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Process-informed material model selection

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ESAFORM 2023 Mariana Conde, Sam Coppieters, António Andrade-Campos Department of Mechanical Engineering, TEMA - Centre for Mechanical Technology and Automation, LASI – Intelligent Systems Associate Laboratory, University of Aveiro, Portugal Department of Materials Engineering, KU Leuven, Belgium

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Process-informed material model selection Mariana Conde1,*, Sam Coppieters2, António Andrade-Campos1 1Department of Mechanical Engineering, TEMA - Centre for Mechanical Technology and Automation, LASI – Intelligent Systems Associate Laboratory, University of Aveiro, Portugal 2Department of Materials Engineering, KU Leuven, Belgium *marianaconde@ua.pt
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Introduction and framework Virtualization of processes Virtualization and realistic simulations • Adequate constitutive model • Accurately identified parameters Development and manufacturing • Precise results • No delays • No waste Industries • High quality • Low costs • High efficiency Images source: https://unsplash.com/photos/jHZ70nRk7Ns ; https://unsplash.com/photos/SVUqHTVyn6w ; https://unsplash.com/photos/t9DooibgMEk
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Introduction and framework Virtualization of processes Virtualization and realistic simulations • Adequate constitutive model • Accurately identified parameters Development and manufacturing • Precise results • No delays • No waste Industries • High quality • Low costs • High efficiency Images source: https://unsplash.com/photos/jHZ70nRk7Ns ; https://unsplash.com/photos/SVUqHTVyn6w ; https://unsplash.com/photos/t9DooibgMEk
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Introduction and framework Virtualization of processes Virtualization and realistic simulations • Adequate constitutive model • Accurately identified parameters Development and manufacturing • Precise results • No delays • No waste Industries • High quality • Low costs • High efficiency Images source: https://unsplash.com/photos/jHZ70nRk7Ns ; https://unsplash.com/photos/SVUqHTVyn6w ; https://unsplash.com/photos/t9DooibgMEk
Isotropic hardening laws Yield functions International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland Kinematic hardening laws Damage models M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Introduction and framework Material constitutive models in the literature
Isotropic hardening laws Yield functions International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland Kinematic hardening laws Damage models M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Introduction and framework Material constitutive models in the literature
Isotropic hardening laws Yield functions International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland Kinematic hardening laws Damage models M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Introduction and framework Material constitutive models in the literature
Kinematic hardening laws Damage models Isotropic hardening laws Yield functions International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland Introduction and framework Material constitutive models in the literature M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection
Kinematic hardening laws Damage models Isotropic hardening laws Yield functions International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland Introduction and framework Material constitutive models in the literature M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Bauschinger effect
Kinematic hardening laws Damage models Isotropic hardening laws Yield functions International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland Introduction and framework Material constitutive models in the literature M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Springback Bauschinger effect TRIP
Kinematic hardening laws Damage models Isotropic hardening laws Yield functions International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland Introduction and framework Material constitutive models in the literature M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Springback Ratcheting Twinning Bauschinger effect TRIP
Isotropic hardening laws Yield functions International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland Kinematic hardening laws Damage models Introduction and framework Material constitutive models in the literature More than 1300possible combinations of models M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Introduction and framework Material constitutive models selection in the literature Brute-force Direct comparison Numerical and experimental data Model calibration Several different models Laboured task Requires specialized knowledge Time consuming task Experimental data generation and analysis Non-precise selection strategy Geometrical measurement, load displacement curve or yield loci plot Limited analysis Model, material, mechanical phenomenon and mechanical process Ben-Elechi et al. 2021; Chatziioannou et al. 2021; Prakash et al. 2020; Kilic et al. 2018; Hou et al. 2017; Barros et al. 2016; Lin et al. 2020; Moreira et al. 2014; Oliveira et al. 2007; Laurent et al. 2009; Nedoushan et al. 2014; Tuo et al. 2021.
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Introduction and framework Material constitutive models selection in the literature Automatic selection tool Direct comparison Numerical and experimental data Model calibration Several different models Laboured task Requires specialized knowledge Time consuming task Experimental data generation and analysis Non-precise selection strategy Geometrical measurement, load displacement curve or yield loci plot Limited analysis Model, material, mechanical phenomenon and mechanical process Ben-Elechi et al. 2021; Chatziioannou et al. 2021; Prakash et al. 2020; Kilic et al. 2018; Hou et al. 2017; Barros et al. 2016; Lin et al. 2020; Moreira et al. 2014; Oliveira et al. 2007; Laurent et al. 2009; Nedoushan et al. 2014; Tuo et al. 2021.
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Application of the proposed solution Unknown numerical material behaviour How to model the material behavior? What constitutive models? What material parameters?
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Application of the proposed solution Unknown numerical material behaviour • DP600 dual-phase steel • AA3104 aluminium alloy • Material parameters from literature
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Application of the proposed solution Constitutive models and materials DP600 Elastic properties E [Gpa] ν 210.000 0.300 Swift law K [Mpa] 𝜀0 n 979.460 0.00535 0.194 Voce law 𝜎y0 Q b 815.600 407.922 7.869 Yld2000-2d criterion 𝛼1 𝛼2 𝛼3 𝛼4 𝛼5 𝛼6 𝛼7 𝛼8 a 1.011 0.964 1.191 0.995 1.010 1.018 0.977 0.935 6.00 A-F model C [Mpa] 𝛾 28896.000 121.000
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Application of the proposed solution Constitutive models and materials AA3104 Elastic properties E [Gpa] ν 68.950 0.330 Swift law K [Mpa] 𝜀0 n 363.128 0.000229 0.0275 Voce law 𝜎y0 Q b 351.260 62.400 27.205 Yld2000-2d criterion 𝛼1 𝛼2 𝛼3 𝛼4 𝛼5 𝛼6 𝛼7 𝛼8 a 0.594 1.177 0.818 0.892 0.967 0.627 0.947 1.152 8.00 A-F model C [Mpa] 𝛾 22885.000 400.000
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Application of the proposed solution Unknown numerical material behaviour How to get more accuracy in simulations? What constitutive models should I use to improve the calibration? Is kinematic hardening relevant? Or anisotropy?
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Proposed solution Process-informed material model selection Sheet metal forming simulation Selected constitutive models Material parameters Simulation specifications Measurements of interest/critical for the process ANOVA analysis Constitute models importance ranking Mechanical process configuration Constitutive models (UMMDp)
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Proposed solution Process-informed material model selection Sheet metal forming simulation Selected constitutive models Material parameters Simulation specifications Measurements of interest/critical for the process ANOVA analysis Constitute models importance ranking Mechanical process configuration Constitutive models (UMMDp)
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Proposed solution Process-informed material model selection Sheet metal forming simulation Selected constitutive models Material parameters Simulation specifications Measurements of interest/critical for the process ANOVA analysis Constitute models importance ranking Mechanical process configuration Constitutive models (UMMDp)
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Proposed solution Process-informed material model selection Sheet metal forming simulation Selected constitutive models Material parameters Simulation specifications Measurements of interest/critical for the process ANOVA analysis Constitute models importance ranking Mechanical process configuration Constitutive models (UMMDp)
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Proposed solution Process-informed material model selection Sheet metal forming simulation Selected constitutive models Material parameters Simulation specifications Measurements of interest/critical for the process ANOVA analysis Constitute models importance ranking Mechanical process configuration Constitutive models (UMMDp)
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Proposed solution Process-informed material model selection Sheet metal forming simulation Selected constitutive models Material parameters Simulation specifications Measurements of interest/critical for the process ANOVA analysis Constitute models importance ranking Mechanical process configuration Constitutive models (UMMDp)
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Proposed solution Process-informed material model selection Sheet metal forming simulation Selected constitutive models Material parameters Simulation specifications Measurements of interest/critical for the process ANOVA analysis Constitute models importance ranking Mechanical process configuration Constitutive models (UMMDp)
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Proposed solution Process-informed material model selection Sheet metal forming simulation Selected constitutive models Material parameters Simulation specifications Measurements of interest/critical for the process ANOVA analysis Constitute models importance ranking Mechanical process configuration Constitutive models (UMMDp)
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Proposed solution Process-informed material model selection Sheet metal forming simulation Selected constitutive models Material parameters Simulation specifications Measurements of interest/critical for the process ANOVA analysis Constitute models importance ranking Mechanical process configuration Constitutive models (UMMDp)
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Implementation Mechanical process configuration Hole expansion test configuration Blank with 0.8 mm thickness R12 R12 55 50 Punch Die 35 150
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Implementation Simulation specifications Abaqus/Standard software Blank: 3D deformable shell revolution Tools: 3D analytical rigid shell revolution R12 R12 55 50 Punch Die
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Implementation Simulation specifications Step-1: Punch with displacement condition Blank fixed in outer edge Die fixed Punch Die
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Implementation Simulation specifications Step-1: Punch with displacement condition Blank fixed in outer edge Die fixed Punch Die
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Implementation Simulation specifications Step-2: Tools release Springback observation Punch Die
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Implementation Simulation specifications Structured mesh 6400 elements 9 integration points along thickness S4R (4-node shell) elements with reduced integration
Type of constitutive model Forming simulation observable International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Implementation ANOVA approach ANOVA Independent variables (groups): Isotropic hardening law Yield criterion Kinematic hardening law Dependent variables: Hole’s circularity Maximum punch force Springback factor
Type of constitutive model Forming simulation observable International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Implementation ANOVA approach ANOVA The null hypothesis is that there is no difference among the groups’ means The alternative hypothesis is that the averages are not all equal If any group means is significantly different from the overall mean, the null hypothesis is rejected. This is observed with the p-value
Type of constitutive model Forming simulation observable International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Implementation ANOVA approach ANOVA The p-value is the probability of obtaining the observed results, assuming that the null hypothesis is true A p-value lower than 0.05 considers the statistical meaning of the analysed group The smaller the p-value is, the more significant is the result
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Implementation 3-way ANOVA analysis Run Isotropic hardening law Yield function Kinematic hardening law 1 Voce’s law von Mises Not considered 2 Voce’s law von Mises A-F model 3 Voce’s law Yld2000-2D Not considered 4 Voce’s law Yld2000-2D A-F model 5 Swift’s law von Mises Not considered 6 Swift’s law von Mises A-F model 7 Swift’s law Yld2000-2D Not considered 8 Swift’s law Yld2000-2D A-F model
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Results Simulations’ output Run 1 2 3 4 5 6 7 8 IHL V V V V S S S S YF vM vM Y2000 Y2000 vM vM Y2000 Y2000 KHL None A-F None A-F None A-F None A-F
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland Factors Hole’s circularity p- value Maximum punch force p- value Springback factor p-value p-value average Ranking DP600 Isotropic hardening law 7.131E-1 1.078E-8 2.534E-7 2.377E-1 2 Yield function 2.342E-4 1.436E-2 9.715E-1 3.287E-1 3 Kinematic hardening law 1.282E-1 8.716E-8 1.444E-6 4.274E-2 1 AA3104 Isotropic hardening law 2.020E-1 3.099E-4 9.909E-6 6.743E-2 2 Yield function 6.778E-4 8.624E-2 1.037E-5 2.898E-2 1 Kinematic hardening law 4.913E-1 2.881E-4 1.569E-5 1.639E-1 3 M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Results ANOVA analysis
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Results DP600 Strain path changes 44 39 35 18
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Results AA3104 Strain path changes 44 39 35 18
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland Factors Hole’s circularity p- value Maximum punch force p- value Springback factor p-value p-value average Ranking DP600 Isotropic hardening law 7.131E-1 1.078E-8 2.534E-7 2.377E-1 2 Yield function 2.342E-4 1.436E-2 9.715E-1 3.287E-1 3 Kinematic hardening law 1.282E-1 8.716E-8 1.444E-6 4.274E-2 1 AA3104 Isotropic hardening law 2.020E-1 3.099E-4 9.909E-6 6.743E-2 2 Yield function 6.778E-4 8.624E-2 1.037E-5 2.898E-2 1 Kinematic hardening law 4.913E-1 2.881E-4 1.569E-5 1.639E-1 3 M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Results ANOVA analysis
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Results Materials anisotropic behaviour
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland • A process-informed material constitutive model comparison and selection strategy was proposed • ANOVA was used to find a relation between the constitutive models and the measurements of interest in a forming simulation • A model’s importance ranking was established based on the p- values • This information can conduct the model calibration procedure in a more efficient way • This methodology is limited to the process and material used M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Conclusions Overall results
International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland • The hole expansion test was studied with a dual-phase steel and an aluminium alloy • For the steel, the most important model type was the kinematic hardening law and the least important was the yield function • For the aluminum, the most important was the yield function, whereas the least important was the kinematic hardening law • This was expected by empirical knowledge and this automatic strategy confirmed it M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Conclusions Specific results
Process-informed material model selection Mariana Conde1,*, Sam Coppieters2, António Andrade-Campos1 1Department of Mechanical Engineering, TEMA - Centre for Mechanical Technology and Automation, LASI – Intelligent Systems Associate Laboratory, University of Aveiro, Portugal 2Department of Materials Engineering, KU Leuven, Belgium *marianaconde@ua.pt

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Process-informed material model selection

  • 1. Process-informed material model selection Mariana Conde1,*, Sam Coppieters2, António Andrade-Campos1 1Department of Mechanical Engineering, TEMA - Centre for Mechanical Technology and Automation, LASI – Intelligent Systems Associate Laboratory, University of Aveiro, Portugal 2Department of Materials Engineering, KU Leuven, Belgium *marianaconde@ua.pt
  • 2. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Introduction and framework Virtualization of processes Virtualization and realistic simulations • Adequate constitutive model • Accurately identified parameters Development and manufacturing • Precise results • No delays • No waste Industries • High quality • Low costs • High efficiency Images source: https://unsplash.com/photos/jHZ70nRk7Ns ; https://unsplash.com/photos/SVUqHTVyn6w ; https://unsplash.com/photos/t9DooibgMEk
  • 3. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Introduction and framework Virtualization of processes Virtualization and realistic simulations • Adequate constitutive model • Accurately identified parameters Development and manufacturing • Precise results • No delays • No waste Industries • High quality • Low costs • High efficiency Images source: https://unsplash.com/photos/jHZ70nRk7Ns ; https://unsplash.com/photos/SVUqHTVyn6w ; https://unsplash.com/photos/t9DooibgMEk
  • 4. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Introduction and framework Virtualization of processes Virtualization and realistic simulations • Adequate constitutive model • Accurately identified parameters Development and manufacturing • Precise results • No delays • No waste Industries • High quality • Low costs • High efficiency Images source: https://unsplash.com/photos/jHZ70nRk7Ns ; https://unsplash.com/photos/SVUqHTVyn6w ; https://unsplash.com/photos/t9DooibgMEk
  • 5. Isotropic hardening laws Yield functions International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland Kinematic hardening laws Damage models M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Introduction and framework Material constitutive models in the literature
  • 6. Isotropic hardening laws Yield functions International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland Kinematic hardening laws Damage models M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Introduction and framework Material constitutive models in the literature
  • 7. Isotropic hardening laws Yield functions International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland Kinematic hardening laws Damage models M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Introduction and framework Material constitutive models in the literature
  • 8. Kinematic hardening laws Damage models Isotropic hardening laws Yield functions International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland Introduction and framework Material constitutive models in the literature M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection
  • 9. Kinematic hardening laws Damage models Isotropic hardening laws Yield functions International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland Introduction and framework Material constitutive models in the literature M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Bauschinger effect
  • 10. Kinematic hardening laws Damage models Isotropic hardening laws Yield functions International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland Introduction and framework Material constitutive models in the literature M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Springback Bauschinger effect TRIP
  • 11. Kinematic hardening laws Damage models Isotropic hardening laws Yield functions International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland Introduction and framework Material constitutive models in the literature M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Springback Ratcheting Twinning Bauschinger effect TRIP
  • 12. Isotropic hardening laws Yield functions International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland Kinematic hardening laws Damage models Introduction and framework Material constitutive models in the literature More than 1300possible combinations of models M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection
  • 13. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Introduction and framework Material constitutive models selection in the literature Brute-force Direct comparison Numerical and experimental data Model calibration Several different models Laboured task Requires specialized knowledge Time consuming task Experimental data generation and analysis Non-precise selection strategy Geometrical measurement, load displacement curve or yield loci plot Limited analysis Model, material, mechanical phenomenon and mechanical process Ben-Elechi et al. 2021; Chatziioannou et al. 2021; Prakash et al. 2020; Kilic et al. 2018; Hou et al. 2017; Barros et al. 2016; Lin et al. 2020; Moreira et al. 2014; Oliveira et al. 2007; Laurent et al. 2009; Nedoushan et al. 2014; Tuo et al. 2021.
  • 14. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Introduction and framework Material constitutive models selection in the literature Automatic selection tool Direct comparison Numerical and experimental data Model calibration Several different models Laboured task Requires specialized knowledge Time consuming task Experimental data generation and analysis Non-precise selection strategy Geometrical measurement, load displacement curve or yield loci plot Limited analysis Model, material, mechanical phenomenon and mechanical process Ben-Elechi et al. 2021; Chatziioannou et al. 2021; Prakash et al. 2020; Kilic et al. 2018; Hou et al. 2017; Barros et al. 2016; Lin et al. 2020; Moreira et al. 2014; Oliveira et al. 2007; Laurent et al. 2009; Nedoushan et al. 2014; Tuo et al. 2021.
  • 15. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Application of the proposed solution Unknown numerical material behaviour How to model the material behavior? What constitutive models? What material parameters?
  • 16. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Application of the proposed solution Unknown numerical material behaviour • DP600 dual-phase steel • AA3104 aluminium alloy • Material parameters from literature
  • 17. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Application of the proposed solution Constitutive models and materials DP600 Elastic properties E [Gpa] ν 210.000 0.300 Swift law K [Mpa] 𝜀0 n 979.460 0.00535 0.194 Voce law 𝜎y0 Q b 815.600 407.922 7.869 Yld2000-2d criterion 𝛼1 𝛼2 𝛼3 𝛼4 𝛼5 𝛼6 𝛼7 𝛼8 a 1.011 0.964 1.191 0.995 1.010 1.018 0.977 0.935 6.00 A-F model C [Mpa] 𝛾 28896.000 121.000
  • 18. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Application of the proposed solution Constitutive models and materials AA3104 Elastic properties E [Gpa] ν 68.950 0.330 Swift law K [Mpa] 𝜀0 n 363.128 0.000229 0.0275 Voce law 𝜎y0 Q b 351.260 62.400 27.205 Yld2000-2d criterion 𝛼1 𝛼2 𝛼3 𝛼4 𝛼5 𝛼6 𝛼7 𝛼8 a 0.594 1.177 0.818 0.892 0.967 0.627 0.947 1.152 8.00 A-F model C [Mpa] 𝛾 22885.000 400.000
  • 19. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Application of the proposed solution Unknown numerical material behaviour How to get more accuracy in simulations? What constitutive models should I use to improve the calibration? Is kinematic hardening relevant? Or anisotropy?
  • 20. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Proposed solution Process-informed material model selection Sheet metal forming simulation Selected constitutive models Material parameters Simulation specifications Measurements of interest/critical for the process ANOVA analysis Constitute models importance ranking Mechanical process configuration Constitutive models (UMMDp)
  • 21. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Proposed solution Process-informed material model selection Sheet metal forming simulation Selected constitutive models Material parameters Simulation specifications Measurements of interest/critical for the process ANOVA analysis Constitute models importance ranking Mechanical process configuration Constitutive models (UMMDp)
  • 22. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Proposed solution Process-informed material model selection Sheet metal forming simulation Selected constitutive models Material parameters Simulation specifications Measurements of interest/critical for the process ANOVA analysis Constitute models importance ranking Mechanical process configuration Constitutive models (UMMDp)
  • 23. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Proposed solution Process-informed material model selection Sheet metal forming simulation Selected constitutive models Material parameters Simulation specifications Measurements of interest/critical for the process ANOVA analysis Constitute models importance ranking Mechanical process configuration Constitutive models (UMMDp)
  • 24. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Proposed solution Process-informed material model selection Sheet metal forming simulation Selected constitutive models Material parameters Simulation specifications Measurements of interest/critical for the process ANOVA analysis Constitute models importance ranking Mechanical process configuration Constitutive models (UMMDp)
  • 25. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Proposed solution Process-informed material model selection Sheet metal forming simulation Selected constitutive models Material parameters Simulation specifications Measurements of interest/critical for the process ANOVA analysis Constitute models importance ranking Mechanical process configuration Constitutive models (UMMDp)
  • 26. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Proposed solution Process-informed material model selection Sheet metal forming simulation Selected constitutive models Material parameters Simulation specifications Measurements of interest/critical for the process ANOVA analysis Constitute models importance ranking Mechanical process configuration Constitutive models (UMMDp)
  • 27. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Proposed solution Process-informed material model selection Sheet metal forming simulation Selected constitutive models Material parameters Simulation specifications Measurements of interest/critical for the process ANOVA analysis Constitute models importance ranking Mechanical process configuration Constitutive models (UMMDp)
  • 28. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Proposed solution Process-informed material model selection Sheet metal forming simulation Selected constitutive models Material parameters Simulation specifications Measurements of interest/critical for the process ANOVA analysis Constitute models importance ranking Mechanical process configuration Constitutive models (UMMDp)
  • 29. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Implementation Mechanical process configuration Hole expansion test configuration Blank with 0.8 mm thickness R12 R12 55 50 Punch Die 35 150
  • 30. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Implementation Simulation specifications Abaqus/Standard software Blank: 3D deformable shell revolution Tools: 3D analytical rigid shell revolution R12 R12 55 50 Punch Die
  • 31. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Implementation Simulation specifications Step-1: Punch with displacement condition Blank fixed in outer edge Die fixed Punch Die
  • 32. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Implementation Simulation specifications Step-1: Punch with displacement condition Blank fixed in outer edge Die fixed Punch Die
  • 33. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Implementation Simulation specifications Step-2: Tools release Springback observation Punch Die
  • 34. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Implementation Simulation specifications Structured mesh 6400 elements 9 integration points along thickness S4R (4-node shell) elements with reduced integration
  • 35. Type of constitutive model Forming simulation observable International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Implementation ANOVA approach ANOVA Independent variables (groups): Isotropic hardening law Yield criterion Kinematic hardening law Dependent variables: Hole’s circularity Maximum punch force Springback factor
  • 36. Type of constitutive model Forming simulation observable International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Implementation ANOVA approach ANOVA The null hypothesis is that there is no difference among the groups’ means The alternative hypothesis is that the averages are not all equal If any group means is significantly different from the overall mean, the null hypothesis is rejected. This is observed with the p-value
  • 37. Type of constitutive model Forming simulation observable International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Implementation ANOVA approach ANOVA The p-value is the probability of obtaining the observed results, assuming that the null hypothesis is true A p-value lower than 0.05 considers the statistical meaning of the analysed group The smaller the p-value is, the more significant is the result
  • 38. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Implementation 3-way ANOVA analysis Run Isotropic hardening law Yield function Kinematic hardening law 1 Voce’s law von Mises Not considered 2 Voce’s law von Mises A-F model 3 Voce’s law Yld2000-2D Not considered 4 Voce’s law Yld2000-2D A-F model 5 Swift’s law von Mises Not considered 6 Swift’s law von Mises A-F model 7 Swift’s law Yld2000-2D Not considered 8 Swift’s law Yld2000-2D A-F model
  • 39. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Results Simulations’ output Run 1 2 3 4 5 6 7 8 IHL V V V V S S S S YF vM vM Y2000 Y2000 vM vM Y2000 Y2000 KHL None A-F None A-F None A-F None A-F
  • 40. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland Factors Hole’s circularity p- value Maximum punch force p- value Springback factor p-value p-value average Ranking DP600 Isotropic hardening law 7.131E-1 1.078E-8 2.534E-7 2.377E-1 2 Yield function 2.342E-4 1.436E-2 9.715E-1 3.287E-1 3 Kinematic hardening law 1.282E-1 8.716E-8 1.444E-6 4.274E-2 1 AA3104 Isotropic hardening law 2.020E-1 3.099E-4 9.909E-6 6.743E-2 2 Yield function 6.778E-4 8.624E-2 1.037E-5 2.898E-2 1 Kinematic hardening law 4.913E-1 2.881E-4 1.569E-5 1.639E-1 3 M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Results ANOVA analysis
  • 41. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Results DP600 Strain path changes 44 39 35 18
  • 42. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Results AA3104 Strain path changes 44 39 35 18
  • 43. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland Factors Hole’s circularity p- value Maximum punch force p- value Springback factor p-value p-value average Ranking DP600 Isotropic hardening law 7.131E-1 1.078E-8 2.534E-7 2.377E-1 2 Yield function 2.342E-4 1.436E-2 9.715E-1 3.287E-1 3 Kinematic hardening law 1.282E-1 8.716E-8 1.444E-6 4.274E-2 1 AA3104 Isotropic hardening law 2.020E-1 3.099E-4 9.909E-6 6.743E-2 2 Yield function 6.778E-4 8.624E-2 1.037E-5 2.898E-2 1 Kinematic hardening law 4.913E-1 2.881E-4 1.569E-5 1.639E-1 3 M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Results ANOVA analysis
  • 44. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Results Materials anisotropic behaviour
  • 45. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland • A process-informed material constitutive model comparison and selection strategy was proposed • ANOVA was used to find a relation between the constitutive models and the measurements of interest in a forming simulation • A model’s importance ranking was established based on the p- values • This information can conduct the model calibration procedure in a more efficient way • This methodology is limited to the process and material used M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Conclusions Overall results
  • 46. International ESAFORM Conference on Material Forming, April 19-21 2023, Kraków, Poland • The hole expansion test was studied with a dual-phase steel and an aluminium alloy • For the steel, the most important model type was the kinematic hardening law and the least important was the yield function • For the aluminum, the most important was the yield function, whereas the least important was the kinematic hardening law • This was expected by empirical knowledge and this automatic strategy confirmed it M. Conde, S. Coppieters, A. Andrade-Campos, Process-informed material model selection Conclusions Specific results
  • 47. Process-informed material model selection Mariana Conde1,*, Sam Coppieters2, António Andrade-Campos1 1Department of Mechanical Engineering, TEMA - Centre for Mechanical Technology and Automation, LASI – Intelligent Systems Associate Laboratory, University of Aveiro, Portugal 2Department of Materials Engineering, KU Leuven, Belgium *marianaconde@ua.pt

Editor's Notes

  1. Demand of industries quality, low costs and efficiency
  2. The development and manufacturing processes should have precise results, no delays and no waste
  3. Virtualization and realistic simulation are required and for that it is necessary an adequate constitutive model and accurately identified parameters
  4. Regarding the constitutive models, several models have been proposed in the literature (give examples of types,…)
  5. Regarding the constitutive models, several models have been proposed in the literature (give examples of types,…)
  6. Regarding the constitutive models, several models have been proposed in the literature (give examples of types,…)
  7. Regarding the constitutive models, several models have been proposed in the literature (give examples of types,…)
  8. Some models account for different types of mech phenomena such as Bauschinger effect, TRIP, springback,…
  9. Some models account for different types of mech phenomena such as Bauschinger effect, springback, TRIP,…
  10. Some models account for different types of mech phenomena such as Ratcheting, twinning,…
  11. One thousand and three hundred combinations of models
  12. Strategies: brute-force by comparing experimental data and find which is more adequate for a specific material and process mainly based on geometrical measurements [1], [13]–[22] and stress-strain curves or load-displacement curves and yield loci [1], [13], [15]–[18], [20]–[23] Time-consuming-> mech experiments, model calibration, simulation and validation of mech process Automatic&flexile tool is missing in industry and sceintific comunities
  13. Strategies: brute-force by comparing experimental data and find which is more adequate for a specific material and process mainly based on geometrical measurements [1], [13]–[22] and stress-strain curves or load-displacement curves and yield loci [1], [13], [15]–[18], [20]–[23] Time-consuming-> mech experiments, model calibration, simulation and validation of mech process Automatic&flexile tool is missing in industry and sceintific comunities
  14. The solution that we want to propose is a tool that will help simulation software users with unknown numerical material behaviour. For instance the user wants to simulate a forming process and asks himself: How ? …? …?
  15. He can start by looking for some models and general parameters in the literature for the material is working with. The parameters were not calibrated exactly for the material he’s working with, but it can be adequate to detect the present mechanical phenomena.
  16. So he can find the elastic properties, swift law, voce law, Yld2000-2d and Armstrong-Frederick model parameters for the DP600 steel.
  17. And the same models for the aluminium alloy and their parameters
  18. But how to get more accuracy in simulation? …? …?
  19. This is where the proposed solution takes place. Thus, we have a constitutive models data base to model the numerical behaviour of materials, for instance the UMMDp
  20. We select some models
  21. And use the material parameters from the literature
  22. We choose the mechanical process that we want to work on and its configuration
  23. And define the simulation specifications
  24. With this we can do a sheet metal forming simulation
  25. Then we can extract the some measurements of interest or critical aspects of the process
  26. And we can use the ANOVA analysis to establish a relation between the different constitutive models and the measurements of interest
  27. With the ANOVA results, we can establish a constitute models importance ranking
  28. To validate this methodology we choose a hole expansion test with a blank of 0.8mm thickness
  29. The process was simulated using Abaqus/Standard software with 3D deformable shell revolution for the blank and analytical rigid tools
  30. In the first step, the punch is moved down with a displacement condition while the blank is fixed in the outer edge and the die is also fixed.
  31. The imposed displacement is chosen in order to don’t reach rupture of the blank whatever the material model used.
  32. In the second step, the tools are released and the springback is observed
  33. A structured mesh was implemented using 6 thousand and 4 hundred S4R elements with 9 integration points along the thickness
  34. Regarding the ANOVA approach, this is a statistical strategy that establish a relation between independent and dependent variables. In this case, we have different types of constitutive models, such as isotropic hardening, … and different forming simulation observables such as the hole’s circularity, maximum punch force, …
  35. We can say that the null hypothesis is that there is no difference among the group’s means The alternative hyphothesis is that the averages are not all equal If any group is significantly different from the overall mean, the null hypothesis is rejected. This can be observed with the p-value
  36. The p-value is the probability of obtaining the observed results, assuming that the null hypothesis is true. A p-value lower than 0.05 considers the statistical meaning of the analysed group. The smaller the p-value, the more significant is the result
  37. Thus, we simulated the hole expansion test with 8 different constitutive model combinations where we implemented either the Voce’s law or the Swift law, the von Mises of the Yld2000-2d or the kinematic A-F model, or no kinematic hardening model
  38. These are the outputted results. Each plot has the analysed measurement of interest for each run and each material. It can be observed that the hole’s circularity is dependent of the yld function used, as expected. The maximum punch force is dependent of the isotropic and kinematic hardening laws, as well as the material used. The springback factor is also dependent of both the isotropic and kinematic hardening laws.
  39. Looking at the p-values, the greens are the values that are below 0.05 and the red are above. For instance, it can be observed that the isotropic and kinematic hardening law have no statistical significance in the hole’s circularity. Where as, depending on the material, the yld function can have no statistical significance in the springback factor of the steel and on the maximum punch force of the alluminium. To better estimate the influence of each type of constitutive model in the mechanical process, we did the average of the p-values for the different measurements of interest. It can be seen that the kinematic hardening law is the model that most influences the simulation process, considering the DP600. But is the least influenceable when considering the Al.
  40. We can look at the strain path changes using the Schmitt parameter and make similar conclusions. The Schmitt parameters takes the value of 1 for monotonic, -1 for reversed and 0 for orthogonal strain paths. It can be observed differences in the strain paths of the simulation using the DP. Schmitt parameters is defined as the cosine of the angle in the strain space between the strain rate tensors during the pre-strain and subsequent strain path.
  41. In the case of the Al, way less strain path changes are observed. This can be explained due to the smaller punch displacement imposed in the AL, compared to the DP. Different displacements were implemented because of the differences in the rupture of the materials.
  42. Looking again at the p-values. For instance the type of model that least influences the DP simulation is the Yld function, showing the largest p-value average. On the contrary, this is the model that largest influence the simulation of the AL.
  43. This can be confirmed by the differences in between the von Mises locus and the Yld2000-2d locus of the two materials
  44. For the steel, …. Thus it is recommend to put more effort in the calibration of a kinematic hardening model and probably discard a complex yld function. For the Al, … Hence, we recommend to calibrate a complex yld function and probably discard the calibration of a kinematic hardening law.