An investigation of a new 2D CDM model in predicting failure in HFQing of an automotive panel

In this paper a comparative analysis of failure prediction when using the solution heat treatment cold die forming and quenching process, known as HFQ™, for forming an aluminium alloy AA6082 automotive panel part (bulkhead panel), is presented. An experimental programme has been designed and a series of tests have been carried out to investigate the effect of process parameters on the success of forming the complex-shaped automotive panel component using the high strength aluminium alloy. A set of unified viscoplastic plane-stress continuum damage mechanics (2D-CDM) constitutive equations was calibrated for AA6082 over a temperature range of 450 ºC–525 ºC and strain rates of 0.1, 1.0 and 10 s-1, and then was integrated into the commercial finite element code, LS-DYNA, via a user-defined material subroutine, UMAT, for the forming process simulation. The results show that the CDM model can be used to provide accurate formability and failure predictions