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<p>The failure mode during the deformation of thin sheet components is primarily governed by the choice of forming processes and the sheet materials. In this research, both the necking and fracture failure of extra deep drawing steel sheets of 1.0&#xa0;mm and 1.5&#xa0;mm thicknesses were investigated while subjected to various forming processes. The stretch-forming (SF) tests, single point incremental forming (SPIF) tests, and central hole (CH) fracture tests were conducted using various sample geometries. These tests were continued until there was a hint of necking failure for SF tests and fracture failure for SPIF and CH tests on the surface. The necking-dominated forming limit diagrams (FLDs) and fracture-dominated fracture FLDs (FFLDs) were analytically estimated using the Marciniak–Kuczyński (MK) theory and Bao–Wierzbicki (BW) ductile fracture theory, respectively, incorporating two different anisotropic yield models including Barlat Yld89 and Yld2000-2d. Moreover, the Yld89 model was calibrated using both plastic strain ratio (Yld89-<InlineEquation ID="IEq1"> <EquationSource Format="TEX">\(r\)</EquationSource> <EquationSource Format="MATHML"><math> <mi>r</mi> </math></EquationSource> </InlineEquation>) and normalized stress ratio based (Yld89-<InlineEquation ID="IEq2"> <EquationSource Format="TEX">\(\sigma\)</EquationSource> <EquationSource Format="MATHML"><math> <mi>σ</mi> </math></EquationSource> </InlineEquation>) approaches. The finite element (FE) virtual experimentation method was used to predict the dome heights, surface strain distributions, and failure locations by implementing various anisotropic material models in conjunction with the FLDs/FFLDs. It was established that using the MK-FLD and BW-FFLD with the Yld2000-2d model exhibited an absolute average error of dome height prediction below 5%, combining all SF and SPIF cups. Furthermore, the strain paths for necked and fractured components were examined separately in the stress triaxiality and Lode parameter locus to get insight into the deformation.</p>

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Application of Necking and Uncoupled Ductile Fracture-Based Models to Estimate Formability of Thin Sheets Using Anisotropic Yield Theories

  • 期刊论文

  • 发表日期：

    2026年2月13日

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  • Amit Kumar,
  • Shamik Basak

摘要

The failure mode during the deformation of thin sheet components is primarily governed by the choice of forming processes and the sheet materials. In this research, both the necking and fracture failure of extra deep drawing steel sheets of 1.0 mm and 1.5 mm thicknesses were investigated while subjected to various forming processes. The stretch-forming (SF) tests, single point incremental forming (SPIF) tests, and central hole (CH) fracture tests were conducted using various sample geometries. These tests were continued until there was a hint of necking failure for SF tests and fracture failure for SPIF and CH tests on the surface. The necking-dominated forming limit diagrams (FLDs) and fracture-dominated fracture FLDs (FFLDs) were analytically estimated using the Marciniak–Kuczyński (MK) theory and Bao–Wierzbicki (BW) ductile fracture theory, respectively, incorporating two different anisotropic yield models including Barlat Yld89 and Yld2000-2d. Moreover, the Yld89 model was calibrated using both plastic strain ratio (Yld89- \(r\) r ) and normalized stress ratio based (Yld89- \(\sigma\) σ ) approaches. The finite element (FE) virtual experimentation method was used to predict the dome heights, surface strain distributions, and failure locations by implementing various anisotropic material models in conjunction with the FLDs/FFLDs. It was established that using the MK-FLD and BW-FFLD with the Yld2000-2d model exhibited an absolute average error of dome height prediction below 5%, combining all SF and SPIF cups. Furthermore, the strain paths for necked and fractured components were examined separately in the stress triaxiality and Lode parameter locus to get insight into the deformation.