Analysis of surface roughening in AA6111 automotive sheet

The finite element method is used to numerically simulate the topographic development in an aluminium sheet, AA6111, under stretching. The measured electron backscatter diffraction (EBSD) data are directly incorporated into the finite element model and the constitutive response at an integration point is described by the single crystal plasticity theory. The effect on surface roughening of sample geometry, strain rate sensitivity, work hardening, imposed deformation path, as well as the EBSD step size, spatial orientation distribution and inhomogeneous deformation within individual grains are discussed. It is concluded that surface roughening is controlled by the spatial distribution of grain orientations through the thickness of the specimen.