Formability analyses during multi-stage SPIF process using optimized ductile fracture locus
Abdul Samad, Shamik Basak
Abstract. Multi-stage single-point incremental forming (MSPIF) is a complicated process requiring specialized methods for predicting formability at fracture inception. Thus, ductile damage criteria are frequently considered essential tools for conceptually assessing formability limitations during the MSPIF process. The current study examined the formability of EDD steel sheets during MSPIF utilizing an uncoupled modified Mohr-Coulomb (MMC) ductile damage model. Furthermore, an attempt was made to calibrate the MMC fracture locus by using the plain strain (PS), shear (SH), and optimized central hole (CH) fracture specimens. It was found that the CH geometry with a 5 mm hole diameter (CHD5) exhibited stress triaxiality and Lode angle parameter values matching with a pure uniaxial tensile stress state. As a result, the CHD5 geometry was regarded as optimal and then used to calibrate the MMC damage model along with the PS and SH geometries. Furthermore, the generated MMC locus was used in a finite element (FE) simulation of the MSPIF process along with the Hill48 anisotropic material model to investigate post-formability behavior. Furthermore, two MSPIF strategies with variations in angle and part depth, namely S1 and S2, were employed to produce the MSPIF cups. It was found that the percentage error in the experimental and numerically anticipated dome height of the MSPIF cups was 7.20% and 4.62% for the S1 and S2 strategies, respectively.
Keywords
Fracture Geometry Optimization, Ductile Damage Modeling, Multi-Stage SPIF
Published online 5/7/2025, 10 pages
Copyright © 2025 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: Abdul Samad, Shamik Basak, Formability analyses during multi-stage SPIF process using optimized ductile fracture locus, Materials Research Proceedings, Vol. 54, pp 1229-1238, 2025
DOI: https://doi.org/10.21741/9781644903599-134
The article was published as article 134 of the book Material Forming
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
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