Analysis of Surface Roughening in AA6111 Automotive Sheet Under Pure Bending

The finite element method is used to numerically simulate the topographic development in an aluminum sheet, AA6111, under pure bending. The measured electron backscatter diffraction 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 effects of strain-rate sensitivity, work hardening, and imposed initial surface roughness on surface roughening are studied. It is found that the grains in top surface layers of the sheet play a big role in controlling the outer surface roughness due to the strain gradient across sheet thickness in bending, while the grain size and texture of the surface layers have a direct impact on finishing surface qualities.