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<p>This work aims to develop polar effective plastic strain (PEPS) forming and fracture forming limit curves (FLC, FFLC) for combinations of DP440 dual-phase steel and AA2024-T3 aluminum alloy sheets, using advanced fracture and anisotropic yield criteria. Initially, experimental Nakajima testing and in-plane notched tensile tests were conducted to determine the conventional forming and fracture limit curves (FLC, FFLC), respectively. Additionally, two ductile fracture criteria (DFC), Lou-Huh and Modified Mohr–Coulomb (MMC), were incorporated to predict plastic strains at fracture associated with stress states, generating the fracture loci (FLs) and PEPS scales. Two different anisotropic yield criteria, specifically Hill’48 and Yld2000-2d, were applied for the formulation of limit curves and finite element analysis. Secondly, non-proportional loading paths were established for formability assessment by both experimental and numerical two-step forming tests to validate the applicability of all developed limit curves. In the comparison of FLs and PEPS curves, FLs demonstrate higher accuracy in predicting drawing depth compared to PEPS fracture limit curves. FLs derived from Lou-Huh (Yld2000-2d) provided excellent acceptable drawing depth at experimental fracture for both material classes. Conversely, the MMC model predicted fracture strains more accurately than Lou-Huh. In a localized necking condition, the established PEPS formability limits could more realistically predict results than the traditional FLC. The PEPS-FLC could enhance the assessment of formability for non-proportional loading paths.</p>

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Formability and fracture prediction using polar effective plastic strains and fracture loci with application in multi-step forming processes

  • 期刊论文

  • 发表日期：

    2025年9月8日

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  • Chutwin Amree,
  • Tanakorn Jantarasricha,
  • Sansot Panich

摘要

This work aims to develop polar effective plastic strain (PEPS) forming and fracture forming limit curves (FLC, FFLC) for combinations of DP440 dual-phase steel and AA2024-T3 aluminum alloy sheets, using advanced fracture and anisotropic yield criteria. Initially, experimental Nakajima testing and in-plane notched tensile tests were conducted to determine the conventional forming and fracture limit curves (FLC, FFLC), respectively. Additionally, two ductile fracture criteria (DFC), Lou-Huh and Modified Mohr–Coulomb (MMC), were incorporated to predict plastic strains at fracture associated with stress states, generating the fracture loci (FLs) and PEPS scales. Two different anisotropic yield criteria, specifically Hill’48 and Yld2000-2d, were applied for the formulation of limit curves and finite element analysis. Secondly, non-proportional loading paths were established for formability assessment by both experimental and numerical two-step forming tests to validate the applicability of all developed limit curves. In the comparison of FLs and PEPS curves, FLs demonstrate higher accuracy in predicting drawing depth compared to PEPS fracture limit curves. FLs derived from Lou-Huh (Yld2000-2d) provided excellent acceptable drawing depth at experimental fracture for both material classes. Conversely, the MMC model predicted fracture strains more accurately than Lou-Huh. In a localized necking condition, the established PEPS formability limits could more realistically predict results than the traditional FLC. The PEPS-FLC could enhance the assessment of formability for non-proportional loading paths.