Ductile damage prediction in sheet and bulk metal forming

This paper is dedicated to the presentation of an advanced 3D numerical methodology for virtual sheet and/or bulk metal forming simulation to predict the anisotropic ductile defects occurrence. First, the detailed formulation of thermodynamically-consistent fully coupled and fully anisotropic constitutive equations is given. The proposed constitutive equations account for the main material nonlinearities as the anisotropic plastic flow, the mixed isotropic and kinematic hardening and the anisotropic ductile damage under large inelastic strains. Second, the related numerical aspects required to solve the initial and boundary value problem (IBVP) are very briefly presented in the framework of the 3D finite element method. The global resolution schemes as well as the local integration schemes of the fully coupled constitutive equations are briefly discussed. Finally, some typical examples of sheet and bulk metal forming processes are numerically simulated using the proposed numerical methodology.