Abstract
A multi-scale simulation of the tip test, developed to determine the tribological characteristics of the back-extrusion process, was conducted on an AA 3003 alloy. A microstructure-level simulation, coupled with crystal plasticity finite element (CPFE) analysis, was utilized to characterize the macro-mechanical properties of the AA 3003. Owing to the limited size of the material provided, we performed CPFE analyses rather than multiple mechanical tests to determine the plastic anisotropy characteristics of the AA 3003 alloy. A three-dimensional finite element (FE) model of the tip test was developed using two different yield functions, namely the generalized von Mises yield function and Hill’s (1948) yield function, with material parameters identified from the CPFE analyses. The results revealed the following: 1. The directionality observed during the tip test is governed by the plastic anisotropy, rather than the frictional conditions. 2. The plastic anisotropy results in different Coulomb friction values. Therefore, the anisotropy should be carefully addressed in the tip test.
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