Physically-based constitutive description of a commercial Al-Mg-Si alloy deformed under cold-warm working conditions

• Published in: Journal of alloys and compounds Vol. 790; pp. 1177 - 1191
• Main Authors: Le Mercier, K., Guérin, J.D., Dubar, M., Dubar, L., Puchi-Cabrera, E.S.
• Format: Journal Article
• Language: English
• Published: Lausanne Elsevier B.V 25.06.2019; Elsevier BV; Elsevier
• Subjects: Alloys; Aluminum alloys; Aluminum base alloys; Cold; Cold forging; Cold working; Constitutive formulation; Contact pressure; Deformation; Dependence; Differential equations; Engineering Sciences; FE modeling; Finite element method; Hardening rate; Magnesium; Mathematical models; Mechanics; Metal working; Plasticity methods; Silicon; Sliding; Strain rate; Stress/strain measurements; Threshold stress; Ultrasonic testing; Upsetting sliding test; Warm working; Working conditions; Yield strength; Constitutive formulation; Stress/strain measurements; Aluminum alloys; Plasticity methods; Upsetting sliding test; FE modeling
• ISSN: 0925-8388; 1873-4669
• DOI: 10.1016/j.jallcom.2019.03.113

The experimental and numerical modeling of cold forging operations conducted on commercial Al alloys requires a precise knowledge of the functional dependence of both flow stress and work-hardening rate on microstructure and deformation conditions. In order to contribute to the improvement of the finite element computer modeling of forming operations conducted on Al alloys, under cold-warm working conditions, an original and rational constitutive description, able to predict accurately both the flow stress and work-hardening rate of an AA6082-T6 Al alloy is proposed. The constitutive formulation has been developed on the basis of the Mechanical Threshold Stress (MTS) model and its applicability is limited to the deformation of the material under cold-warm working conditions, that is to say, in the temperature range of 298–423 K. A novel differential equation for the description of the continuous change in the work-hardening rate of the alloy has been developed, which allows the prediction of the changes in flow stress and work-hardening rate during deformation either under constant and variable temperature and strain rate conditions. The validation of the developed constitutive description has been accomplished by its implementation into a finite element (FE) model for the accurate prediction of the change in some local contact parameters, such as contact pressure, sliding velocity and interface temperature, during the friction test employed in the evaluation of friction conditions in metalworking, known as the Upsetting Sliding Test (UST). •An original and rational constitutive description for the 6082-T6 Al alloy is proposed.•A novel differential equation for describing the change in the work-hardening rate of the alloy has been developed.•The model developed is able to describe the changes in flow stress under transient deformation conditions.•The model has been validated by means of experiments and FEM analysis of the upsetting sliding test.