In order to achieve reliable but cost-effective crash simulations of stamped parts, sheet-forming process effects were incorporated in simulations using the ideal forming theory mixed with the three-dimensional hybrid membrane and shell method, while the subsequent crash simulations were carried out using a dynamic explicit finite element code. Example solutions performed for forming and crash simulations of I- and S-shaped rails verified that the proposed approach is cost effective without sacrificing accuracy. The method required a significantly small amount of additional computation time, less than 3% for the specific examples, to incorporate sheet-forming effects into crash simulations. As for the constitutive equation, the combined isotropic-kinematic hardening law and the nonquadratic anisotropic yield stress potential as well as its conjugate strain-rate potential were used to describe the anisotropy of AA6111-T4 aluminum alloy sheets.

Issue Section:
Technical Papers
Keywords:
aluminium alloys, rails, impact testing, sheet metal processing, forming processes, automobile industry, metal stamping, yield stress, internal stresses, reliability, cost reduction, finite element analysis, Crashworthiness, Ideal Forming, Hybrid Method, Isotropic-Kinematic Hardening, Nonquadratic Anisotropic Yield Potential, Yield Potential and Strain-Rate
Topics:
Anisotropy, Engineering simulation, Hardening, Kinematics, Membranes, Rails, Shells, Simulation, Stress, Yield stress, Finite element analysis, Aluminum alloys
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