Multi-scale modelling of evolving plastic anisotropy during Al-alloy sheet forming

Accurate modelling of local evolving texture and yield surface evolution in complex strain path are of crucial importance to the accurate sheet metal forming simulations. This work proposed a novel multi-scale computational scheme, in which the full-field crystal plasticity (CP) modelling is mapped and real-time updated into each integration point following the local strain path in the finite element (FE) model. By the real-time close-loop feedback and update between the FE model and CP model, the evolving texture and its induced anisotropic plasticity evolution are considered utilizing on-the-fly virtual tests in the full deformation field. To carefully verify the developed computational framework, a comprehensive validation including plastic anisotropy characterization, cyclic hardening tests and deep drawing tests is conducted in an AA6016-T4 aluminium sheet with strong cube texture using ESAFORM Benchmark 2021. By comparison with experimental results and the conventional approaches with constant yield surface for the forming case, the newly developed method is thoroughly validated, showing that the significant texture evolution is observed in large plastic deformation and various strain paths lead to different texture evolution. The local evolving texture induced plastic anisotropy evolution has a considerable effect on the prediction accuracy of the deep drawing simulations, such as earing profile, wall thickness and loading history. Additionally, this method does not increase too much computation cost, enabling cost-effectively simulation of complex forming processes.

Automated summary

Accurate modelling of local evolving texture and yield surface evolution in complex strain path is crucial for accurate sheet metal forming simulations. This study proposes a novel multi-scale computational scheme that utilizes full-field crystal plasticity modelling mapped onto each integration point in the finite element model, allowing for real-time updates along the local strain path. The developed method is thoroughly validated through comprehensive tests, demonstrating the significant influence of evolving texture induced plastic anisotropy on the prediction accuracy of deep drawing simulations. Furthermore, this method is cost-effective and enables simulation of complex forming processes.