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Experimental Techniques for Shear Testing of Thin Sheet Metals and Compression Testing at Intermediate Strain Rates

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Experimental Techniques for Shear Testing of Thin Sheet Metals and Compression Testing at Intermediate Strain Rates Experimental Techniques for Shear Testing of Thin Sheet Metals and Compression Testing at Intermediate Strain Rates THESIS Presented in Partial Fulfillment of the Requirements for the Degree Master of Science in the Graduate School of The Ohio State University By Kevin Alexander Gardner, B.S. Graduate Program in Mechanical Engineering The Ohio State University 2013 Master’s Examination Committee: Dr. Amos Gilat, Advisor Dr. Mark Walter c Copyright by Kevin Alexander Gardner 2013 Abstract A new specimen geometry for the characterization of thin sheet metals in simple shear is introduced. The objective of this work is to develop methods to generate experimental data that populate material models for numerical simulations. The new simple shear specimen, based on ASTM B831, can be tested in both quasi- static and dynamic conditions using a servo-hydraulic load frame and tension Kolsky bar, respectively. Specimens are fabricated from a 0.5in Al2024-T351 plate with their gage sections orientated in various directions. Tests are conducted at shear strain rates ranging from 0.01s−1 to 9000s−1. Traditionally, shear characterization is performed through torsion tests on thin walled tube specimens, which are impossible to fabricate from thin sheet metals. The proposed specimen geometry is evaluated by comparing data obtained using the new specimen to existing torsion data. Three- dimensional Digital Image Correlation (DIC) is used to directly measure deformation on the surface of specimen gage sections for all tests. Stress versus strain curves obtained from tests using both specimen geometries agree, indicating that the new specimen geometry is suitable for use in characterizing thin sheet metals in shear. Additionally, the new specimen geometry is able to capture anisotropic effects which are averaged in torsion data on thin walled tube specimens. A parallel LS-DYNA simulation is conducted to investigate the strain state within the gage section during ii a test and compare to experimental data measured with DIC. Results show that a nearly uniform state of shear strain exists until large strains are developed. An intermediate strain rate apparatus is used to characterize Al2024-T351 and Cu-101 in compression at a strain rate of 100s−1. The proposed intermediate strain rate apparatus consists of a linear hydraulic actuator to generate the loading and a long transmitter bar. The specimen is placed on the end of the transmitter bar and loaded directly by the actuator. When the specimen is loaded, a compression wave propagates down the transmitter bar and reflects back towards the specimen when it reaches the end of the bar. A long transmitter bar allows the test to continue until the reflected wave reaches the specimen. Ample time (16ms) is provided to accumulate significant strain at intermediate strain rates without inertial effects (ringing) that are common to other intermediate strain rate testing techniques. Two materials, Al2024- T351 and Cu-101 are tested. Previous data shows Al2024 does not exhibit strain rate sensitivity below 5000s−1 while Cu-101 does. Specimens from both materials are tested in compression at strain rates ranging from 0.01s−1 to 5000s−1 using a load frame, the proposed intermediate strain rate apparatus, and a compression Kolsky bar. DIC is used to measure deformation on the surface of the specimen for all tests. Experimental data shows the intermediate strain rate apparatus is able to capture the expected data trends and is not subjected to the ringing observed by other common intermediate strain rate test techniques. iii This document is dedicated to my family and close friends. iv Acknowledgments There have been many people who have helped me reach this point in my life and I would like to acknowledge them for all of their help and support. First and foremost I would like to thank my parents Kevin and Anayanci Gardner. Their constant love and support has helped me in attaining my goals. My advisor, Professor Amos Gilat, has made my graduate experience all that it is. He is both inspiring and supportive and it is a great honor to work with such a highly regarded expert in the field of mechanics of materials. Recognition is due to Dr. Jeremy Seidt as well. Jeremy has become a good friend and an esteemed colleague, constantly offering insight and guidance making him invalueable as a second advisor. I would also like to thank Professor Mark Walter for taking the time to serve as my thesis defense committe member. I would like to thank Jerry Hoff, Larry Antal, and Ryan Shea of the Chemistry Dept’s machine shop. They fabricated all of the specimens and fixtures used in this research. This research was funded by the Federal Aviation Administration. Thanks to Don Altobelli, Bill Emmerling, and Chip Queitzsch from the FAA for all of the support given and the strong relationship they have developed with our research group. The construction of the intermediate strain rate apparatus was supported by NASA (NRA Grant NNX08AB50A). v Thanks also to Steven Whitaker, Jarrod Smith, Tim Liutkus, Jeremiah Hammer, Tom Matrka, and Bob Lowe. These students and researchers in the Mechanical and Aerospace Engineering Department at The Ohio State University have been integral in my efforts through technical discussions and more importantly, the friendships they have provided. vi Vita 2007 ........................................Warren Local High School, Vincent, OH 2011 ........................................B.S. Mechanical Engineering, The Ohio State Univeristy 2011-2012 ..................................Graduate Fellow, Dynamic Mechanics of Materials Laboratory, Department of Mechanical and Aerospace Engineering, The Ohio State University 2012-present ................................Graduate Research Assistant, Dynamic Mechanics of Materials Laboratory, Department of Mechanical and Aerospace Engineering, The Ohio State University Publications: Gardner, K.A., Seidt, J.D., Isakov, M., Gilat, A., “Characterization of Sheet Metals in Shear over a Wide Range of Strain Rates”, Proceedings of the 2013 SEM Annual Conference and Exposition on Experimental and Applied Mechanics, Lombard, IL, June, 2013 Fields of Study Major Field: Mechanical Engineering Specializations: Experimental Mechanics, Dynamic Behavior of Materials, Plastic- ity, Computational Mechanics vii Table of Contents Page Abstract....................................... ii Dedication...................................... iv Acknowledgments.................................. v Vita ......................................... vii ListofTables.................................... xi ListofFigures ................................... xii 1. Introduction.................................. 1 1.1 MotivationandObjectivesfortheResearch . 4 2. ShearTestingofThinSheetMetals . 6 2.1 Literature Review - Characterizing Thin Sheet Metals in Shear . 6 2.1.1 DoubleNotchShearSpecimen . 7 2.1.2 Eccentric Notch Shear Specimen . 10 2.1.3 Twin Bridge Shear Specimen . 12 2.1.4 Shear-CompressionSpecimen . 14 2.1.5 Simple Shear Specimen . 16 2.2 IntroductionofaShearSpecimen . 18 3. Simple Shear Experimental Results and Discussion . 20 3.1 ExperimentalTestPlan ........................ 21 3.1.1 Simple Shear Specimens . 23 3.1.2 TorsionSpecimens ....................... 24 viii 3.2 Quasi-StaticTestingTechnique . 25 3.3 HighStrainRateTestingTechniques . 28 3.3.1 High Strain Rate Tension Apparatus . 29 3.3.2 High Strain Rate Torsion Apparatus . 38 3.4 DigitalImageCorrelation ....................... 43 3.5 ExistingExperimentalData . 47 3.6 StrainRateEffects........................... 51 3.7 AnisotropicEffects ........................... 52 3.8 Results from Numerical Simulation . 53 4. IntermediateStrainRateTesting . 59 4.1 Literature Review - Intermediate Strain Rate Testing . 59 4.1.1 RepeatedLoadingTechnique . 60 4.1.2 ModalAnalysisofLoadFrame . 62 4.1.3 LongKolskyBar ........................ 64 4.2 Introduction of an Intermediate Strain Rate Apparatus . .. 65 5. Compression Experimental Results and Discussion . .. 67 5.1 ExperimentalTestPlan ........................ 67 5.1.1 CompressionSpecimens . 69 5.2 Quasi-StaticTestingTechnique . 70 5.3 Intermediate Strain Rate Testing Technique . 71 5.4 HighStrainRateCompressionApparatus . 78 5.5 IntermediateStrainRateData . 83 5.6 StrainRateEffect ........................... 85 6. SummaryandConclusions.......................... 87 6.1 Simple Shear Experimental Conclusions . 87 6.2 Compression Experimental Conclusions . 88 Appendices 90 A. Experimental Results from the Simple Shear Test Series . .. 90 A.1 SimpleShearResults.......................... 91 A.1.1 Rolled Direction . 91 A.1.2 TransverseDirection . 95 A.1.3 45◦ from Rolled Direction . 99 A.2 TorsionResults............................. 103 ix B. Experimental Results from the Test Series Evaluating the Intermediate StrainRateApparatus . .. .. 104 B.1 Results from the 0.5inAl2024-T351Plate . 105 B.2 Results from the 0.25inCu-101Rod ................. 109 Bibliography .................................... 113 x List of Tables Table Page 3.1 Test plan to evaluate simple shear geometry . 22 3.2 Material parameters used for numerical study . 55 5.1 Test plan to evaluate intermediate strain rate apparatus . .. 68 xi List of Figures Figure Page 1.1 Experimental test techniques for various strain rates . .... 5 2.1 Ti-6Al-4V shear stress vs. shear strain data from torsion tests on spool shapedspecimensatvariousstrainrates . 7 2.2 Guo, et al.’s FE model of the SHB clamp assembly . 8 2.3 Guo, et al.’s double notch specimen . 8 2.4
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