An Experimental and Numerical Assessment of Sheet-Bulk Formability of Mild Steel DC04

This paper presents investigations on development of a new way of teeth-forming, which is related to sheet-bulk metal forming, with application of incremental bulk forming process to sheets. For this purpose, a combined experimental-numerical study on damage assessment in sheet-bulk forming of DC04 is presented. Using scanning electron microscope (SEM) and glow discharge optical emission spectrometry (GDOS), a combined quantitative/qualitative metallurgical survey is carried out on undeformed specimens to illuminate microstructural aspects in the context of nonmetallic inclusion content, distribution and size which act as prime failure factors. These surveys are extended to monitor ductile damage accumulation with cavitation at different stages of the incremental sheet indentation process over certain sections. An anticipated failure mode is captured where formability is limited by severe macro-cracking preceded by localization with void sheeting. To this end, using a developed VUMAT subroutine for the micromechanically based Gurson damage model which is recently enhanced for shear fracture, the processes are simulated in ABAQUS/Explicit and comparisons with experiments are provided. The results support the requirement of integrating powerful coupled accumulative damage models in the virtual process design procedure for sheet-bulk metal forming. This requirement also arises from distinct features of these class of processes from conventional sheet metal forming processes which preclude use of forming limit curves.