Multiscale simulation of surface roughening of a deep drawing steel due to subsurface plastic deformation

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Abstract

Surface roughness due to plastic deformation is important as it impacts both the surface properties of finished parts and tribological conditions during metal forming. In the present study, an approach for modeling free surface roughening due to the heterogeneous microstructure of polycrystals, where grains deform differently, is presented and validated experimentally for uniaxial tension. Roughening is modelled by finite element crystal plasticity simulations. Two methods of applying boundary conditions to the polycrystal are used. One method involves multi-scale modeling, where the continuum-scale simulation provides the submodel boundary conditions. In the second method, the elongation is applied directly by a moving periodic boundary. Material properties of DC04 steel sheet are measured by uniaxial tensile testing. Microstructure is characterized by optical microscopy and electron backscatter diffraction is used as input to generate representative simulation models. Material parameters for crystal plasticity are determined by matching simulation results to experimental stress-strain behavior. Experimental surface topography measurements by confocal microscopy after deformation are presented and compared to simulated surface topographies to assess the accuracy of the finite element model. Simulated surface roughness values of free surfaces in the model are also used as figures of merit for a convergence study of finite element parameters.
Original languageEnglish
Article number01062
JournalMATEC Web of Conferences
Volume408
Number of pages6
ISSN2261-236X
DOIs
Publication statusPublished - 2025
Event44th Conference of the International Deep Drawing Research Group - Lisbon, Portugal
Duration: 1 Jun 20255 Jun 2025

Conference

Conference44th Conference of the International Deep Drawing Research Group
Country/TerritoryPortugal
CityLisbon
Period01/06/202505/06/2025

Keywords

  • Multiscale simulation
  • Crystal plasticity
  • Surface roughening
  • Deep drawing steel

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