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    Journal of Materials Processing Technology 172 (2006) 451460

    Numerical modelling and experimental validationof steel deep drawing processesPart I. Material characterization

    Claudio Garca a, Diego Celentano a,, Fernando Flores b, Jean-Philippe Ponthot c

    a Departamento de Ingeniera Mec anica, Universidad de Santiago de Chile, Avda. Bdo. OHiggins 3363, Santiago de Chile, ChilebDepartamento de Estructuras, Universidad Nacional de Cordoba, Casilla de Correo 916, 5000 Cordoba, Argentina

    cLTAS-Milieux Continus et Thermomecanique, Universite de Liege, 1 Chemin des Chevreuils, B-4000 Liege-1, Belgium

    Received 9 August 2004; accepted 8 November 2005

    Abstract

    This work presents an experimental characterization of the mechanical behaviour of the EK4 deep drawing steel. The experimental procedure

    encompasses spectrometry, metalography, tension testing and hardness measurements. Special attention is devoted to the derivation of the elastic

    and plastic parameters involved in the assumed constitutive model based on the anisotropic Hill-48 yield criterion. The simulation of the deformation

    process during the whole tensile test is subsequently performed with the aim of assessing the adequateness of the proposed methodology. It should

    be mentioned that the material parameters obtained with this procedure are the basic data for the modelling and experimental validation of different

    deep drawing applications presented in Part II of this work.

    2005 Elsevier B.V. All rights reserved.

    Keywords: Forming process; Deep drawing; Material characterization

    1. Introduction

    A relevant aspect that has to be considered in the analysis

    of any forming process is the knowledge of the mechanical

    behaviour of the materials involved in it. This is particularly

    difficult in metal sheet deep drawing operations due to the dif-

    ferent complex mechanisms (finite strain plasticity, hardening,

    damage, viscous effects, etc.) that develop in the blank material

    during its deformation. Therefore, an adequate material charac-

    terization is a crucial task that needs to be carried out in order

    to design, control and/or eventually optimize the production of

    a prescribed component.

    Themanufacturing of steel sheets by means of press-working

    represents a large industry that produces numerous parts for a

    wide variety of applications. Specifically, the steelcommercially

    known as EK4is nowadays extensively used in many deep draw-

    ing operations (see, for instance [1]). Some particular features

    Corresponding author.

    E-mail addresses: [email protected] (C. Garca),

    [email protected] (D. Celentano), [email protected] (F. Flores),

    [email protected] (J.-P. Ponthot).

    of it are specified in [2]: maximum admissible values for car-bon and nitrogen contents, ultimate tensile strength (UTS), yield

    strength and hardness and, in addition, a minimum bound for

    the fracture elongation. However, it is a well-known fact that

    the final properties of the material under the EK4 denomination

    are not a world-wide standard since rolled sheets provided by

    various steel companies may behave completely different when

    being deformed. This drawback definitely restricts the flexibility

    of the process since usually expensive trial and error calibration

    tests are required to tune the appropriate operation parameters.

    The aim of this work is to present an experimental charac-

    terization of the mechanical behaviour of a specific EK4 deep

    drawing steel broadly employed in the industry [1]. Spectrom-

    etry, qualitative metalographic observations, tensile testing and

    hardness measurements are undertaken to this end. In particular,

    the tensile tests have been conducted according to the standard

    specifications [36] using specimens oriented at 0, 45 and 90

    with respect to the sheet rolling direction. The experimentally

    derived elastic and plastic parameters are the basic data for the

    constitutive modeladopted to describe the material response dur-

    ing the deformation process. A hyperelastic elastoplastic law

    written in terms of Hencky stress and strain measures is con-

    sidered [7]. Strain hardening and normal anisotropy (along the

    0924-0136/$ see front matter 2005 Elsevier B.V. All rights reserved.

    doi:10.1016/j.jmatprotec.2005.11.015

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    452 C. Garca et al. / Journal of Materials Processing Technology 172 (2006) 451460

    sheet thickness) effects are both considered via the Hill-48 asso-

    ciate plasticity model [8]. Afterwards, this model is used in the

    simulation of the material behaviour during the whole test via

    a large strain shell formulation discretized within the finite ele-

    ment context. Finally, the numerical results are validated with

    the experimental measurements.

    2. Material constitutive model

    The constitutive model adopted in this work to describe the

    sheet material behaviour is briefly presented below. More details

    about this model can be found in [7], and references therein.

    2.1. Strain and stress measures

    The so-called Hencky deformation tensor is chosen here

    as the main kinematic state variable since it is an objective

    (Lagrangian) strain measure and constitutes, in addition, a natu-

    ral extension of the unidimensional logarithmic strain. Consid-

    ering the sheet as a thin shell with a curvilinear local coordinatesystem over its middle surface, this deformation is defined as:

    e = LT ln()L (1)

    where and L, respectively, include the eigenvalues and the

    associated eigenvectors of the right stretch tensor U such that

    U2 =FTF, F being the deformation gradient tensor (T is the

    transpose symbol). Note that the strain related to the sheet thick-

    ness variation is simply e3 =ln(t/t0), where t/t0 is the thickness

    ratio between the deformed and initial configurations. The other

    two eigenvalues define the principal (in-plane) stretches in the

    shell surface. Consistently, the Hencky stress tensor T, whose

    expression is given in Section 2.2, is used in this context.

    2.2. Stressstrain law

    A linear hyperelastic stressstrain law expressed in terms

    of Hencky measures is considered to describe the material

    behaviour:

    T = C : (e ep) (2)

    where C is the isotropic elastic constitutive tensor correspond-

    ing to the plane stress condition and ep is the plastic contribution

    ofe. As can be seen, an additive elasticplastic decomposition

    of the Hencky strain is assumed based in the fact that the elas-tic deformations are usually small in many steel deep drawing

    processes. The evolution law ofep is given below.

    2.3. Plastic behaviour

    It has been long recognized that the use of the associate rate-

    independent plasticity theory including the classical anisotropic

    Hill-48 yield criterion is a useful framework to simulate sheet

    responses subjected to deep drawing operations [8]. Although

    the further assumption of planar isotropy (or normal anisotropy)

    appreciably simplifies the formulation, this situation was found

    to be approximately fulfilled in many applications (see e.g.

    [1012]). In this context, the yield function written in terms of

    the Cauchy stress tensor (that can be derived from T through

    a proper kinematic transformation; see Section 4.1) under the

    plane stress condition (i.e. 33 = 13 = 23 = 0) reads:

    F= 211 + 222

    2R

    1+ R1122 +

    2(1+ 2R)

    1+ R212 (C

    p)2 = 0

    (3)

    where R is the average Lankfords coefficient accounting for the

    non-isotropic plastic behaviour along the shell thickness and Cp

    is the isotropic hardening function given by:

    Cp = Ap(ep0 + e

    p)np

    (4)

    where Ap and np are the hardening parameters, ep is the effec-tive plastic deformation and e

    p0 is an assumed initial value such

    that y = Ap(e

    p0)

    np

    , with y being the yield strength defining the

    material initial elastic domain. The effective plastic deformation

    rate is computed as ep=

    2/3 ep : ep with the following evo-

    lution equation for ep:

    ep=

    F

    (5)

    where is the rate (or increment in this framework) of the plas-

    tic consistency parameter calculated according to the standard

    procedures of the plasticity theory [13].

    The yield strength together with the hardening parametersand average Lankfords coefficient are all derived, as described

    in Section 3, from the experimental data measured during tensile

    tests applied to the EK4 steel.

    3. Experimental procedure

    Theexperimentalprocedure adoptedin thiswork to characterize themechan-

    ical behaviour of the EK4 steel consisted in the following steps.

    3.1. Chemical composition

    This routine taskaimed at checking the adequate composition of the selected

    materialis carried outby means of an optical spectrometer. Theaveragechemical

    compositionof theEK4 steelis shown in Table1. Itis seen that thecarboncontent

    present in this materialis less than 0.08%whichis themaximum bound typically

    required for this kind of deep drawing steels [2].

    3.2. Metalography

    Metalographic observations in the sheet plane and thickness for the unde-

    formed material are, respectively, shown in Figs. 1 and 2. A ferritic matrix with

    Table 1

    Average chemical composition of EK4 steel (% in weight)

    C (%) 0.0457 Mn (%) 0.1936 P (%) 0.0093 S (%) 0.0045 Cr (%) 0.0375

    Ni (%) 0.0114 Al (%) 0.0049 Cu (%) 0.0302 Co (%) 0.0080 Fe (%) 99.58

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    C. Garca et al. / Journal of Materials Processing Technology 172 (2006) 451460 453

    Fig. 1. Metalography of EK4 steel in the sheet plane.

    Fig. 2. Metalography of EK4 steel in the sheet thickness.

    uniformly distributed equiaxial grains can be appreciated in both planes pre-

    cluding in this way the presence of any grain alignment.

    3.3. Tensile test

    The geometric configuration of the EK4 steel sheet sample to be tested

    according to the standard specifications [3,4] is sketched in Fig. 3. The distance

    between thetwo markers denotes theinitial extensometer lengthtaken as 50mm

    in this case. Therespectiveinitial values forthe width andthickness in thework-

    ing zone are w0 = 12.5 mm and t0 = 0.6 mm. The specimens have been cut along

    three differentorientations (0,45 and90) with respect to therolling directionof

    the sheet during its manufacturing process. A nearly gradual reduction in width

    is considered in order to trigger the necking development that has to take place

    approximately at the middle of the extensometer length. This tapered profile

    fits the usual standards since the difference between the adopted maximum and

    minimum width values existing in the extensometer length is lower than 1%

    [3,4].

    The average engineering stressstrain curves obtained with 18 samples (six

    for each orientation) considering a load cell of 2.5 mm/min are plotted in Fig. 4.

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    454 C. Garca et al. / Journal of Materials Processing Technology 172 (2006) 451460

    Fig. 3. Tensile specimen (dimensions (mm)).

    Fig. 4. Average engineering stressstrain curves of EK4 steel for specimens

    oriented at 0, 45 and 90 with respect to the rolling direction.

    The material uniformity was reflected in the remarkably low dispersion found

    in the measurements for each orientation. As usual, the engineering stress is

    defined as P/A0, where P is the axial load and A0 = w0t0 is the initial transversal

    area, whilethe engineering strainor elongation is computed as (LL0)/L0, with

    L and L0 being the current and initial extensometer lengths, respectively. At the

    beginning of the deformation process, the material behaves elastically. Once

    the yield strength is reached, a plastic deformation without hardening develops

    within theelongationrangeof 0.481%.Thisresponse, usuallyknownas Luders

    band formation [14], is a typical phenomenon observed for low carbon steels

    whose negative effect on the drawing properties has been limited in this case by

    means of a cold rolling applied to the material during its manufacturing process.

    Then, the plastic hardening starts and the load increases up to a maximum value

    Table 2

    Parameters obtained from the tensile test applied to EK4 steel samples

    Youngs

    modulus

    (GPa)

    Yield

    strength

    (MPa)

    Maximum

    load (kN)

    UTS

    (MPa)

    Fracture

    elongation

    (%)

    Average 212 183 2.168 285 46.7

    Range () 6.80 2.80 0.030 3.00 4.1

    Table 3

    Average original and final dimensions of EK4 steel tensile samples

    Original Final Ratio (final/original)

    Width (mm) 12.5 7.67 0.61

    Thickness (mm) 0.600 0.397 0.66

    Extensometer length (mm) 50.0 72.3 1.44

    Transversal area (mm2) 7.50 3.05 0.41

    that takes place in a wide elongation plateau (from 25 to 35%, approximately).

    For higher levels of elongation, as it is well-known, the load decreases since

    the effect of the reduction of the transversal area at the necking zone is stronger

    than that of the hardening mechanism. As can be observed in Fig. 5, a highly

    localised(ductile) necking develops until the rupture of the specimen that occurs

    at a elongation of about 47%. The average experimentally measured values

    (considering the three orientations) for the Youngs modulus, yield strength,

    maximum load, ultimate tensile strength (UTS) and elongation at the fracture

    stage are summarized in Table 2. It is seen that these values fit the admissible

    bounds usually considered for the EK4 steel [2], i.e. maximum yield strength of

    210 MPa, UTS ranging from 270 to 350 MPa and minimum fracture elongation

    of 38%. Moreover, some average original and final characteristic dimensions of

    the sample are presented in Table 3.

    The experimental characterization of the plastic behaviour that is subse-

    quently accomplished is mainly aimed at deriving the hardening parameters Ap

    and np and the average Lankfords coefficient R involved in the constitutive

    model described above. Details of the methodology followed to obtain such

    constants are given below.

    Since the engineering stressstrain relationship cannot provide a proper

    description of the hardening material response during the whole tension pro-

    cess, an alternative stressstrain curve defined in terms of an equivalent stress

    eq andan equivalentstrain eq isusedtothisend [5]. Accordingto theprocedure

    Fig. 5. Geometric configurations of the sample: (a) necking zone and (b) rupture.

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    C. Garca et al. / Journal of Materials Processing Technology 172 (2006) 451460 455

    Fig. 6. Mean equivalent stress vs. equivalent deformation.

    originally proposedby Bridgman[15], these variables can be, respectively, com-

    puted as eq =fBP/A and eq = eq/E+ p, wherefB(p) 1 is an assumed known

    correction factor (i.e. the conditions fB =1 and fB < 1, respectively, account

    for the uniaxial and triaxial stress distributions that occur before and after thenecking formation) applied to the mean true axial stress P/A, A is the current

    transversal area at the necking zone (A = wt, where w and t are the current

    width and thickness, respectively), Eis the Youngs modulus and p =ln(A0/A)

    is the true (logarithmic) deformation. As can be seen, w and tare the additional

    variables to be measured. It should be mentioned that the correction factor fBhas been exclusively obtained for isotropic materials tested in specimens that

    only develop diffuse necking (e.g. either cylindrical or strip samples with a

    relativelyhigh t0/w0 ratio [16]). Therefore,this methodologycannot be straight-

    forwardly applied to the present case. However, a simplified procedure can be

    adopted. It basically consists in plotting a eq eq curve with the available

    experimental data within the deformation range that exhibits uniaxial stress dis-

    tribution (035% for this material), i.e. prior to the onset of necking where the

    condition fB = 1 holds. Although this simpler approach is not strictly valid for

    the whole deformation range up to rupture, it ensures a reasonably accurate

    material characterization. Fig. 6 shows the experimental data (correspondingto 10 specimens) for the eq eq relationship together with the potential

    correlation derived from them via the application of a classical least-squares

    technique to Eq. (4). The resulting hardening parameters are: Ap = 566 MPa and

    np = 0.345.

    The measurement of the average Lankfords coefficient accounting for the

    normal anisotropy of the sheet has been performed according to the standard

    specifications [6]. The recommended expression to compute this parameter,

    defined as the ratio between the width and thickness deformations for sheets

    specimens oriented at 0, 45 and 90 with respect to the rolling direction, is

    R0,45,90 =ln(w/w0)/ln(l0w0/lw) which, as can be seen, assumes the incompress-

    ible nature of the plastic flow. In order to minimize the experimental errors

    associated with the measurement of the sample dimensions, the adequate use of

    this equation is restricted to the elongation range corresponding to the develop-

    ment of uniaxial stress with hardening, i.e. around 1025% in this case. The

    average Lankfords coefficient is given by R = 1/4(R0 + 2R45 +R90). Theassumption of planar isotropy can be assessed by the so-called earing index

    defined as R = 1/4(R0 2R45 +R90). The Lankfords coefficient together with

    the earing index for the EK4 steel are summarized in Table 4. As can be

    appreciated, this steel presents a relatively high value of R that makes it appro-

    priate for deep drawing applications. Moreover, the small value of R found

    for this steel indicates that it exhibits a low planar anisotropy and, therefore,

    Table 4

    Lankfords coefficients and earing index of EK4 steel

    R0 R45 R90 R R

    Average 1.62 1.50 2.00 1.65 0.16

    Range () 0.13 0.06 0.12

    Fig.7. Engineering stressstraincurves for differentload cellvelocities V(spec-

    imens oriented at 0 with respect to the rolling direction).

    this fact justifies the use of a simplified yield crietrion as that presented in

    Section 2.3.

    The influence of strain rate effects on the mechanical behaviour of the EK4steel has been evaluated by measuring the variation of both the yield strength

    and UTS when performing tensile test at different load cell velocities. The cor-

    responding results are shown in Fig. 7 and Table 5. Although a noticeable strain

    rate dependency can be observed on the yield strength, the maximum difference

    in the plastic responses (given for instance by the UTS values) is around 10%.

    This relatively small difference allows the application of the hardening parame-

    ters obtainedabove under lowload cell velocities to other deformation stiuations

    undergoing higher strain rates (e.g. a reasonable bound within which many real

    applications fit is ep

    < 0.1 s1 [1012,14]).

    A photographic tracking of the necking formation that develops at high

    levels of tensile elongation is sketched in Fig. 8 with the sake of qualitatively

    characterizing the fracture of this material. The necking evolution starts with

    two symmetric diffuse shear bands that progressively become more localised

    as the elongation increases. The severe thickness reduction that mainly takes

    place at the center of the sample causes a sudden initiation of a crack thatimmediately propagates in an unstable form along only one shear band that can

    be visually detected as a narrow groove inclined around 68 with respect to the

    axial direction of the specimen. It is seen that the grid drawn on the sample

    distorts until the very instant of crack propagation since from that time onwards

    thefurther deformation is completely confined to theshearbandwhere, as noted

    in [16], the plane stress condition is no longer valid.

    3.4. Hardness test

    The objective of the hardness measurements carried out in this work is two-

    fold: first, to check thesuitableness of thehardnessvalue foundfor theEK4 steel

    considered here and, second, to verify the well-known relationship stating the

    direct proportion between hardnessvaluesand strain hardening effects expressed

    by the variable Cp (see Eq. (4)). The hardness Rockwell unit in the scale 30T

    (HR30T) is used in the measurements done to original and deformed samples.

    Table6 summarizes theseresults. It is appreciated thatthe averagehardness value

    found for the original sample fits the standard requirements (according to [2],

    the corresponding maximum value is 50). Moreover, higher hardness values are

    Table 5

    Average parameters of EK4 steel obtained at different load cell velocities

    Load cell velocity (mm/min) Yield strength (MPa) UTS (MPa)

    2.5 183 285

    100 220 309

    250 232 312

    300 236 314

    400 243 316

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    456 C. Garca et al. / Journal of Materials Processing Technology 172 (2006) 451460

    Fig. 8. Necking formation evolution for different levels of elongation (magnification: 30).

    Table 6

    Hardness values of EK4 steel measured in the HR30T scale

    Original sample Deformed sample

    Zone 1 Zone 2 Zone 3 Zone 4 Zone 5 Zone 6 Zone 7

    Average 38.5 39.3 53.8 52.5 48.4 51.1 51.7 40.4

    Range () 1.3 0.7 1.8 2.9 3.6 3.2 2.8 3.6

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    C. Garca et al. / Journal of Materials Processing Technology 172 (2006) 451460 457

    observedin those zones thatexperienced larger strain hardening effects ratifying

    the validity of the above mentioned relationship.

    4. Numerical simulation of the tensile test

    The performance of the adopted constitutive model including

    the material parameters obtained via the experimental character-

    ization describedabove areboth assessed in thesimulation of the

    mechanical response during the tensile test of EK4 steel sheet

    samples. Some relevant features of the discretized formulation

    used in the analysis are concisely given below. A full description

    of it can be found in [7,9].

    4.1. Principle of virtual work

    The Hencky strainstress pair eTdescribed in Section 2 can

    be easily transformed to the usual Green-Lagrange strain E and

    second PiolaKirchhoff stress S. These last conjugated tensors

    present, as it is well-known, some practical advantages when

    solving the equilibrium equation through the principle of virtualwork whose expression is [17]:

    0

    ETSd0 =

    0

    uTB0 d0 +

    0

    uTt0 d0 (6)

    where 0 is the material configuration of a body subjected to

    a body force B0 and a traction force t0 on its boundary 0 and

    u is the displacement vector field. The mentioned strainstress

    transformations are, respectively, given by [7]:

    E =1

    2L

    T(2 1)L (7)

    and

    S= LTSLL (8)

    with 1 being the the unity tensor and

    [SL] =1

    2

    L

    TTL

    [SL] =2ln(/)

    (2 2)

    L

    TTL

    (9)

    Furthermore, the Cauchy stress tensor can be computed as

    [17]:

    =1

    det(F)FSFT

    4.2. Discretized formulation

    A simple rotation-free thin (KirchhoffLove) shell triangle

    is used in the simulation [7]. The basic idea of this discretized

    formulation is to combine the standard finite element interpo-

    lation with finite volume concepts which allows to express the

    curvatures over a control domain in terms of the displacement

    gradients along the domain edges. These gradients are in turn

    written as a function of the deflections of the nodes belonging to

    an element patch surrounding the control domain and this leads

    Fig. 9. Basic shell triangle (BST): element patch definition.

    Table 7

    Material properties of EK4 steel used in the simulations

    Youngs modulus (E) 212 GPa

    Poissons ratio (v) 0.32

    Yield strength (Cth) 183 MPa

    Hardening parameter (Ap) 566 MPa

    Hardening exponent (np) 0.345

    Average Lankfords coefficient (R) 1.65

    Fig. 10. Finite element mesh used in the simulation (mesh composed of 511

    shell elements and 292 nodes).

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    458 C. Garca et al. / Journal of Materials Processing Technology 172 (2006) 451460

    to a relationship between curvatures and nodal displacements.

    This three-node shell triangle termed BST (for basic shell trian-

    gle; see Fig. 9) has showed an excellent behaviour for both linear

    and non-linear analysis of shell structures. Moreover, a very

    good performance was observed when modelling large strain

    plasticity responses as those typically found in sheet stamping

    problems by using, in particular, the hyperelastic material con-

    stitutive model described in Section 2. Different aspects related

    to the accuracy and efficiency of this formulation are reported

    in [7,9].

    4.3. Results and discussion

    Based on the experimental characterization of the EK4 steel

    described above, the main objective of the present analysis is to

    validate the predictions of the material constitutive model with

    the experimental measurements obtained in the tensile test of

    sheet specimens.

    The material properties considered in the numerical analysis

    are shown in Table 7. The spatially non-uniform finite element

    mesh shown in Fig. 10 has been chosen in order to describe

    Fig. 11. Comparison between experimental and numerical results. (a) Engineering stressstrain curve. Results at the section undergoing extreme necking: (b) mean

    true axial stress vs. true deformation; (c) load vs. true deformation; (d) ratio of current to initial width (mean values along thickness); and (e) ratio of current to initial

    thickness (mean values along width).

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    C. Garca et al. / Journal of Materials Processing Technology 172 (2006) 451460 459

    correctly the large stress and deformation gradients expected in

    the necking zone. Due to symmetry, only one-fourth of the spec-

    imen is studied. Fitting the specifications of Fig. 3, the neck in

    the middle of the specimen is triggered by assuming a very small

    linear width variation along its length. The axial displacement

    imposed at the top boundary is denoted as Uand it is increased

    up to a value that corresponds to the fracture elongation (see

    Table 2). Moreover, four layers have been considered to per-

    form the numerical integration of the constitutive law along the

    sheet thickness [9].

    Fig. 11 shows a comparison between experimental and

    numerical results for the engineering stressstrain relationship

    and some variables at the section undergoing extreme necking:

    the mean true axial stress and load both against the true (loga-

    rithmic) deformation and, in addition, the width and thickness

    ratios versus the elongation. These curves include experimen-

    tal measurements corresponding to specimens oriented at 0, 45

    and 90 with respect to the rolling direction. An overall good

    agreement between the numerical predictions and the average

    experimental values can be observed in these curves. The rel-atively small differences can be considered as approximately

    bounded within the experimental uncertainty range.

    The experimentalnumerical discrepancies appearing in the

    engineering stressstrain curve can be mainly attributed to the

    inaccuracy of the potential correlation at the beginning of the

    plastic region. The experimentally measured load decreases

    from an elongation of 35% or, equivalently, to a logarithmic

    deformation of 0.38 onwards. The corresponding deformations

    provided by the simulation are very similar to these values. As

    already commented on in Section 3.3, a geometrical instability

    (instead of a constitutive one) caused by the necking formation

    occurs since the mean true axial stress continues increasing until

    the fracture stage. Moreover, note that the well-known simplified

    condition [14] stating that the related logarithmic deformation

    at the point of maximum load has to be equal to the hardening

    exponent is approximately verified in this case. At high levels

    of deformation, the regions of the specimen outside the necking

    zone are being elastically unloaded.

    The numerical predictions for the mean w/w0 and t/t0 ratios

    match the normal anisotropy condition quantified by the Lank-

    fords coefficient (see Section 3.3). This is apparent at the begin-

    ning of the test, where a uniaxial stress is achieved, since the

    reduction in t/t0 is, as expected, lower than that of w/w0. In this

    case, the following relationship (ww0)/w0 R(t t0)/t0 is

    approximately fulfilled. Once the neck is formed, a reverse trendis found, i.e. a stronger variation in t/t0 is observed such that

    (ww0)/w0 < R(t t0)/t0.

    Although the hardening parametershave beenexperimentally

    derived within an elongation range upperly bounded by the point

    for which the load starts decreasing, the reasonably good fitting

    Fig. 12. Effective plastic deformation contours for an elongation of 43.2%: (a) whole sample and (b) detail at the necking zone.

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    of thenumerical results to theexperimental ones shownin Fig.11

    confirms the validity of the material characterization carried out

    in Section 2 even beyond such point.

    The effective plastic deformation contours at a deformation

    stage close to the rupture of the specimen are sketched in Fig. 12.

    A non-uniform distribution is clearly obtained due to the com-

    plex deformation pattern of the neck. A diffuse shear band

    development canalso be appreciated where its slope nearly coin-

    cides with that observed in the experiments (see Section 3.3). It

    should be mentioned, however, that the constitutive model used

    in the simulation cannot cope with the modelling of damage and

    crack propagation effects.

    5. Conclusions

    A detailed experimental characterization of the EK4 deep

    drawing steel has been presented. In particular, the low disper-

    sion found in the experimental data measured during the tensile

    test allowed a consistent derivation of some material parame-

    ters which, in turn, are involved in a constitutive model that wassubsequently used to simulate the material response during such

    deformation process. The experimental validation of the numer-

    ical results has been satisfactory. Hence, the procedure followed

    to characterize the mechanical behaviour of this material has

    proved to be a basic and useful tool to undertake a realistic

    experimentally-based modelling of complex sheet forming pro-

    cesses.

    Acknowledgements

    The supports provided by the Chilean Council of Research

    and Technology CONICYT (FONDECYT Projects No.

    1020026 and 7020026) and the Department of Technological

    and Scientific Research at the University of Santiago de Chile

    (DICYT-USACH) are gratefully acknowledged. The authors

    wish to express their appreciation to the Aeronautical Techni-

    cal Academy at Santiago de Chile and the Compa na Tecno-

    Industrial (CTI) for the provision of experimental facilities.

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