Ductile failure prediction during the flow forming process

Vural H., Erdoğan C., Fenercioglu T. O., Yalçınkaya T.

2nd International Workshop on Plasticity, Damage and Fracture of Engineering Materials, IWPDF 2021, Ankara, Turkey, 18 - 20 August 2021, vol.35, pp.25-33 identifier

  • Publication Type: Conference Paper / Full Text
  • Volume: 35
  • Doi Number: 10.1016/j.prostr.2021.12.044
  • City: Ankara
  • Country: Turkey
  • Page Numbers: pp.25-33
  • Keywords: Ductile fracture, Flow forming process, Modified Mohr-Coulomb model
  • Middle East Technical University Affiliated: Yes


© 2021 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of IWPDF 2021 Chair, Tuncay YalçinkayaFlow forming is an incremental metal-forming technique used for manufacturing thin-walled seamless tubes where a hollow metal material flows axially along the mandrel by a rotating mandrel and multiple cylinders. Flow formed materials are frequently used in the aviation and defence industry and it is crucial to examine the influence of the process on the material in terms of ductile fracture. However, the process requires in-depth failure analysis considering different process parameters and materials. The current study is concerned with investigating the ductile fracture behavior during flow forming process which includes complex stress states in terms of stress triaxiality and Lode parameter. Ductile fracture is simulated through the modified Mohr-Coulomb model. A user material subroutine (VUMAT) has been developed to implement the plasticity behavior and the damage accumulation rule. The model is validated through finite element (FE) simulations performed in Abaqus/Explicit and using the experimental data in Granum et al. (2021). The validated framework is applied to a finite element model of flow forming process with single and three rollers. The incremental forming with three rollers significantly reduces the damage accumulation. The initial results show a highly damaged region outer and inner surfaces of the workpiece after 40% thickness reduction ratio, and the forming limit is predicted as about 40-45%. The modeling framework is planned to be applied using various process parameter for different materials.