Fatigue strength prediction in incrementally formed sheet-parts with varying residual stresses
Source abstract
Abstract
The residual stress state of a formed component influences its mechanical performance. By adjusting the process parameters of the incremental sheet metal forming process, the deformation mechanisms and thus the residual stress state of the component can be influenced, leading to geometrically identical components with different properties. Within the scope of this paper, numerically predicted fatigue strength for various residual stress states is analyzed. Therefore, geometrically identical truncated cones are manufactured experimentally by different parameter sets of the process of single point incremental forming from aluminum alloy AA5083. The numerically determined residual stress state after forming and springback is introduced as the initial value of a fatigue strength analysis using the software Abaqus and FE-Safe. The predicted results of the fatigue strength tests are compared to experimentally performed High-Cycle Fatigue tests. The results enable the maximization of the fatigue life, for a given load case, by setting the residual stress states through changing the tool path of the forming process.
Source: openalex_inverted_index · Quality: baseline
Research context
OpenAlex topics: Metal Forming Simulation Techniques · Fatigue and fracture mechanics · Material Properties and Failure Mechanisms
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (42)
Show source-provided references
1. Advances in anisotropy of plastic behaviour and formability of sheet metals10.1007/s12289-020-01580-x ↗
2. Flow behavior of automotive aluminum sheets during In-Plane uniaxial and biaxial compression loading, teel researchinternational
3. Fatigue analysis of automotive components of inhomogeneous material under variable-amplitude cyclic loads
4. Loading classification proposal for fatigue design of automotive chassis-parts: a relevant process for variable amplitude and multi-input load cases10.1016/j.ijfatigue.2022.107284 ↗
5. Failure modes, mechanisms and causes of shafts in mechanical equipment10.1016/j.engfailanal.2022.106216 ↗
6. A review of bearing failure modes, mechanisms and causes10.1016/j.engfailanal.2023.107518 ↗
7. 2007
8. Suresh · 2012
9. The resistance of metals to cyclic deformation
10. The fatigue performance of machined surfaces10.1111/j.1460-2695.1991.tb00662.x ↗
11. Residual stress distributions and their influence on fatigue lifetimes10.1016/S0142-1123(01)00133-5 ↗
12. High- and very high-cycle plain fatigue resistance of shot peened high-strength aluminum alloys: the role of surface morphology10.1016/j.ijfatigue.2014.07.002 ↗
13. Surface characterization and fatigue evaluation in GH4169 superalloy comparing results after finish turning; shot peening and surface polishing treatments10.1016/j.ijfatigue.2018.04.009 ↗
14. Microstructure and residual stress modulation of 7075 aluminum alloy for improving fatigue performance by laser shock peening10.1016/j.ijmachtools.2022.103979 ↗
15. An analysis of longitudinal residual stresses in EN AW-5083 alloy strips as a function of cold-rolling process parameters10.1515/jmbm-2022-0297 ↗
16. Influence of process parameters on residual stresses in deep-drawing process with FEM and experimental evaluations10.1007/s40430-018-1085-9 ↗
17. An overview of stabilizing deformation mechanisms in incremental sheet forming10.1016/j.jmatprotec.2008.10.003 ↗
18. Theory of single point incremental forming10.1016/j.cirp.2008.03.047 ↗
19. Residual stress in sheet metal parts made by incremental forming process
20. Interaction of process parameters, forming mechanisms, and residual stresses in single point incremental forming10.3390/met10050656 ↗
21. Targeted residual stress generation in single and two point incremental sheet forming (ISF)10.1007/s00419-021-01935-z ↗
22. Experimental and numerical investigation of the influence of process parameters in incremental sheet metal forming on residual stresses
23. Forming mechanisms-related residual stress development in single point incremental forming, prod10.1007/s11740-018-0867-3 ↗
24. Prediction of material failure in incremental sheet metal forming
25. A comprehensive benchmark dataset for sheet metal forming: advancing machine learning and surrogate modelling in pro-cess simulations10.1051/matecconf/202540801090 ↗
26. Overview on the prediction models for sheet metal forming failure: necking and ductile fracture10.1007/s10338-018-0026-6 ↗
27. Forming defects prediction for sheet metal forming using gaussian process regression
28. Prediction of forming limit diagrams for steel sheets with an artificial neural network and comparison with empirical and theoretical models10.17515/resm2023.32ma0825rs ↗
29. The real-time prediction of cracks and wrinkles in sheet metal forming according to changes in shape and position of drawbeads based on a digital twin10.3390/app15020700 ↗
30. Integrating effect of forming in fatigue life prediction: review of present scenario and challenges10.1177/0954405412437621 ↗
31. Fatigue lifetime prediction for oil tube material based on ABAQUS and FE-SAFE, J fail
32. Kasun · 2015
33. Fatigue damage analysis and life prediction of e-clip in railway fasteners based on ABAQUS and FE-SAFE10.1177/1687814018767249 ↗
34. Maaß · 2024
35. Detailed evaluation of methods for estimation of fatigue properties10.1016/0142-1123(95)99737-U ↗
36. Gezielte Steuerung der Bauteileigenspannungen durch inkrementelle Blechumformung10.1007/s10010-021-00485-8 ↗
37. Güner · 2013 · 663
38. Effect of surface finish on fatigue strength10.1016/0013-7944(94)00297-U ↗
39. A fatigue life model accounting for the combined effect of surface roughness and microstructure: application to SLM fabricated Hastelloy-X10.1016/j.ijfatigue.2024.108298 ↗
40. A microstructure based approach to model effects of surface roughness on tensile fatigue10.1016/j.ijfatigue.2019.105229 ↗
41. High cyclic fatigue behaviour of ultrafine grained Al 5083 alloy10.1179/1743284713Y.0000000496 ↗
42. High cycle fatigue behavior and numerical evaluation of alloy 690TT steam generator tube10.1016/j.ijfatigue.2020.105662 ↗