Failure modelling in metal forming by means of an anisotropic hyperelastic-plasticity model with damage

In metal forming, formability is limited by the evolution of ductile damage in the work piece. The accurate prediction of material failure requires, in addition to the description of anisotropic plasticity, the inclusion of damage in the finite element simulation. This paper discusses the application of an anisotropic hyperelastic-plasticity model with isotropic damage to the numerical simulation of fracture limits in metal forming. The model incorporates plastic anisotropy, nonlinear kinematic and isotropic hardening and ductile damage. The constitutive equations of the proposed model are numerically integrated both implicitly and explicitly, and the model is implemented as a user material subroutine UMAT in the commercial solvers ABAQUS/Standard and LS-DYNA, respectively. The numerical examples investigate the potential of the constitutive framework regarding the prediction of failure in metal forming processes such as, e.g. cross-die deep drawing. In particular, simulations of the Nakazima stretching test with varying specimen geometry are utilized to simulate the forming limit diagram at fracture and the numerical results are compared to experimental data for aluminium alloy sheets.