Effects of Residual Stress on Springback and Part Performance Brad Kinsey University of New Hampshire UNH - 28 October 2016 Sheet Metal Forming.

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Presentation transcript:

Effects of Residual Stress on Springback and Part Performance Brad Kinsey University of New Hampshire UNH - 28 October 2016 Sheet Metal Forming

Objective and Technical Benefits Objectives: Develop effective methodologies to characterize residual stress and springback After forming but still in tooling After release from tooling Zecevic and Knezevic, JOM, 2017 Coupled elasto-plastic self-consistent crystal plasticity model of cup drawing, AA6022-T4 TD=Z RD=X TD=Z RD=X Technical Benefits: Improved dimension accuracy and structure performance of formed parts Examples include springback after stamping in automotive industry and collapse of well casing (tube) after hydraulic fracturing Improved product quality and reduced costs UNH - 28 October 2016 Sheet Metal Forming

Technical and Non-Technical Obstacles NIST, Center for Neutron Research Residual stress measurement methods Neutron diffraction X-ray diffraction Hole drilling, strain gauge Cup drawing, split ring test Limitations in residual stress measurements Specimen size Spatial resolution Destructive methods Required for accurate prediction in FEA Constitutive modeling, including material anisotropy Loading-unloading behavior of material Gréze et al., IJMS, 2010 UNH - 28 October 2016 Sheet Metal Forming

Path to Implementation Korkolis, unpublished DQSK DP 590 Investigate the residual stress and springback in: Air bending Stretch/draw bending Cup drawing Evaluate strain-relief methods Comparison of experiments with numerical simulation results Expand to roll forming of long, tubular products; stamping of automotive parts; and manufacturing of metal containers UNH - 28 October 2016 Sheet Metal Forming

Discussion Topics Timing: priority, resources available when needed? Obstacles: technical & business? Resources: level, type & issues? Anything missing for active industry support? Estimated benefits realistic & complete? Technical and non-technical obstacles complete or over reaching? Alternative implementation paths or better approaches? Conflicts with intellectual property or trade secrets? NHBB, residual stresses UNH - 28 October 2016 Sheet Metal Forming