Effect of anisotropy on the formability and fracture prediction with the electrohydraulic forming FEM
摘要
Although the consideration of material anisotropy is crucial for predicting the formability in conventional low-speed forming, its effect is often neglected in high-speed forming finite element analysis. This study investigated the influence of anisotropy on the fracture prediction of 0.5 mm thick STS430 sheets during the electrohydraulic forming process. Finite-element models incorporating both isotropic and anisotropic properties were developed and validated. A numerical approach was used to derive effective dynamic hardening functions by fitting strain rate dependent stress and strain data extracted directly from finite element analysis. These functions were then coupled with the Marciniak-Kuczynski (M-K) model to generate the dynamic forming limit curves. The analysis revealed that although both isotropic and anisotropic models accurately predicted the macroscopic bulge height under non-fracture conditions, their predictions diverged significantly at higher energy levels where fracture occurred. The anisotropic model realistically simulated the localization of strain and thinning in the rolling direction, which was consistent with the experimental observations. In contrast, the isotropic model failed to predict this behavior, and its strain paths remained well below the forming limit, thus failing to predict the experimental fracture. Crucially, the strain paths from the anisotropic model successfully crossed the dynamic forming limit curve, accurately predicting the fracture occurrence, location, and orientation in precise agreement with the experiments. These findings demonstrate that the inclusion of anisotropy is essential for the accurate prediction of localized deformation and fracture in high-speed bulge-forming processes.