Study of the Effect of Calibration Procedure on the Accuracy of the Phenomenological Ductile Fracture Criteria in Sheet Metal Forming

In this paper, determination of the fracture onset by the ductile fracture criteria was studied and the effect of damage function, calibration method, and calibration tests were investigated on the fracture prediction accuracy. Based on the stress state analysis, three different tension tests including the uniaxial, plane strain, and notched tension tests were conducted to determine the critical value of the ductile fracture criteria. In order to investigate the fracture behavior of AA6061-T6 aluminum alloy sheets, The Ayada, Rice-Tracey, and normalized Cockroft-Latham phenomenological ductile fracture criteria were calibrated through a hybrid experimental-numerical method. The finite element (FE) method were used to simulate the process and calibrated fracture criteria were implemented using an appropriate user subroutine. Experimental force-displacement curve and the fracture displacement were used to validated the numerical simulation and investigate the fracture prediction accuracy. According to the result, calibration method based on the history of the stress state lead to higher fracture prediction accuracy compared to average value method (3.4% decrease in average value of the fracture prediction error). Among all the possible condition, the normalized Cockroft-Latham fracture criteria with the plane strain tension test are the most suitable fracture criterion and calibration test to predict the fracture in the positive value of the stress triaxiality.