Finite element modeling of a novel cutting deformation mode of AA6061-T6 tubes employing higher order Lagrangian element formulations

A finite element model of axial cutting of an aluminum extruded tube was developed with the IMPETUS Afea solver®. Uniaxial tensile tests and VDA 238 plate bending tests were completed to identify material model parameters including the necessary data for a Cockcroft-Latham damage model. Inverse material model development was completed with a custom interface between LS-OPT and IMPETUS. The Cockcroft-Latham parameter was noted to be approximately 100% larger when identified from inverse material modeling with respect to analytical calculations from uniaxial tensile tests. The model is capable of accurately capturing the force versus deflection response with Oberkampf-Trucano validation metrics exceeding 0.9 demonstrating greater accuracy than previous modeling efforts with an alternative commercial solver. Additionally, the IMPETUS model captures deformation mechanisms critical to the development of an analytical model with less than 20% error enhancing confidence in both approaches.