Experimental and numerical study on shear-punch test of 6060 T6 extruded aluminum profile

In the present work a comprehensive experimental/numerical study on a 6060 T6 bumper profile subjected to combined shear-compression (shear-punch test) load is carried out. A set of key plasticity and fracture parameters to predict correctly the mechanical response of the structural component is required. Fracture initiation tests on lab scale specimens provide the sufficient data needed to calibrate the newly extended non-quadratic yield function Yld2000-3d and the isotropic Modified Mohr-Coulomb (MMC) fracture model. The calibrated plasticity and fracture constitutive model is then validated upon disk-shaped specimen. Moreover, test results are reported on full-scale extruded aluminum bumper subjected to shear-punch load. A detailed FE model of the bumper and the supporting structure was built. The numerical simulation outcomes demonstrate that the calibrated material model predicts correctly not only the global force-displacement response but also the local fracture behavior at multiple initiation points. It was shown that various part of the multi-cell cross-section of the extruded profile underwent different loading histories. Thus, in one single test a wide range of stress triaxialities develop which requires to introduce a very complete plasticity and fracture model.