Prediction of fracture limits of Ni-Cr based alloy under warm forming condition using ductile damage models and numerical method
(1. Department of Mechanical Engineering, Birla Institute of Technology and Science-Pilani, Hyderabad Campus, Hyderabad, India;
2. Mechanical Engineering Department, Gokaraju Rangaraju Institute of Engineering and Technology, Hyderabad, India;
3. Advanced Manufacturing Laboratory, Institute of Infrastructure Technology Research and Management (IITRAM), Ahmadabad, India;
4. Department of Mechanical Engineering, G. L. Bajaj Institute of Technology and Management, Greater Noida, India;
5. Mechanical Engineering Department, the Pennsylvania State University, Erie, PA, United States)
2. Mechanical Engineering Department, Gokaraju Rangaraju Institute of Engineering and Technology, Hyderabad, India;
3. Advanced Manufacturing Laboratory, Institute of Infrastructure Technology Research and Management (IITRAM), Ahmadabad, India;
4. Department of Mechanical Engineering, G. L. Bajaj Institute of Technology and Management, Greater Noida, India;
5. Mechanical Engineering Department, the Pennsylvania State University, Erie, PA, United States)
Abstract: The stretch forming and the deep-drawing processes were carried out at 300 and 673 K to determine the safe forming and fracture limits of IN625 alloy. The experimentally obtained strain-based fracture forming limit diagram (FFLD) was transformed into a stress-based (σ-FFLD) and effective plastic strain (EPS) vs triaxiality (η) plot to remove the excess dependency of fracture limits over the strains. For the prediction of fracture limits, seven different damage models were calibrated. The Oh model displayed the best ability to predict the fracture locus with the least absolute error. Though the experimentally obtained fracture limits have only been used for the numerical analysis, none of the considered damage models predicted the fracture strains over the entire considered range of stress triaxiality (0.33<η<0.66). The deep drawing process window helped to determine wrinkling, safe and fracture zones while drawing the cylindrical cups under different temperature and lubricating conditions. Further, the highest drawing ratio of 2 was achieved at 673 K under the lubricating condition. All the numerically predicted results of both stretch forming and deep drawing processes using the Hill 1948 anisotropic yielding function were found to be good within the acceptable range of error.
Key words: IN625 alloy; warm forming; ductile damage models; formability; forming limit diagram; deep drawing; processing window; finite element analysis