A multiscale approach to modeling formability of dual-phase steels

A multiscale modeling approach is used to predict how the formability of dual-phase (DP) steels depend on the properties of their constituent phases and microstructure. First, the flow behavior of the steels is predicted using microstructure-based finite element simulations of their 3D representative volume elements, wherein the two phases (ferrite and martensite) are discretely modeled using crystal plasticity constitutive models. These results are then used to calibrate homogenized constitutive models which are then used in large-scale finite element simulations to compute the forming limit diagrams (FLDs). The multiscale approach is validated by predicting the FLDs of two commercial DP steels and comparing the predictions with experimental measurements. Subsequently, the approach is used to compute flow behavior and FLDs of a series of 'virtual' DP steels, constructed by varying the microstructural parameters in the commercial DP steels. The results of these computations suggest that combining the ferrite from one of the two commercial steels with the martensite of the other and optimizing the phase volume fractions can yield 'virtual' steels with substantially improved properties. These include a material with an FLD0 (plane strain) that exceeds those of the commercial steels by 75% without a degradation in strength; and a material with a flow strength (0.2% offset) that exceeds those of the commercial steels by ~30% without degradation of formability.

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