Abstract
Simulation codes use constitutive relations of work hardening to virtually predict shape change during metal forming. Recent analysis has shown that the modified Hollomon-type relation correlates to stress -aided thermal activation at obstacles for dislocation movement. The sweeping action of dislocation gives rise to strain and the dislocation intersections to strain rate sensitivity during work -hardening. The constitutive relation analyses (CRA) encompass fitting parameters which remain constant with strain and its validation is the precision to replicate the measured stress -strain diagram. In this study, digital constitutive analyses (DCA) are examined whereby the modelled -fit parameters are simultaneously numerically adjusted as strain proceeds. For bulk properties such as expended work, volume fraction of vacancy creation and mean slip velocity, CRA predictions have been validated. However, DCA enables the identification of defects being created with strain using derived obstacle -strength factor (alpha gamma). The changes in mechanisms during work -hardening can be decoded using the alpha gamma - gamma plot whereby constant alpha gamma indicate steady-state deformation and its rapid decrease, the start of diffuse necking. Thus, alpha gamma is a composite factor of defects being continuously created whereas conventional alpha is a measure of the stored work up to that strain. The tensile data from polycrystalline super -pure aluminum tested at 78 K were used to validate the derived relations which were applied to the DCA of age-hardenable aluminum alloys tested at 298 K. The present work shows that integral replication of stress -strain diagram is essential, but a differential analysis is required to devolve the creation of crystal defects with strain.