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Mechanical and damage analysis along a flat-rolled wire cold forming schedule

Abstract : Numerical simulation is used to study patented high-C steel flat-rolled wire cold forming processes. An elasto-plastic power law, identified from mechanical tests, is used into Forge2005® finite element (FEM) package in order to describe the material behaviour during wire drawing followed by cold rolling. A through-process approach has been favoured, transferring residual wire-drawing stresses and strain into the flat-rolling preform. This mechanical analysis, associated with a triaxiality study, points to dangerous areas where fracture may initiate due to high tensile stresses. Lemaître's isotropic damage criterion, including crack closure effect, a -1/3 cut-off value of stress triaxiality, and tension/compression damage asymmetry, has been used and has confirmed the previous analysis. A number of non-coalesced voids nucleated on inclusions have been observed in the Scanning Electron Microscopy (SEM), especially in high-deformation zones ("blacksmith's cross"). Their evolution has been simulated in the FEM model using spherical numerical markers, which deform into oblate or prolate ellipsoids. The deformation-induced morphological evolution of voids observed in the SEM compares well with the geometrical evolution of the markers, which suggests that the morphologies observed do not result from micro-crack propagation, but from material transport of the nucleated voids.
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Submitted on : Thursday, March 24, 2011 - 11:21:34 AM
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Thomas Massé, Yvan Chastel, Pierre Montmitonnet, Christian Bobadilla, Nicolas Persem, et al.. Mechanical and damage analysis along a flat-rolled wire cold forming schedule. International Journal of Material Forming, Springer Verlag, 2012, 5 (2), pp.129-146. ⟨10.1007/s12289-011-1032-0⟩. ⟨hal-00579556⟩



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