manoj Simha
Department of Mechanical and Mechatronics Engineering,
e-mail: simha@lagavulin.uwaterloo.ca
University of Waterloo
, Waterloo, ON, N2L 3G1, Canada
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Rassin Grantab,
Rassin Grantab
Department of Mechanical and Mechatronics Engineering,
University of Waterloo
, Waterloo, ON, N2L 3G1, Canada
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Michael J. Worswick
Michael J. Worswick
Department of Mechanical and Mechatronics Engineering,
e-mail: worswick@lagavulin.uwaterloo.ca
University of Waterloo
, Waterloo, ON, N2L 3G1, Canada
Search for other works by this author on:
C. Hari Manoj Simha
Department of Mechanical and Mechatronics Engineering,
University of Waterloo
, Waterloo, ON, N2L 3G1, Canadae-mail: simha@lagavulin.uwaterloo.ca
Rassin Grantab
Department of Mechanical and Mechatronics Engineering,
University of Waterloo
, Waterloo, ON, N2L 3G1, Canada
Michael J. Worswick
Department of Mechanical and Mechatronics Engineering,
University of Waterloo
, Waterloo, ON, N2L 3G1, Canadae-mail: worswick@lagavulin.uwaterloo.ca
J. Manuf. Sci. Eng. Oct 2008, 130(5): 051007 (11 pages)
Published Online: August 14, 2008
Article history
Received:
November 24, 2006
Revised:
October 16, 2007
Published:
August 14, 2008
Citation
Simha, C. H. M., Grantab, R., and Worswick, M. J. (August 14, 2008). "Application of an Extended Stress-Based Forming Limit Curve to Predict Necking in Stretch Flange Forming." ASME. J. Manuf. Sci. Eng. October 2008; 130(5): 051007. https://doi.org/10.1115/1.2844593
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