Article (Scientific journals)
Impact of hardening law on the FEM prediction of residual stresses in copper-clad aluminum wires
Dashti, Alireza; Keller, Clément; Vieille, Benoit et al.
2023In International Journal of Advanced Manufacturing Technology
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Keywords :
Aluminum; Bimetallic composite; Copper; Finite element analysis; Isotropic-kinematic hardening; Wire drawing; Aluminum wires; Back stress; Bimetallic composites; Copper clad aluminium; Finite element analyse; Hardening laws; Isotropics; Near surfaces; Tensile residual stress; Control and Systems Engineering; Software; Mechanical Engineering; Computer Science Applications; Industrial and Manufacturing Engineering
Abstract :
[en] Near-surface axial tensile residual stresses (from manufacturing) are reportedly detrimental to the yield strength of cold-drawn wires. Therefore, a reliable evaluation of their magnitude is necessary. The size and geometry of electrical wires can pose challenges for experimental measurement of those residual stresses. For that reason, the finite element analysis can prove useful. However, great care must be taken with the right choice of strain hardening law for a sound assessment of residual stresses. Given the complex loading condition during cold drawing, cyclic loading arises through the wire cross section even in single-pass drawing. As a result, it is of crucial importance to account for associated backstresses. The current study makes a comparison between two different hardening laws’ prediction of axial residual stress profiles in numerically cold-drawn Cu–Al composite wires of various Al volume fractions. The impact of die geometry on this prediction was also examined for a 25%Al-wire. To that end, a combined isotropic-kinematic law and a pure isotropic constitutive equation were considered. The results imply a possible overestimation of residual stresses by the pure isotropic model at relatively low Al volume fractions. The difference between the maximum magnitudes of tensile or compressive residual stresses (predicted by the two models) could be as large as about 100 MPa (larger than the yield strength of the starting materials). Furthermore, the tooling geometry minimally affects the prediction of the hardening models. In conclusion, backstresses are not to be overlooked for accurate estimations of drawing residual stresses at low Al volume fractions.
Disciplines :
Materials science & engineering
Author, co-author :
Dashti, Alireza ;  Groupe de Physique Des Matériaux, UMR CNRS 6634, Normandie Université, avenue de l’Université, Saint-Etienne du Rouvray, France
Keller, Clément;  LGP - Laboratoire Génie de Production – ENIT, Tarbes, France
Vieille, Benoit;  Groupe de Physique Des Matériaux, UMR CNRS 6634, Normandie Université, avenue de l’Université, Saint-Etienne du Rouvray, France
Guillet, Alain;  Groupe de Physique Des Matériaux, UMR CNRS 6634, Normandie Université, avenue de l’Université, Saint-Etienne du Rouvray, France
Gallo, Calogero  ;  Université de Liège - ULiège > Urban and Environmental Engineering
Habraken, Anne  ;  Université de Liège - ULiège > Département ArGEnCo > Département Argenco : Secteur MS2F
Duchene, Laurent  ;  Université de Liège - ULiège > Département ArGEnCo > Analyse multi-échelles dans le domaine des matériaux et structures du génie civil
Language :
English
Title :
Impact of hardening law on the FEM prediction of residual stresses in copper-clad aluminum wires
Publication date :
2023
Journal title :
International Journal of Advanced Manufacturing Technology
ISSN :
0268-3768
eISSN :
1433-3015
Publisher :
Springer Science and Business Media Deutschland GmbH
Peer reviewed :
Peer Reviewed verified by ORBi
Funders :
INSA Rouen - Institut National des Sciences Appliquées de Rouen [FR]
Funding text :
The authors received the funding from The Region of Normandy.
Available on ORBi :
since 21 February 2024

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