Numerical modelling of electrohydraulic free-forming and die-forming of DP590 steel |
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| Institution: | 1. Department of Mechanical, Automotive, and Materials Engineering, University of Windsor, 401 Sunset Ave., Windsor N9B 3P4, Canada;2. Ford Research & Innovation Center, Dearborn, MI, USA;1. Ford Motor Company, Ford Research and Innovation Center, P.O. Box 2053, Mail Drop 3135 RIC, Dearborn, MI 48121-2053, USA;2. Oakland University, Rochester, MI 48309, USA;1. Department of Mechanical, Automotive, and Materials Engineering, University of Windsor, Windsor N9B3P4, Canada;2. Department of Mechanical and Aerospace Engineering, University of Waterloo, Waterloo, N2L6A5, Canada;3. Ford Research & Innovation Centre, Dearborn, Michigan 48121, USA;1. Mechanical Engineering Department 170 DHE, Oakland University, 2200 N. Squirrel Road, Rochester, MI 48309-4401, USA;2. Ford Motor Company, Ford Research and Innovation Center, P.O. Box 2053, Mail Drop 3135 RIC, Dearborn, MI 48121-2053, USA |
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| Abstract: | Electrohydraulic forming (EHF) is a high energy rate forming process in which the strain rate in the sheet metal can vary from 5 × 102 to 105 s−1 depending on various factors. Several mechanisms have been reported to cause an improvement in formability in EHF such as material deformation mechanisms, inertial effects and the dynamic impact of the sheet against the die. EHF is a complex high speed forming process and experimental work alone is not sufficient to properly understand this process. To understand the variation of some influential variables in EHF, electrohydraulic die-forming (EHDF) and free-forming (EHFF) of DP590 dual phase steel were simulated in ABAQUS/Explicit by considering the fluid/structure interactions. Three-dimensional finite element simulations were conducted by modelling the water with Eulerian elements with a view to investigating the effect of released energy on the sheet deformation profile history, strain distribution, loading path and damage accumulation type. The Johnson–Cook constitutive material model was used to predict the sheet behaviour and the parameters in this model were calibrated based on experimental test results available for DP590 at various strain rates. The Johnson–Cook phenomenological damage model was also used to predict the ductile failure (damage accumulation) in both EHDF and EHFF. Predicted final strain values and damage accumulation type showed good agreement with the experimental observations. |
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| Keywords: | Electrohydraulic forming High strain rate Finite element Eulerian Johnson–Cook damage criterion |
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