A new test for determining the mechanical and fracture behavior of materials in sheet-bulk metal forming

Abstract

This paper presents a new experimental test for determining the stress–strain curve and the fracture toughness of sheets to be used in sheet-bulk metal forming (SBMF) applications. The test is based on the utilization of double-notched specimens loaded in shear and combines the plane stress loading conditions of sheet metal forming with the three-dimensional plastic flow conditions of bulk metal forming, which are commonly found in SBMF processes. The methodology to obtain the stress–strain curve involves calculation of the shear stresses and strains along the two symmetric plastic shear zones of the test specimens up to point where cracks start to propagate along the ligaments that connect each pair of opposite notches. The determination of fracture toughness involves characterization of the evolution of load with displacement for a number of test cases performed with specimens having different ligaments between the two symmetric opposite notches. The work is performed on aluminium alloy EN AW 5754 H111 sheets with 5 mm thickness and the results obtained by means of the new proposed test are compared against those from conventional mechanical and fracture characterization tests.