RE-ORIENTATION OF ORTHOTROPIC AXES IN SHEET METAL USING A DEVELOPED METHOD BASED ON A SIMPLE SEMI GEOMETRICAL MODEL

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1 U.P.B. Sci. Bull., Series D, Vol. 75, Iss. 4, 2013 ISSN RE-ORIENTATION OF ORTHOTROPIC AXES IN SHEET META USING A DEVEOPED METHOD BASED ON A SIMPE SEMI GEOMETRICA MODE Mohammad ZEHSAZ 1, Hadi MAHDIPOUR 2, Alireza Ali MOHAMMADI 3 Exerimental investigations demonstrate that when orthotroic sheet metal secimens are subjected to off-axis uniaxial tension, re-orientation of the axes occurs at moderate tensile lastic strain levels, while orthotroic symmetries are reserved. In this work this henomenon has been investigated and simulated by using a develoed method which is based on a simle semi geometrical model. In this model, a 3-elements mechanism with arbitrary angle reresents two substructure textures of a cold rolled sheet metal. An exlicit formulation has been obtained to determine the rotation angle of the orthotroic symmetry axes of the sheet metal under off-axis uniaxial tension. Also a simle method has been roosed to determine the direction of the orthotroic axes rotation under off-axis uniaxial tension. It is shown that the roosed formulations can be used to calculate the magnitude and direction of the rotation of the orthotroic axes under this tye of loading and the results show good agreement with the exerimental data. Keywords: Orthotroic axes, Semi geometrical method, Re-Orientation, Sheet metal 1. Introduction The theory of anisotroic lasticity of materials is a well known toic with great technological significance. The first work on the orthotroic material with reresentation of a yield function was roosed by Hill in 1950 [1]. Anisotroy indicates the difference of a roerty or resonse, e.g. the yield stress or the stress-strain resonse of the material in different directions. Therefore it can be characterized by two fundamental characteristics, its intensity and its orientation [2]. Re-orientation of the orthotroic directions is a very significant feature that is related to the secondary anisotroic roerty and its investigation is the major concern of this aer. Although both the intensity and orientation of the orthotroic axis are imortant, but most of the revious research works address the former subject. For examle, extensive exerimental works have been carried out in understanding the yield and flow behavior of the cold rolled anisotroic materials [3-4]. Also, a number of researches have been reorted based on theoretical methods in this subject [5-13]. In addition, anomalous behavior 1 Associate Prof., Det.of Mech. Eng., University of Tabriz, Iran, zehsaz@tabrizu.ac.ir 2 3 M.Sc., Det.of Mech. Eng., University of Tabriz, Iran, h.mahdiour87@ms.tabrizu.ac.ir, ar.alimohammadi@hotmail.com 3 3 M.Sc., Det.of Mech. Eng., University of Tabriz, Iran, h.mahdiour87@ms.tabrizu.ac.ir, ar.alimohammadi@hotmail.com

2 138 Mohammad Zehsaz, Hadi Mahdiour, Alireza Ali Mohammadi observed in aluminum by Woodthroe and Pearce [14] motivated extensive studies on the yield functions [14-25]. There are also few works that address orientation of the ortotroic axis. For examle, Kim observed that during the twisting of the cold drawn tubes, the orthotroic symmetry is maintained and the orthotroy axes are rotated in the twisting direction [26]. Boehler et al., Kim and Yin and osilla et al. have shown that the cold rolled sheet metals under uniaxial off-axes tension loading remain aroximately orthotroic but there is a large in-lane orientation of the orthotroic symmetric axes [27-29]. Bunge and Nielsen have used both exerimental techniques and ODF measurement aroaches to obtain the magnitude of the texture rotation of the orthotroic Aluminum cold rolled sheet secimen subjected to off-axis stretching [30]. Tugcu and Neale studied the orthotroic axes rotation using the orthogonal tensor R that secified the olar decomosition of the deformation with no exerimental evidence [31]. Attemts have also been made to solve the roblem of orthotroic re-orientation [32-33]. The main theoretical tool to exlain orientation of orthotroic axes is the concet of lastic sin that at first suggested by Mandel [34]. This henomenon is described and simulated by Dafalias using a simle theory of lasticity, which combines Hill s quadratic yield criterion for orthotroic sheet metals with the concet of lastic sin as an essential constitutive comonent for the orientational evolution of the anisotroic tensorial internal variables [2]. Tong et al. resented a simlified anisotroic lasticity theory which is used to exlain the anisotroic flow behavior of the orthotroic olycrystalline sheet metals under off-axis uniaxial tension. Their theory was formulated in terms of the intrinsic variables of rincial stresses and a loading orientation angle and its uniaxial tension. They acquired a suitable analytical formula of macroscoic lastic sin roosed for orthotroic sheet metals with reserved but rotated orthotroic symmetry axes under off-axis uniaxial tension [35]. Also Tong in the years 2005 and 2006 resented a henomenological theory based on the lastic sin concet, Fourier series and concets of microscoic olycrystalline lasticity for describing the anisotroic lastic flow of orthotroic olycrystalline aluminum sheet metals under lane stress [36, 37]. Although the models mentioned above are based on exerimental or theoretical methods, their alication in industry is difficult due to their comlexity. Therefore, in this work, the orientation of orthotroic axis is described and simulated using a simle geometrical method and a 3-elements system of substructure textures of cold rolled sheet metal. For this urose, an exlicit analytical formulation is roosed to determine the rotation angle of the orthotroic symmetry axes of a sheet metal under off-axis uniaxial tension. Also, associated material anisotroic constants have been

3 Re -orientation of orthotroic axes in sheet metal [ ] on a simle semi geometrical model 139 obtained and comared with those given by Kim and Yin based on exerimental tests [28]. Finally, a simle method is develoed with associated uations to determine the direction of the orthotroic axes rotation. 2. Descrition of roblem Are the orthotroic symmetries reserved when orthotroic sheet metals are subjected to in-lane off-axis uniaxial tension loading where the direction of loading is fixed with resect to the initial orthotroic axes? Moreover, if orthotroic symmetries are reserved, do the orthotroic axes remain the same, or they rotate? If yes, towards which direction? Finally, how fast do they rotate in relation to the lastic strain induced by the non-coaxial loading? [2] The above questions should be answered by exerimental observations before develoing a theory of anisotroic re-orientation. These answers can show whether the theoretical objective is worth ursuing or not. Kim demonstrated that the answer of the first question is ositive [26]. Kim and Yin s exeriments [28] corroborate the results of Kim s exeriment [26]. In the next ste, they answered to the second and third questions. Meanwhile, if the answer to the third question is that the orthotroic axes do rotate but very slowly, again one may reason that for ractical uroses, the orthotroic orientation may be assumed to remain fixed. Kim and Yin erformed an exerimental method to study the cold rolled sheet metals anisotroy with tensile tests at different angles to the rolling direction [39]. They utilized variation of uniaxial yield stresses with tensile loading axis orientation which can be used to set u orthotroic symmetry. They selected cold rolled sheets of low carbon steel widely used in the automotive industry for the tests. This alloy has moderate initial orthotroy. To increase the degree of orthotroy, full size sheets were stretched along the rolling direction by 3 and 6 ercent of tensile strains. Then tensile secimens were cut at an angle ψ from the rolling direction (R.D.). Fig. 1 resents a schematic diagram of the secimens. The R.D. and T.D. (Transverse Direction) are the initial orthotroic axes. Fig 1. Schematic resentation of the tensile secimen and the different directions and related angles,ψ, β, and θ.

4 140 Mohammad Zehsaz, Hadi Mahdiour, Alireza Ali Mohammadi Three values of ψ were chosen at 30, 45 and 60 degrees which for each value of ψ, the secimens were subjected to a tensile second re-strain ε of magnitude 1, 2, 5, and 10 ercent along their axis. To investigate the ossible reorientation of the initial orthotroic directions R.D. and T.D. due to the mentioned re-straining, small size secimens were cut from the re-strained secimens at different angles and tested in tension. For tracing the evolution of orthotroic symmetries and orientation by following the shift, with resect to the second re-strain ε, the record of tensile yield stress distribution are carried out for the small secimens at each ε and ψ. It was shown that the answers of two questions mentioned at the beginning of this section are ositive. Meanwhile, it was ossible to investigate the evolution of the orientation of the orthotroic axes X and Y with resect to the second re-strain ε. This can be done by calculating the shift of the symmetrical yield stress distribution using their angle β from the ε direction (see Fig. 1). 3. Modeling of magnitude of rotation of orthotroic axes In this aer for the modeling of the orientation of the orthotroic axes of sheet metals due to the uniaxial off-axis tension (second re-strain), a semigeometrical model is used which is based on the concet of substructure textures (see Fig. 2). Two arbitrary stries of substructure texture of a second re-strained secimen are simulated using the 3-element mechanism (see Fig. 2) in which one of the elements is grand and fixed and the other two elements can move. The angle between elements a and b is arbitrary and it is not necessary to be at 45 degree. The horizontal element AC shown in Fig. 2 indicates the orthotroic axis and its rotation reresents the orientation of orthotroic axes under uniaxial offaxis tension and the element AB is fixed. Fig. 2. Semi-geometrical model which is based on the concet of substructure textures and is used to modeling of the orientation of the orthotroic axes.

5 Re -orientation of orthotroic axes in sheet metal [ ] on a simle semi geometrical model 141 Two joints of A and B have only one degree of freedom i.e. AC can solely rotate around joint A and therefore BC can rotate around joint B. Joint C has three degrees of freedom i.e. both AC and BC can rotate around C and joint C can move both horizontally and vertically. When second lastic re-strain is alying, both AC and BC start yielding contemoraneously, according to Fig. 2. Consuently, the system reaches a new osition which is shown with dashed lines in Fig. 2. In this simulation, the symbols ofψ, θ and ε are uivalent to Kim and Yin s [28] exerimental quantities and are defined in Fig. 1. Due to the second re-strain exeriments of Kim and Yin s the elements of BC and AC are subjected to strains of ε 1 and ε 2 resectively. With the assumtion of AB = 1, following uations can be obtained: a = 21 ( + ε1 ) (1) b = 1+ ε ( 2 ) π θb = δ a 4 All the geometrical arameters in these uations are defined in Fig.s 1 and 2. By the substitution of Equation (2) into (1), it can be written as: π 2 δ ( 1+ ε 1 ) 4 θ = (3) ( 1+ ε 2 ) And from triangle of ABC it can be shown that: a sinα = cosθ (4) By substitution of Equation (1) into (4), it can be written as: cosθ sinα = (5) 21 ( + ε1 ) And from triangle of BCC it can be demonstrated that: π π sin δ sin π 2 δ 4 4 = (6) a 2 a Moreover, the substitution of Equation (2) in the above relation leads to: π 1 cos δ = (7) 4 1+ ε1 The result of the combining Equations (3) and (7) is: 1+ ε 1 1 θ = 2 arccos (8) 1+ ε 2 1+ ε1 And with the assumtion of ε = K εε, = Kε (9) (2)

6 142 Mohammad Zehsaz, Hadi Mahdiour, Alireza Ali Mohammadi In addition, by substitution of Equation (9) into (8) gives: 1+ θ = 2 arccos (10) 1+ K2ε 1+ Where at above uations K 1 and K 2 are material constants. Equation (10) should satisfy two following initial and boundary conditions: If ε = 0 then θ = 0, which is satisfied in Equation (10). For any orthotroic sheet metal beside the initial orthotroic axes, there is a direction, ψ or uivalent angle that if the loading is alied in this direction, the initial orthotroic axes do not show any rotation. Also, there is a limit for the second re-strain and if it is reached, the orthotroic axes do not rotate; and therefore, one of the orthotroic axes coincide with the secondary loading direction, in other words, this boundary condition for ψ < ψ leads to θ ( ε ) = ψ π and for ψ > ψ results in θ ( ε ) = ψ. 2 The second boundary condition for ψ < ψ in Equation (10) is obtained as: 1+ ψ = 2 arccos (11) 1+ K2ε 1+ Where strain limit is shown with ε. Above uation can be re-written as: 1 K2 = ψ + 2 ( 1+ ) arccos (12) ψε 1 + And by substitution of Equation (12) into Equation (10) and for simlicity with the assumtion of K1 = K, it is easily shown than: 2 ( 1+ Kε ) arccos 1 + Kε θ = (13) ε 1+ ψ + 2( 1+ Kε ) arccos ψε 1 + Kε The above uation is valid for ψ < ψ and forψ > ψ, the same rocedure leads to: π 1+ ψ = 2 arccos (14) 2 1+ K2ε 1+ As a result: 1 π K2 = ψ 2 ( 1 ) arccos π + + (15) 2 1+ ψ ε 2 By substitution of Equation (15) into (10) and again for simlicity assuming that K1 = K, it is easily shown that forψ > ψ :

7 Re -orientation of orthotroic axes in sheet metal [ ] on a simle semi geometrical model ( 1+ Kε ) arccos 1 + Kε θ = (16) ε π 1 + ( ψ ) + 2( 1+ Kε ) arccos π 2 1+ Kε ψ ε 2 Above relation, have two distinct and indeendent constants, which consist of, K and ε which can be determined using exerimental data. In ractice, K 1 and K 2 used in Equation (11) are relaced by K and ε in Equation (13). An advantage of this relacement is that the value of ε, can be determined easily using exerimental data and therefore, only one unknown constant ( K ) is remained which can be calculated using data fitting of the exerimental tests. 4. Re-orientation direction of the orthotroic axes under uniaxial offaxis tension loading In the roblem of re-orientation of the orthotroic axes under uniaxial offaxis tension, both the magnitude and direction of the orientation should be determined. Dafalias [2] has discussed on the direction of the re-orientation of the orthotroic axes under uniaxial off-axis tension using the relation which Hill 2 reresented in 1950 [1] in the form of tan ψ = ( g + 2h 1 ) / ( f + 2h 1) where f, g and h are normalized coefficients of Hill s quadratic criteria. Dafalias showed that for the reorted values of f, g and h by Kim and Yin [28], ψ = In this investigation, we roose a simle relationshi for the roblem of orientation direction of orthotroic axes under off-axis uniaxial tension. To determine the relation forψ, we suose that the yield stress for the initial sheet in ψ is σ so the following uilibrium uations are satisfied: 2 Y σ sin ψ = σt. D. (17) 2 Y σ cos ψ = σr. D. Y Y Where σ RD.. and σ T. D. are the yielding stress for initial sheet in the rolling and transverse directions, resectively. Dividing both sides of the uilibrium uations give: σ ψ = arctan (18) σ Y TD.. Y R. D. The uivalent angles are obtained based on Equation (18) and Kim and Yin s [28] exerimental data which is given in Table (1).

8 144 Mohammad Zehsaz, Hadi Mahdiour, Alireza Ali Mohammadi Table 1. Variation of uivalent angle with initial re-strain obtained using uation (18) Initial re-strain 0% 3% 6% ψ (uivalent angle) By combination of Equation (13) and (18) the final relationshi for orientation of orthotroic axes under off-axes uniaxial tension leads can be obtained as forψ < ψ : 2 ( 1+ Kε) arccos sign 1 ( ψ ψ) + Kε θ = ε 1+ ψ + 2( 1+ Kε ) arccos ψε 1 + Kε And for ψ > ψ as: 5. Results 2 ( 1+ Kε) arccos sign 1 ( ψ ψ) + Kε θ = ε π 1+ ψ 2( 1 Kε ) arccos π Kε ψ ε 2 The reorientation of the orthotroic axis of the sheet metal under uniaxial off-axis tension is obtained using Equations (19) and (20) with different material constants. The results are resented in Fig.s (3) to (5). These results are comared with Kim and Yin s [28] exerimental data for a metal sheet by 3% initial restrain. (19) (20) Fig. 3. Rotation of the orthotroic axis for loading angles of 30 degree with ε = 0.2.

9 Re -orientation of orthotroic axes in sheet metal [ ] on a simle semi geometrical model 145 Fig. 4. Rotation of the orthotroic axis for loading angles of 45 degree with ε = 0.2. Fig. 5. Rotation of the orthotroic axis for loading angles of 60 degree with ε = 0.2. The uations (19) and (20) are exlicit formulation of the state of orientation of anisotroic orthotroy under off-axes uniaxial tension. The rotation of the orthotroic axis can be obtained using these uations based on two variables of loading angle (ψ ) and secondary re-strain ε. The secondary restrain consists of elastic and lastic strains but the former is neglected due to its low value. In addition to these variables, two other constants K and ε are ruired which can be obtained using exerimental data with given initial anisotroy for any secific material. Equations (13) and (16) give the value of the rotation of the axis and to obtain the direction of the rotation it is necessary to combine Equation (18) with them which lead to Equations (19) and (20). To comare the exerimental results, the constants of Equations (19) and (20) are extracted for the orthotroic sheet metal using Kim and Yin s exerimental data [28]. The Fig.s (3), (4) and (5) show the rotation of the orthotroic axis for three loading angles of 30, 45 and 60 degrees resectively. These results are obtained using Equations (19) and (20) for low carbon sheet steel with 3% initial re-strain. The material constants are given in each Fig. The agreement with exerimental

10 146 Mohammad Zehsaz, Hadi Mahdiour, Alireza Ali Mohammadi data is good for loading angle of 30 degrees because the loading angle is smaller than the uivalent angle ( ψ < ψ ), also, the difference between loading angle and uivalent angle is significant. For the same reason, for 60-degree loading angle the results comare well with the exerimental data in site of the fact that the loading angle is larger than the uivalent angle ( ψ > ψ ). But there is a relatively large difference between the exerimental data and the calculated values for the loading angle of 45-degrees. The main reason for this difference is that the loading angle is close to the uivalent angle, which we can consider that these two angles are coinciding. The limit strain, ε, is an imortant arameter and its value is assumed to be the same for all loading conditions. ε = Discussion Dafalias in the year 2000 in the course of a work on the subject of this aer elaborately discussed the re-orientation of orthotroic axes under uniaxial off-axes tension loading [2]. He entirely connected the roblem of orthotroic axes re-orientation to lastic sin and also concet of rotation of substructure texture. We have been insired by work of Dafalias [2] and his secial aroach regarding the concet of lastic sin and re-orientation of orthotroic axes, esecially on 2-dimensional roblems. He esecially discussed about concet of uivalent angle and direction of re-orientation of orthotroic axes. However, the model roosed by Dafalias is difficult to use due to its comlexity. On the contrary, the formulation resented in this aer is very simlest and very succinct and also alicable. Presented model in this work is on the basis of Kim and Yin s [39] exerimental data and so Dafalias s work [2]. To make the roosed model more flexible, one can increase the number of the mechanism elements and this can be a future work for this research rogram. Also, to imrove the model, the relation between the rotation tensor of the substructure texture of the sheet metal and stretching tensor should be taken into account. For achieving to this target, must be a fixed suort in the modeling mechanism. 7. Conclusion The orientation of orthotroic axis is described and simulated using a simle geometrical method. For this urose, an exlicit analytical formulation is roosed to determine the rotation angle of the orthotroic symmetry axes of a sheet metal under off-axis uniaxial tension. Also, associated material anisotroic constants have been obtained and comared with those given by Kim and Yin [28] based on exerimental tests. Finally, a simle method is develoed with associated uations to determine the direction of the orthotroic axes rotation.

11 Re -orientation of orthotroic axes in sheet metal [ ] on a simle semi geometrical model 147 The results show that using this model, the orientation and intensity of the orthotroic axis can be calculated for uniaxial off-axis loading with good agreement with exerimental data. This model only ruires one material constant and this adds to its flexibility and ruires affordable number of tests. R E F E R E N C E S [1]. R. Hill, The Mathematical Theory of Plasticity, First ublished in oxford classic series, [2]. Y.F. Dafalias, Orientational evolution of lastic orthotroy in sheet metals, Journal of the Mechanics and Physics of Solids, vol. 48, issue 11, 2000, [3]. K. Mallick, S.K. Sanabta and A. Kumar," An exerimental study of the evolution of yield loci for anisotroic materials subjected to finite shear deformation", J. Eng. Mat. Tech. Trans. ASME113, 1991, [4]. H.P. Truong Qui, H. imann, "Plastic sin and evolution of an anisotroic yield condition", International Journal of Mechanical Sciences, vol. 43, issue 9, Set. 2001, [5]. A.N. Surun, "A constitutive model with three lastic constants: The descrition of anisotroic work hardening" International Journal of Plasticity", vol. 22, issue 7, July 2006, [6]. B. Plunkett, R.A. ebensohn, O. Cazacu and F. Barlat, "Anisotroic yield function of hexagonal materials taking into account texture develoment and anisotroic hardening", Acta Materialia, vol. 54, Issue 16, Set. 2006, [7]. H. Haddadi, S. Bouvier, M. Banu, C. Maier and C. Teodosiu, "Towards an accurate descrition of the anisotroic behaviour of sheet metals under large lastic deformations: Modeling, numerical analysis and identification", International Journal of Plasticity, vol. 22, Issue12, Dec. 2006, [8]. Weilong Hu, " Constitutive modeling of orthotroic sheet metals by resenting hardeninginduced anisotroy", International Journal of Plasticity, vol. 23, Issue 4, Aril 2007, [9]. Myoung-Gyu ee, R.H. Wagoner, J.K. ee, K. Chung and H.Y. Kim, "Constitutive modeling for anisotroic/asymmetric hardening behavior of magnesium alloy sheets", International Journal of Plasticity, vol. 24, Issue 4, Aril 2008, [10]. B. Plunkett, O. Cazacu and F. Barlat, "Orthotroic yield criteria for descrition of the anisotroy in tension and comression of sheet metals", International Journal of Plasticity, vol. 24, Issue 5, May 2008, [11]. H.Hahm, K.H.Kim, "Anisotroic work hardening of steel sheets under lane stress", International Journal of Plasticity, vol. 24, Issue 7, July 2008, [12]. O. Cazacu, I. R. Ionescu and J. W. Yoon, "Orthotroic strain rate otential for the descrition of anisotroy in tension and comression of metals", International Journal of Plasticity, vol. 26, Issue 6, June 2010, [13]. G. Rousselier, F. Barlat and J.W. Yoon, "A novel aroach for anisotroic hardening modeling. Part II: Anisotroic hardening in roortional and non-roortional loadings, alication to initially isotroic material", International Journal of Plasticity, vol. 26, Issue 7, July 2010, [14]. J. Woodthroe, R. Pearce, "The anomalous behaviour of aluminium sheet under balanced biaxial tension", International Journal of Mechanical Sciences, vol.12, Issue 4, Aril 1970, [15]. R. Hill, "Theoretical lasticity of textured aggregates", Mathematical Proceedings of the Cambridge Philosohical Society, vol. 85, 1979, [16]. R. Hill, "Constitutive modeling of orthotroic lasticity in sheet metals", Journal of the Mechanics and Physics of Solids, vol. 38, Issue 3, 1990,

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