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 HFQTM, 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 ∘C–525 ∘C 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.