Finite element assisted prediction of ductile fracture in sheet bulging

With growing demand for energy efficiency, there is much focus on reducing oil consumption rates and utilising alternative fuels. A contributor to the solution in this area is to produce lighter vehicles that are more fuel efficient and/or allow for the use of alternative fuel sources (e.g. electric powered automobiles). Near-net-shape manufacturing processes such as hydroforming have great potential to reduce structural weight while still maintaining structural strength and performance. Finite element analysis techniques have proved invaluable in optimizing such hydroforming processes, however, the majority of such studies have used simple predictors of failure which are usually yield criteria such as von Mises stress. There is clearly potential to obtain more optimal solutions using more advanced predictors of failure. This paper compared the Von Mises stress failure criteria and the Oyane's ductile fracture criteria in the sheet hydroforming of magnesium alloys. It was found that the results obtained from the models which used Oyane's ductile fracture criteria were more realistic than those obtained from those that used Von Mises stress as a failure criteria.