Preceding deformation effects on the crush response of the circular cup

Automotive body structure is made up of formed components which have undergone plastic deformation during forming process that altered the structural behaviour of these components. Ignoring the preceding deformation effects in subsequent crush analysis could lead to inaccurate crashworthiness evalua...

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Main Author:	Mohd Amman, Rosmia
Format:	Thesis
Language:	English English
Published:	2018
Subjects:	T Technology (General)
Online Access:	http://eprints.utem.edu.my/id/eprint/23495/1/Preceding%20Deformation%20Effects%20On%20The%20Crush%20Response%20Of%20The%20Circular%20Cup%20-%20Rosmia%20Mohd%20Amman%20-%2024%20Pages.pdf http://eprints.utem.edu.my/id/eprint/23495/2/Preceding%20deformation%20effects%20on%20the%20crush%20response%20of%20the%20circular%20cup.pdf
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id	my-utem-ep.23495
record_format	uketd_dc
institution	Universiti Teknikal Malaysia Melaka
collection	UTeM Repository
language	English English
advisor	Dhar Malingam, Sivakumar
topic	T Technology (General) T Technology (General)
spellingShingle	T Technology (General) T Technology (General) Mohd Amman, Rosmia Preceding deformation effects on the crush response of the circular cup
description	Automotive body structure is made up of formed components which have undergone plastic deformation during forming process that altered the structural behaviour of these components. Ignoring the preceding deformation effects in subsequent crush analysis could lead to inaccurate crashworthiness evaluation. In this study, the crush response of circular cup has been studied to quantify the effects of neglecting the preceding deformation effects such as geometrical changes and work hardening effects. The draw formed circular cups were fabricated through draw forming experiment on advanced high strength steel, dual-phase (DP600) steel with a nominal sheet thickness of 1.2 mm. Quasi-static crush experiment was subsequently performed on the draw formed circular cup to examine the preceding deformation effects on crush response. The draw forming simulation was performed at various punch speeds to investigate the geometrical changes and strain rates effect on deformation behaviour. An ideal computer-aided design (CAD) and draw formed cup model were used to developed finite element (FE) crush models in order to investigate the effects of geometrical changes and work hardening incurred during the draw forming process. The measured global load-displacement curve from experiments were used to validate the FE models developed using HyperWork. All draw forming and quasi-static crush experiments were simulated using Radioss solver employing Johnson-Cook constitutive model with isotropic hardening rule. The subsequent crush simulation was performed with and without incorporating mapped contour. Results show that draw forming process at various punch speeds affected the material strength and deformation behaviour of draw formed circular cup. In case of crush simulation without mapping (case A and case B), the geometrical changes from preceding draw forming process greatly affected the crush response of circular cup. The maximum force recorded at the end of crush process led to 46% and 15.2% higher for ideal CAD and draw formed cup geometry, respectively compared to the experiment. While in the case of with mapping (case 1 and case 2), work hardening effect resulted from draw forming process overcame the thinning effect and therefore made the structure stiffer and led to higher force value when compared to the case of without mapping. The percentage difference of maximum load recorded at the end of crush analysis with and without mapped residual contour was 12.9% and 3.8% for ideal CAD and draw formed cup model, respectively. Dynamic crush event showed higher response compared to quasi-static crush event in terms of load-displacement, stress and energy absorption behaviour by 45.5%, 40.7% and 30.7% respectively due to strain rates and inertia effects. Based on the crush response of the circular cup, the preceding deformation effects should be included in subsequent crush analysis by mapping the residual contour on draw formed geometry, instead on ideal CAD geometry in order to improve crashworthiness prediction.
format	Thesis
qualification_name	Master of Philosophy (M.Phil.)
qualification_level	Master's degree
author	Mohd Amman, Rosmia
author_facet	Mohd Amman, Rosmia
author_sort	Mohd Amman, Rosmia
title	Preceding deformation effects on the crush response of the circular cup
title_short	Preceding deformation effects on the crush response of the circular cup
title_full	Preceding deformation effects on the crush response of the circular cup
title_fullStr	Preceding deformation effects on the crush response of the circular cup
title_full_unstemmed	Preceding deformation effects on the crush response of the circular cup
title_sort	preceding deformation effects on the crush response of the circular cup
granting_institution	Universiti Teknikal Malaysia Melaka
granting_department	Faculty of Mechanical Engineering
publishDate	2018
url	http://eprints.utem.edu.my/id/eprint/23495/1/Preceding%20Deformation%20Effects%20On%20The%20Crush%20Response%20Of%20The%20Circular%20Cup%20-%20Rosmia%20Mohd%20Amman%20-%2024%20Pages.pdf http://eprints.utem.edu.my/id/eprint/23495/2/Preceding%20deformation%20effects%20on%20the%20crush%20response%20of%20the%20circular%20cup.pdf
_version_	1747834051525345280
spelling	my-utem-ep.234952022-05-17T14:53:39Z Preceding deformation effects on the crush response of the circular cup 2018 Mohd Amman, Rosmia T Technology (General) TA Engineering (General). Civil engineering (General) Automotive body structure is made up of formed components which have undergone plastic deformation during forming process that altered the structural behaviour of these components. Ignoring the preceding deformation effects in subsequent crush analysis could lead to inaccurate crashworthiness evaluation. In this study, the crush response of circular cup has been studied to quantify the effects of neglecting the preceding deformation effects such as geometrical changes and work hardening effects. The draw formed circular cups were fabricated through draw forming experiment on advanced high strength steel, dual-phase (DP600) steel with a nominal sheet thickness of 1.2 mm. Quasi-static crush experiment was subsequently performed on the draw formed circular cup to examine the preceding deformation effects on crush response. The draw forming simulation was performed at various punch speeds to investigate the geometrical changes and strain rates effect on deformation behaviour. An ideal computer-aided design (CAD) and draw formed cup model were used to developed finite element (FE) crush models in order to investigate the effects of geometrical changes and work hardening incurred during the draw forming process. The measured global load-displacement curve from experiments were used to validate the FE models developed using HyperWork. All draw forming and quasi-static crush experiments were simulated using Radioss solver employing Johnson-Cook constitutive model with isotropic hardening rule. The subsequent crush simulation was performed with and without incorporating mapped contour. Results show that draw forming process at various punch speeds affected the material strength and deformation behaviour of draw formed circular cup. In case of crush simulation without mapping (case A and case B), the geometrical changes from preceding draw forming process greatly affected the crush response of circular cup. The maximum force recorded at the end of crush process led to 46% and 15.2% higher for ideal CAD and draw formed cup geometry, respectively compared to the experiment. While in the case of with mapping (case 1 and case 2), work hardening effect resulted from draw forming process overcame the thinning effect and therefore made the structure stiffer and led to higher force value when compared to the case of without mapping. The percentage difference of maximum load recorded at the end of crush analysis with and without mapped residual contour was 12.9% and 3.8% for ideal CAD and draw formed cup model, respectively. Dynamic crush event showed higher response compared to quasi-static crush event in terms of load-displacement, stress and energy absorption behaviour by 45.5%, 40.7% and 30.7% respectively due to strain rates and inertia effects. Based on the crush response of the circular cup, the preceding deformation effects should be included in subsequent crush analysis by mapping the residual contour on draw formed geometry, instead on ideal CAD geometry in order to improve crashworthiness prediction. UTeM 2018 Thesis http://eprints.utem.edu.my/id/eprint/23495/ http://eprints.utem.edu.my/id/eprint/23495/1/Preceding%20Deformation%20Effects%20On%20The%20Crush%20Response%20Of%20The%20Circular%20Cup%20-%20Rosmia%20Mohd%20Amman%20-%2024%20Pages.pdf text en public http://eprints.utem.edu.my/id/eprint/23495/2/Preceding%20deformation%20effects%20on%20the%20crush%20response%20of%20the%20circular%20cup.pdf text en validuser https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=112800 mphil masters Universiti Teknikal Malaysia Melaka Faculty of Mechanical Engineering Dhar Malingam, Sivakumar 1. Abbasi-Bani, A., Zarei-Hanzaki, A., Pishbin, M.H. & Haghdadi, N., 2014. A comparative study on the capability of Johnson-Cook and Arrhenius-type constitutive equations to 2. describe the flow behavior of Mg-6Al-1Zn alloy. Mechanics of Materials, 71, pp.52–61. Abedrabbo, N., Mayer, R., Thompson, A., Salisbury, C., Worswick, M. & van Riemsdijk, I., 2009. 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