AA5052 failure prediction of electromagnetic flanging process using a combined fracture model

Electromagnetic forming process could significantly increase the forming limit of aluminum alloy. However, high-speed fracture prediction of aluminum alloys is a major problem in the development of electromagnetic flanging process. In this study, notched specimen tensile tests with high-speed Digital Image Correlation system were conducted under the strain rate range from 0.001 to 100 s(-1). A fracture model of AA5052 alloys which combined of an uncoupled fracture model, Gissmo damage evolution model and Johnson-Cook strain rate effect was established. Electromagnetic flanging experiments were conducted to verify the failure criteria effectiveness. Results showed that failure strain was significantly influenced by strain rate under various loading path. Compared with the experiments, the percentage error of established electromagnetic flanging process FEM model was less than 4%. The fracture model established could well predict notched specimen high-speed failure, and also accurately predict sheet failure model of electromagnetic flanging experiments and, thus, verified the effectiveness of the established dynamic failure criteria in electromagnetic flanging process. [GRAPHICS] .

Automated summary

This study investigates the high-speed fracture problem of aluminum alloys in electromagnetic forming process through experiments and model establishment. The results show that the fracture strain is significantly influenced by strain rate. The established fracture model accurately predicts high-speed fracture and verifies the effectiveness of the failure criteria in electromagnetic flanging process.