Abstract
Mechanical shearing introduces a material limit lower than the onset of local necking. This new limit is critical for understanding and predicting material performance in industrial forming applications. The sheared edge condition, influenced by strain hardening and microstructural damage, reduces ductility in the shear-affected zone, posing challenges for reliable characterization and numerical prediction. This study presents an approach that integrates finite element modelling (FEM) with geometric shape matching to establish a practical, simulation-compatible material limit for sheared-edge formability. Instead of relying on localized strain measurements, the methodology determines the punch displacement in FEM simulations that best replicates the experimentally observed deformed geometry of Hole Expansion Capacity (HEC) test specimens, along with the corresponding maximum deformation of elements at the stretched edges. The method proves effective for industrial forming processes, enhancing FEM-based edge failure prediction and providing a valuable tool for process optimization and defect troubleshooting in sheet metal forming.
Keywords
Metal forming, Shearing, Sheet metal, Strain measurement, Edge conditions, Element models, Industrial practices, Laboratory practices, Local necking, Material limits, Material performance, Mechanical shearing, Micro-structural damages, Numerical predictions, Ductility
Reference
Chezan, T., Dhawale, T., Pilthammar, J., Barlo, A., Hol, J., & Manopulo, N. (2025). Bridging laboratory and industrial practices in sheared edge ductility evaluation. In Journal of Physics : Conference Series (Vol. 3104, Article 012020). Institute of Physics (IOP). Presented at 13th International Conference on Numerical Simulation of 3D Sheet Metal Forming Processes, NUMISHEET 2025, July, 7-11, 2025. https://doi.org/10.1088/1742-6596/3104/1/012020