Fracture Evaluation of Anisotropically Deformed Advanced High-Strength Sheet Steel through Stress-Based Forming Limit Curves and Fracture Loci

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This research focuses on formability analysis of the complex S-rail drawing parts made out of the 1-mm thick DP590 and DP780 advanced high-strength steel sheets. Developing formability evaluation tools across an extensive breadth of deformation states begins with the acquirement of principal fracture strains at varying strain ratios. Two simple tensile tests on two different sophisticatedly designed butterfly specimens are carried out to obtain fracture strains on the pure-shear state and the state in between the pure shear and uniaxial tension. Meanwhile, for the strain states from the uniaxial to the balanced biaxial tension, the stretching test with a hemispherical punch are conducted on Nakajima samples with five varying widths. Based on those strain data, a fracture forming limit curve (FFLC), a fracture forming limit stress curve (FFLSC) and two fracture loci (FLs) based on the Lou-Huh (LH) and Hosford-Coulomb (HC) ductile fracture criteria (DFCs) are settled for both steels. All fracture criteria are experimentally and simulatively verified against strain or stress paths extracted from the fracture area of the deep-drawn DP590 and DP780 S-rail parts. Both strain-based FFLCs unfortunately do not sense part failure. In contrast, the FFLSCs, LH-FLs and HC-FLs, counting on the anisotropic Hill’48 yield criterion and hybrid Swift-Voce strain hardening law, well capture the fracture moment of both deep-drawn DP590 and DP780 S-rail parts. By the way, the DP780 LH-FL debatably has the edge over the DP780 HC-FL. This study confirms the need for inclusion of such deformation behaviors as anisotropy and strain hardening into sheet formability investigation of complex parts.

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Materials Science Forum (Volume 1173)

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3-10

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December 2025

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© 2025 Trans Tech Publications Ltd. All Rights Reserved

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