Numerical investigation on bending characteristic and ductile fracture of AA7075 thin-walled beam using advanced orthotropic plasticity and fracture models

Abstract

Thin-walled structures manufactured from the 7075 aluminum alloy are gaining tremendous attention in the automotive industry for their potential to reduce vehicle weight. However, the bending characteristics and rupture behavior of the AA7075 thin-walled beams under unexpected collision events have not been extensively studied. This study aims to fill that gap through a detailed numerical investigation of the bending deformation and failure mechanism of AA7075 thin-walled beams under quasi-static three-point bending at room temperature. Full-size, three-dimensional numerical simulations of laboratory-scale AA7075-T6 hat-shaped beam were conducted using the ABAQUS/Explicit solver. The material elastic–plastic response is described by a rate-independent constitutive description, incorporating advanced non-quadratic orthotropic plasticity and anisotropic ductile fracture criteria via VUMAT subroutines. Results indicate that the simulations accurately reproduced experimental observations, including the loading-displacement curves and deformation patterns. The bending behavior of the AA7075-T6 thin-walled beams aligns with typical bending collapse mechanisms, consistent with Kecman’s theory. The rupture process exhibits ductile fracture characteristics, with heterogeneous stress distribution across the material thickness affecting crack initiation rates between the upper and lower surfaces. Notably, the stress state at the fracture’s half-thickness section approximates an equi-biaxial tension condition. These findings provide essential insights into the bending deformation and failure mechanisms of AA7075 thin-walled structures under unexpected impact loading.