Modelling of Damage in Blanking Processes

Fracturing by ductile damage occurs quite naturally in metal forming process due to the development of microcracks associated with large straining or due to plastic instabilities associated with material behavior and boundary conditions. Metal forming processes generally introduce a certain amount of damage in the material being formed. Predictions of the damage formation and growth in a series of forming steps may assist in optimizing the individual operations and their order. This is particularly true for operations such as cutting and blanking, which rely on the nucleation of damage and cracks in order to separate material. In this work numerical simulation of the blanking process, using Deform 2D, taking in account the damage, has been performed. In order to evaluate the accuracy of the numerical solution, experimental test have been performed. Furthermore a numerical – experimental correlation has been carried out.