Physically-based constitutive description of a commercial Al-Mg-Si alloy deformed under cold-warm working conditions

Abstract

The experimental and numerical modeling of cold forging operations conducted on commercial Al alloys requires a precise knowledge of the functional dependence of both flow stress and work-hardening rate on microstructure and deformation conditions. In order to contribute to the improvement of the finite element computer modeling of forming operations conducted on Al alloys, under cold-warm working conditions, an original and rational constitutive description, able to predict accurately both the flow stress and work-hardening rate of an AA6082-T6 Al alloy is proposed. The constitutive formulation has been developed on the basis of the Mechanical Threshold Stress (MTS) model and its applicability is limited to the deformation of the material under cold-warm working conditions, that is to say, in the temperature range of 298–423 K. A novel differential equation for the description of the continuous change in the work-hardening rate of the alloy has been developed, which allows the prediction of the changes in flow stress and work-hardening rate during deformation either under constant and variable temperature and strain rate conditions. The validation of the developed constitutive description has been accomplished by its implementation into a finite element (FE) model for the accurate prediction of the change in some local contact parameters, such as contact pressure, sliding velocity and interface temperature, during the friction test employed in the evaluation of friction conditions in metalworking, known as the Upsetting Sliding Test (UST).