Evaluation of Bao-Wierzbicki (BW) damage model in sheet metal forming processes

Damage growth phenomenon in sheet metal forming processes is one of the most important issues in the manufacturing industries. Predicting the onset and location of crack can help engineers to postpone the failure as well as to produce safe parts. In this research, first, six different calibration methods are employed for the Bao-Wierzbicki damage criterion. Then, to evaluate the accuracy of the calibration approaches, a few conventional sheet metal forming processes with the positive stress triaxiality are numerically simulated. Finally, the numerical predicted results are compared with the empirical tests. The comparisons reveal that the hyperbolic quadratic hyperbolic 3 (HQH3) method is the best calibration approach, due to its accuracy and the fewer number of required experimental tests for the calibration.