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65
MORIYA OYANE
Industrial S u m m a r y
Criteria for ductile fracture of pore-free materials and porous materials are described.
A method of estimating material constants in these criteria is also given. Applications of
the criteria to prediction of the fracture strain in several types of metal working processes
for pore-free materials and porous materials are described. These processes involve various
strain paths and stress paths; in other words, various paths of hydrostatic stress component -- which has a great effect on fracture strain -- are involved. The fracture strain in
one process differs from that in another.
Although many studies of ductile fracture have already been undertaken, these are not
applicable to estimate formability in various metal working processes. In this study, an
attempt is made to predict the fracture strain in actual processes using the basic criterion.
The calculated fracture strains are in adequate agreement with experimentally measured
values.
1 Introduction
In t h e s t u d y o f t h e w o r k i n g limits o f the materials in m e t a l w o r k i n g processes, t h e f o l l o w i n g p o i n t s s h o u l d be c o n s i d e r e d :
(i) the material m u s t n o t f r a c t u r e in t h e f o r m i n g processes,
(ii) t h e p r o d u c t m u s t n o t have d e f e c t s w h i c h lead t o f r a c t u r e in service.
I f the material is d e f o r m e d , voids will be initiated at a certain strain, el,
with f u r t h e r d e f o r m a t i o n causing the g r o w t h and coalescence o f t h e voids.
Even if s o m e small voids are initiated in t h e material, t h e m e c h a n i c a l properties o f the material are n o t necessarily w o r s e n e d . W h e t h e r or n o t f r a c t u r e occurs in service d e p e n d s o n the c o n d i t i o n s in w h i c h the p r o d u c t s are used. F o r
these reasons, it is n o t possible t o d e t e r m i n e t h e w o r k i n g limit e x a c t l y . F o r
66
simplicity, however, the fracture strain, el, is determined from noting the
point when the crack is observable by the naked eye.
A criterion for the ductile fracture of pore-free materials is derived from the
equations of plasticity theory for porous materials. In order to apply the
criterion to the ductile fracture of porous materials, it is so rearranged that
it includes a relative density term.
Firstly the criteria are applied here to predict the fracture strain during
forming processes and comparisons are made between the calculated and
the measured fracture strains. Secondly, the mechanical behaviour of coldworked materials is studied; in particular, the effects of surface cracks due
to cold working on the mechanical properties are investigated. A fatiguelife test on torsionally pre~trained specimens is presented and the relation
between the fatigue life and pre-strain is described.
2. Criterion for ductile fracture
f~ O2n- ldev =
deeq
(1)
eeq.i
where f is a function of the relative density p (defined by the ratio of the apparent density of the porous material to the density of its pore-free matrix),
n is a constant, Oeq is the equivalent stress, Om is the hydrostatic component of
stress (i.e. (ol + o: + o3)/3), eeq.i is the equivalent strain at which voids are
initiated, eeq.f is the equivalent strain at which fracture occurs and A is a
material constant. The quantity of the left-hand side of eqn. (1) is dependent
only on the material. Therefore eqn. (1) reduces to the following form:
eeq.f
Aa e-q deeq=C,
eeq.i
(2)
67
where C is a material constant, i.e.
e vf
C= /
(f2p:n-llA)dev
Osakada et al. [3] have reported that the strain at which voids are initiated
depends on the pressure. As a first approximation, however, it can be assumed
that the value, eeq.i, is a material constant regardless of the atmospheric pressure. If eeq.i = 0, eqn. (2) reduces to a very simple form:
1+
dE eq = C
(3)
A Oeq
0
(4)
where n is a constant and Oeq is again the yield stress, or equivalent stress, referred to the matrix material. Since pnoeq Can be defined as the flow stress
of the porous materials, Oeq in eqn. (3) is replaced by pnoeq. Assuming that
the value of the right-hand side in eqn. (3) for the porous material is related
to the initial relative density of the porous material, it may be written as
CpoB (B: a constant, P0: initial relative density). Thus the following ductile
fracture criterion can be advanced for porous materials:
eeq.f
f
0
1 +
A pnoeq
deeq = Cpo B
(5)
When the initial relative density P0 (and hence p ) is equal to 1.0, eqn. (5) coincides with eqn. (3).
3. Estimation o f material c o n s t a n t s
68
0"6
1,0
a Ho/Do= I'0
o H~Do= 1.25
~e
I..~/Do=I.5
/o
0"3
.~.o~/*
Eo.6
uJ
~D
~ 1
o HJ~- J-25
HJD.ffiI'0
0"8
/@
~ HI / H o
0"4
0"2
- 0"3
0
-0"6
0.2
0"4
.......
0"6
_J
0"8
4H/Ho
Fig.1. Variation of principal strains (e 0 ,e z ) with height reduction
free surface, in compression with grooved dies.
Fig.2. Relationship between height reduction
equatorial free surface.
AH/I-t o
AH/H
at the equatorial
cr
~k) !_o.s
0"6
F /,./o..,.o
i)
(~"
0"6
0 HJDo:I25
/0////
H./D..I
0 r//o/
0-2
1
~eq
-0.04
0'04
0'08
-0"2
Om/ ~q d ~eq
-0.4
Fig.3. Relationship between equivalent strain eeq and hydrostatic stress component a m/aeq
at the equatorial free surface.
eeq.f
69
Equation (3) is rewritten as
eeq'f
(6)
aeq
When a surface crack was observable by the naked eye, the specimen was unloaded and the reduction AH/Ho was measured; this will be called the "limit
reduction". The fracture strain, eeq.f , at the equatorial free surface was obtained from this limit reduction (AH/Ho)f and Fig.2. The value,
eeq.f
f
(am/Oeq ) deeq, was then calculated from the experimentally obtained
0
eeq.f and Fig.3. The experimentally derived relationship between
eeq.f
f
0
0
e eq.f
I'D 0.1
Fig.5. Relationship between height reduction A H / H o and principal strains (eO,e z ) at the
equatorial free surface, in compression with grooved dies for (a) various initial relative
densities p 0 and (b) various initial height-to.diameter ratios H o / D o.
-,,\
0.2
0.3
(b)
Ho/D.=7.13
H./D~I. 44
0 H,/D~0.94
~--0.69
-0.1 ~ ' ~
-0.5 -
-0-5
0.5 0.6
aH/Ho
-O-4 -
0.4
-0-~
(a)
0.3
-0.3-
I
0.2
-0.3
0.1
oO 0
0.3-
-0.2 L
_~
o ?.--0.74
d) .P.=0.69
oO
0.4 -
-0.2
-0.1
Ol y
uJ 0.2
CO
e ?,=o.a3
o f.=o.aB
O.3 -
~'o=1.0o
H o/'0o:1.13
~o=0.
93
0.4 -
0.5
~H/Ho
0.4
Ee
q~
2.3,rf:F
, ~___
":'"
C=o.83
o',q
AH/H o
and stress
0.5
"H / Ho
o"
0.4,
0.5
0.1
0.2
0 ~
0
0.1
0.2
0.3
u,) 0.3
u3
0.4 -
0.5
o.
0.1
0-2
o,.~.=o.92
~,o=O.88
0.2
(b)
0.3
0.3
///
0.5 0.6
"H I Ho
~,/,, .-
0-4
0.4
0.5
"H / Ho
(D'~o~0'69
0.1
/~/.
H./Do=I.13
Fig.7. Relationship between height reduction , x H / H o and equivalent strain eeq for (a)
various initial relative densities p 0 and (b) various initial height-to-diameter ratios H o l d
-I. 0 -
-0.5
~ o.s-
~.o!-
b=4
72
5f
0-4
o3I
~o=0.88
01-1,/[3,=0.92
@H./O.:1.14
(} HJDo=].39
e ~ D.-~.7~
0.2
/ /
0"1
f-O0
-0.1
0,
/0(06
0!2
-0.2
-0.:
-04
n=Z.5
am/Priaeq.
which were obtained from torsion tests using specimens of relative densities
of Po = 0.88, 0.83 and 0.69.
From eqn.(5), the equivalent fracture strain eeq.f is expressed as
B
eeq.f
1 ~eq.~ am
= CPo --~
pnoeq
(7)
deeq
eq.f
(m/pneq)deeq
(see Fig.9). Except for the initial relative density Po = 0.69, the results obtained from the compression test (for Po = 0.88 and 0.83) agree fairly well
with those from the torsion test. Omitting the results for p o = 0.69, material
constants A, B and C were determined from Fig.9 as follows:
A = 0.424, B = 4.40, C = 0.455.
(8)
Using these constants, the limit reduction for all specimens was calculated,
and compared with the experimental results, as shown in Fig.10. There is
satisfactory agreement b e t w e e n the calculated and the experimental results.
73
10.6
0.5
kkJ
f :
"~,~Y.--0.69
(D ~o=0.69
~ 0.2
~?.=o.8o
n=2.5
-0-15
"
-0.10
-f
0.1
ol
-0.05
O~=o.a8
d~q
-jo"O'eq"
.)o
eeq.f
Fig.9. Relationship b e t w e e n
fy
am/pnaeqdeeq and
1.0
0.5
= 0.8
0.4
..t
"T
o"
--r 0.6
"1-
U 5 0"3
_
~e
"-'0.4
0.2
//
0.2
0.1 --
Z:o83
o ~:o.e8
/
0 /
0
--
(9 ~P0=o.74
0.2
0.4,
0.6
0.8
(AH/ Ho)~.~,
1.0
0
0.5
0.6
0.7
0.8
0-9
1.0
Fig. 10. Comparison of calculated and experimental values of limit reduction (~ H/H o)f in
compression with grooved dies.
Fig. 11. Relationship b e t w e e n initial relative density p 0 and equivalent fracture strain
eeq.f o b t a i n e d f r o m torsion tests.
74
The ductile fracture criterion for porous materials was then applied to the
torsion test. Substituting o m = 0 into eqn. (5), the equivalent fracture strain
eeq.f is obt~dned as
6eq -f = C P o B
(9)
Figure 11 shows the relationship between the initial relative density p0 and
the equivalent fracture strain. The solid line in Fig. 11 represents the values
calculated from eqn. (9); there is thus seen to be satisfactory agreement between the calculated and the experimental results.
4.Application of criterion
(a) Pore-free materials
Two examples of the application are shown below; further examples are
given elsewhere [ 5].
Simple upsetting
Upset tests under different frictional conditions were carried out using a
pore-free material. The experimentally derived relationship between eeq and
Om/Oeq at the equatorial free surface is plotted in Fig.12 from which the
empirical expression for a m/Oeq is obtained.
Om/Oeq = 1.38 1.57~ .s 6eq ~ - ' 2 s - 0 . 3 3 ,
(10)
1.4
06
0"4
0"2
- 0"4
,N.=0.57
,U= 0"25
M= 0'15
1"2
ij(=H./o.)=~.o / p=o
I'0
#= 0"055
(IdJD,= 1-251
k.tO
0"8
0"6
0
-0"2
0
@
0s ,io
-o.57 1
0'4.
'
0-2
L
0
0
0-2
0.4.
0'6
0'8
4 HIHo
Fig. 12. Relationship between equivalent strain eeq and hydrostatic stress component
am/aeq.
Fig. 13. Relationship between height reduction A H / H o and equivalent strain 6eq.
I'0
75
compression test, and ~ is the initial height-to<liameter ratio, Ho/Do. The
solid lines in Fig.12 show the value calculated using eqn. (10). The relationship between AH/Ho and eeq in the same upset test is shown in Fig.13. Substituting eqn. (10) into eqn. (3),
0.33\
1 . 3 8 1.57p 08
1 - - - - ~ ) eeq'f + A (~ + 0.57) eeq.f ~+'Ts = C
(11)
Substituting the material constants, initial billet size (i.e. ~ = Ho/Do ) and coefficient of friction in eqn. (11), the fracture strain eeq.f in upsetting is estimated. Combining the calculated value of eeq.f and Fig.13, the limit reduction, (hH/Ho)f, is obtained. The comparison between the calculated limit
reductions and experimental values is shown in Fig.14.
I'0
,',
S55C
0 ,U=0.57
0"8
/
--~ /
).Jr- o.15
l l ~ /
o
7"
-r-
0"6
0.4
0"2
0-2
0"4
-0--e-~
I
0"6
/~ : 0-57
,U = 0.25
,uz 0.15
JU-"O'05S
I
0-8
I'0
(4H/Ho)f.col
Fig. 14. Comparison of calculated and experimental values of limit reduction (A H/H o)f.
76
~ ~ 3"2
(a)
--
2.8
2.4
R=4.75
/ R=2-88
~R-1.98
~2"0
oi/ l i /
LL) i-6
1"2
0"8
0"4
0
I , I
Fig.15. Relationship between the ratio of the thickness of the base to the diameter of
cup t/Dc and equivalent strain eeq.
in simultaneous indirect extrusion, b u t it is difficult to check non<iestructively the point at which the cracks are initiated. The working limit in this
process can be estimated b y the use of eqn. (3). The expression for Om/aeq
at the centre of the specimen is obtained experimentally as
om/Oeq = 97.7R-S eeq2.__0.68,
(12)
where R is the extrusion ratio. Substituting eqn. (12) into eqn. (3),
(97.7 R -~ eeq.f 3/3A) + (1--0.68/A) eeq.f = C.
(13)
The relationship b e t w e e n eeq at the centre of the specimen and t/De is shown
in Fig.15. The fracture strain eeq.f is calculated from eqn. (13) and the working limit (t/Dc)f is evaluated with the calculated fracture strain, eeq.f, and
Fig.15. The comparison b e t w e e n the calculated working limits (t/Dc)f and
the experimental ones is made in Fig.16, where solid lines show the calculated results. Solid points denote that central cracks have already appeared,
and hollow points that cracks have n o t y e t occurred.
77
O
0'1
0.2
O
E3
0"3
4.--
~-)'~,-- 0 , _ ~ .
0"4
To
0-5
O--I
17S(os
o--e
17S
received)
A - - A CU
Mg
0-6
-o-
0"7
- -e- 6063T5
--CHJ
I
R
Fig. 16. Comparison of calculated (solid lines) and experimental values of working limits.
(b ) Porous materials
In upsetting with open dies, as shown in Fig.17, fracture occurs along the
equatorial free surface, as in compression with grooved dies or simple upsetting.
In open-die upsetting, the material at the unconstrained part flows into the constrained part. The density at the constrained part therefore increases during
1.0
o.8'
0.9 -
0.7
0.E
0"50
Lubricated(Mo)
~/
H,/D,-I.24.
T,=5.06
I
0.1
0.2
0.3
0.4
0.5
0.6
=H/Ho
Fig.17. Change in density at the constrained part of the specimen during upsetting with
open dies.
78
upsetting; this may provide different results from compression with grooved
dies or simple upsetting. Fig. 17 shows the change in density at the constrained
part of the specimen in open-die upsetting.
Experiments were carried out to investigate the effects of the initial relative
density P0, the initial height-to-diameter ratio tto/Do, the depth of the constrained part and the lubrication conditions. The relationship between height
reduction AH/Ho and (e0, ez ) at the equatorial free surface was determined
as in compression with grooved dies. Employing the same method as described in section 3, the relationships between: height reduction AH/Ho and
(o0 Heq, az/oeq, Om/aeq); height reduction Att/tto and equivalent strain eeq;
and equivalent strain eeq a n d Om/pnoeq, Can also be obtained. Then the relationship between equivalent strain eeq and 1 + a m / A pnOeq cart also be obtained
using the material constant as in eqn. (8). Figure 18 shows an example of
these relationships. By graphical integration of function (1 + a m/,4 p n o eq)
(see eqn. (5)), the equivalent fracture strain eeq.f is obtained. Using the relationship between height reduction AH/Ho and equivalent strain eeq, the limit
2oF
3--~3.06
1.6 ~-
0 H./D,-1.06
H,/D.-I. 24
OH,/D.-1.71
1.4
1.2
-I
.p
v--
<
1.0
0.4
0.5
0.8
0.6
0.4
0.2
ol
0.1
0.2
0.3
0.6
Fig. 18. Relationship between equivalent strain eeq and 1 + a m/A p n a eq in upsetting with
open dies.
79
0.6
0.4
/
0.2 [-0 V
0
o~o.87
e~rO.82
(D9o-'0.73
r
0.2
1
0.4
I
0.6
I
0.8
1.0
PH/Ho)r
Fig.19. Comparison of calculated and experimental limit reduction
with open dies.
5. Working limit from the viewpoint of the mechanical properties of coldforged materials
To study the effect of surface cracks on the mechanical properties, it is
necessary to test the formed specimen without removing the surface layer.
Fatigue-life, impact value and quasi-static tensile strength were tested with
the torsionally pre-strained specimens. Since the shapes of the specimens
should be identical regardless o f the amount of pre-straining, the torsion
test was chosen for the pre-straining method. The results of fatigue-life tests
are here described. The material for these tests was $55C carbon steel (0.55% C),
normalized at 800C for 90 minutes. The specimens were pre-strained in
torsion and then tested on a Schenck-type fatigue testing machine. To evaluate the experimental results, the equivalent stress and the equivalent strain
from the Von Mises criterion were introduced. The fatigue life N (number
of cycles to fracture) for a constant equivalent stress of a e q = 363MPa is
shown in Fig.20. The fatigue life N decreases drastically at an equivalent prestrain of eeq.1 * ~ 0.43, which is less than the ductile fracture strain e e q . f
(~0.545) calculated from eqn. (3). Since the surface roughness of a torsion
80
testpiece increases with increasing strain, the fatigue test was then carried
out using specimens where the surface layer had been removed after prestraining. Figure 21 shows the relationship between fatigue life and the thickness of the surface layer removed AS O~m). When the pre-strain is less than
the ductile fracture strain (eeq. 1 = 0.44, 0.48 and 0.50), the removal of the
10 e
O
0"-
10 5
O
O
Io"
0
0"1
0.2
0"3
0"4
0,5
0-6
(~eq'l
O~ 0~
i 0 6 /
(~;/:
0--
.,....-.- 0
i~eq.I=0.56
"
,,
,,
67
Z
I 05
104(~
34
= 0"50
= 0'48
= 0,44
2(t,S) #m
Fig.21. Relationship between' 2AS (~m) and fatigue life N. (AS: thickness of surface
layer removed).
81
surface layer of 4--5 pm provides sufficient recovery in fatigue life; the thickness of the surface layer removed corresponds to the surface roughness of the
pre-stralned specimen. However, when the pre-strain was larger than the
ductile fracture strain (eeq. 1 = 0 . 5 6 ) , the fatigue life did not recover.
6. Conclusions