A Flow Stress Model of the AA3104-H19 Alloy for the FEM Simulation of the Beverage Can Manufacturing Process under Large Plastic Deformations
Abstract
:1. Introduction
2. Materials and Methods
2.1. Technological Process
2.2. Existing Flow Stress Model of the AA3104-H19 Alloy for Large Plastic Deformations
2.3. Numerical Simulations
2.4. Development of Specimens for the Plastometric Tests
2.5. Calibration of the Flow Stress Model
3. Results of the Experimental Study
3.1. Tensile Tests of the Blank Material
3.2. Calibration of the New Flow Stress Model
4. Discussion
5. Conclusions
- A methodology was developed to determine the flow stress model of the AA3104-H19 alloy for large plastic deformations;
- Since it was not possible to cut the standard samples for the plastometric tests from the wall of the beverage can, a miniaturized specimen was developed and verified;
- A numerical model of the beverage can manufacturing process was used to determine the locations of the samples for the plastometric tests and the effective strain in the center of those samples;
- The developed flow stress model covers the range of the actual effective strain in the beverage can manufacturing process up to 2.0. This model also takes into consideration the deformation history and the Bauschinger effect;
- The developed model describes the flow characteristics of the material much more effectively than the model provided by the sheet metal supplier. This results in a better representation of the material thickness in the simulation process. On the cup and redraw operations, the difference in thickness relative to the actual thickness decreased from 5 to 1 and 11.5 to 0.5 µm, respectively;
- The presented flow stress model can be used in the development process of beverage can shaping and manufacturing technology.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Grade Designation | Si | Fe | Cu | Mn | Mg | Zn | Ga | V | Ti | Unspecified Other Elements | Al | |
---|---|---|---|---|---|---|---|---|---|---|---|---|
Each | Total | |||||||||||
3104 | 0.176 ± 0.009 | 0.431 ± 0.003 | 0.129 ± 0.001 | 0.833 ± 0.005 | 1.191 ± 0.020 | 0.032 ± 0.001 | 0.009 ± 0.001 | 0.031 ± 0.002 | 0.015 ± 0.002 | - | 0.071 ± 0.002 | 97.082 ± 0.162 |
Sample Type | a0 (mm) | b0 (mm) | S0 (mm2) | YS (MPa) | UTS (MPa) | A (%) |
---|---|---|---|---|---|---|
Standard sample | 0.240 ± 0.001 | 12.51 ± 0.03 | 3.008 ± 0.005 | 286.74 ± 1.43 | 315.31 ± 1.16 | 4.92 ± 0.36 |
Miniature sample | 0.240 ± 0.001 | 10.00 ± 0.07 | 2.404 ± 0.019 | 286.10 ± 0.93 | 318.33 ± 0.33 | 6.10 ± 0.39 |
Forming Step | a0 (mm) | b0 (mm) | YS (MPa) | UTS (MPa) | A (%) |
---|---|---|---|---|---|
cupping | 0.245 ± 0.0010 | 10.01 ± 0.01 | 293.65 ± 1.05 | 328.10 ± 0.60 | 2.46 ± 0.06 |
redrawing | 0.239 ± 0.0015 | 10.01 ± 0.01 | 290.15 ± 0.85 | 325.95 ± 0.85 | 1.52 ± 0.48 |
ironing #1 | 0.206 ± 0.0005 | 9.98 ± 0.03 | 301.20 ± 5.92 | 330.97 ± 0.33 | 1.41 ± 0.33 |
ironing #2 | 0.158 ± 0.0005 | 9.92 ± 0.01 | 320.70 ± 0.20 | 351.00 ± 0.60 | 0.92 ± 0.08 |
ironing #3 | 0.099 ± 0.0005 | 9.86 ± 0.05 | 345.80 ± 2.60 | 374.05 ± 2.65 | 0.72 ± 0.12 |
A | m1 | m2 | m3 | m4 |
---|---|---|---|---|
377.524 | 0.024674 | −0.00088 | −0.73833 | 0.4027 |
A | m1 | m2 | m3 | m4 |
---|---|---|---|---|
376.974 | 0.02430 | −0.000879 | −0.7217 | 0.3921 |
Numerical Models and Measurement | The Thickness of Can Wall in Material Point P (µm) | ||||
---|---|---|---|---|---|
Cupping | Redrawing | Ironing #1 | Ironing #2 | Ironing #3 | |
Existing flow stress model (Equation (1)) | 250 | 251 | 209 | 158 | 99 |
Proposed flow stress model (Equation (2)) | 246 | 239 | 208 | 158 | 99 |
Mean value of measured specimens | 245 | 239.5 | 205.7 | 157.5 | 98.5 |
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Wędrychowicz, P.; Kustra, P.; Paćko, M.; Milenin, A. A Flow Stress Model of the AA3104-H19 Alloy for the FEM Simulation of the Beverage Can Manufacturing Process under Large Plastic Deformations. Materials 2021, 14, 6408. https://doi.org/10.3390/ma14216408
Wędrychowicz P, Kustra P, Paćko M, Milenin A. A Flow Stress Model of the AA3104-H19 Alloy for the FEM Simulation of the Beverage Can Manufacturing Process under Large Plastic Deformations. Materials. 2021; 14(21):6408. https://doi.org/10.3390/ma14216408
Chicago/Turabian StyleWędrychowicz, Przemysław, Piotr Kustra, Marek Paćko, and Andrij Milenin. 2021. "A Flow Stress Model of the AA3104-H19 Alloy for the FEM Simulation of the Beverage Can Manufacturing Process under Large Plastic Deformations" Materials 14, no. 21: 6408. https://doi.org/10.3390/ma14216408