Anti-Buckling Device for Ultra-Thin Metallic Sheets Under Large and Reversed Shear Strain Paths

Abstract

The kinematic contribution to the hardening of ultra-thin metallic sheets characterized by monotonic and reversed simple shear tests is of high interest in the sheet metal forming industry, because of its influence on the accurate prediction of springback. However, ultra-thin sheets are very sensitive to buckling when submitted to shear stress because of the large gauge width to thickness ratio, the stress perturbations induced by the clamping and the alignment of sample, which thus limit the attainable strain levels using conventional simple shear devices. In this paper, a new simple shear test dedicated to ultra-thin metallic sheets is proposed through the development of a specific support. A transparent glass part enables the application of a normal tightening force to prevent the out-of-plane buckling of the sheets whilst also allowing full field strain measurements to be taken. Firstly, the capabilities of the device are shown by comparing the mechanical behavior in a simple shear test on an austenitic stainless steel with and without the support. A good reproducibility of the flow curves is observed with the support and large shear strains are reached without buckling. Secondly, the influence of friction due to the contact between the sample and the support is checked by finite elements simulations and shown to be negligible compared to the shearing force. Finally, monotonic and reversed shear tests on a pure copper sheet with a thickness of 0.1 mm were performed up to rupture without buckling, these were not previously conceivable on such a low thichness, and demonstrate the potential of the proposed device.