Characterization and modeling of aluminum extrusion damage under crash loading

This paper studied the deformation and damage behaviors of aluminum-alloy under different loadings. A series of static and dynamic plate tension tests, notch tension tests and shear tests were carried out and were combined with the finite element model to acquire material parameters. This work demonstrated that damage behavior of aluminum-alloy depends strongly on stress triaxiality and cannot be modeled with simple damage models based on one constant fracture strain. A systematic investigation shows that the micromechanical Gurson damage model and phenomenological Johnson-Cook model can be used to simulate crash behavior of aluminum components. The tests on an aluminum component of extrusion under static loading were performed and simulated to validate the applicability of Gurson damage model. Since damage parameters depend on element size, the component calculation was performed with the calibrated parameters optimized with the element sizes.