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Testing and simulation of deformation and damage behavior of different aluminum profiles

Wednesday (08.11.2017)
17:40 - 18:00
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Extruded aluminum profiles are increasingly used in automobile construction due to the combination of light weight benefits with efficient manufacturing and large energy absorption with optimal folding. The deformation and damage behavior of a profile depends not only on the chemical composite and the manufacture processes including heat treatments but also on loading situation. Until now it is still not clear which kinds of mechanical tests are relevant for the evaluation of crash behavior of a profile. The other open question is how the crash behavior of a profile can be reliably simulated based on the material data determined from specimen tests. In this work different extruded aluminum profiles from five different 6000er and 7000er alloys were investigated by systematical characterization and simulations. To vary the stress state smooth tensile, holed tensile, notched tensile, shear and punch specimens were tested under static and partially under dynamic loading. Local strain fields in the specimens were measured with an optical method (ARAMIS) during test. A correlation between strength and anisotropy effect was found. The specimen tests were simulated with isotropic and anisotropic material models in the cases that the anisotropic effect is pronounced. A damage model based on a failure strain as a function of stress triaxiality is used. Several component tests on profiles under compression and bending were performed to validate the applied material and damage model. The crash behavior of the profiles is influenced by the profile geometry especially the wall thickness and loading type. The used simulation method is able to predict the deformation patterns and damage developments in the deformed profiles. In many cases the application of the isotropic material model in combination with the isotropic damage model results in a rather good agreement between simulations and component tests with respect to both global and local behavior.


Dr. Dong-Zhi Sun
Fraunhofer Institute for Mechanics of Materials IWM
Additional Authors:
  • Dr. Florence Andrieux
    Fraunhofer Institute for Mechanics of Materials IWM
  • Clemens Fehrenbach
    Fraunhofer Institute for Mechanics of Materials IWM