Prediction and analysis of fracture in single point incremental forming using a damage based material model

Rajiv Malhotra, Liang Xue, Jian Cao, Ted Belytschko, K. Scott Smith, John Ziegert

Research output: Chapter in Book/Report/Conference proceedingConference contribution


Incremental forming is a sheet metal forming process that has envisioned considerable interest in the research community due to greater formability, economical and product independent tooling and greater process flexibility. However, lack of the ability to predict fracture has considerably hindered its industrial adoption. This work uses finite element analysis with a damage based material model to predict fracture in Single Point Incremental Forming (SPIF). The fracture envelope is described in the stress space and is a function of both the hydrostatic pressure and the deviatoric stress state. The tool forces and fracture depths from simulations and those from experiments are found to agree with each other well. An in-depth analysis of the deformation is performed to show that the through-the-thickness shear affects the formability much more significantly than the hydrostatic pressure. Furthermore, the implications of this effect on increasing formability in SPIF are discussed.

Original languageAmerican English
Title of host publication39th North American Manufacturing Research Conference 2011 - Transactions of the North American Manufacturing Research Institution of SME
Number of pages10
StatePublished - 2011
Externally publishedYes
Event39th Annual North American Manufacturing Research Conference, NAMRC39 - Corvallis, OR, United States
Duration: Jun 13 2011Jun 17 2011

Publication series

NameTransactions of the North American Manufacturing Research Institution of SME


Other39th Annual North American Manufacturing Research Conference, NAMRC39
Country/TerritoryUnited States
CityCorvallis, OR

ASJC Scopus subject areas

  • Mechanical Engineering
  • Industrial and Manufacturing Engineering


  • Damage plasticity model
  • Fracture
  • Hydrostatic pressure
  • Single point incremental forming (SPIF)
  • Through-the-thickness-shear

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