The effect of the width to thickness ratio on the bendability of sheet metal is investigated using the finite element method (FEM) employing the Gurson–Tvergaard–Needleman (GTN) model. Strain path changes in the sheet with change in the width/thickness ratio. It is shown that bendability and fracture strain increase significantly by decrease in the width/thickness ratio. The stress state is almost uniaxial when the stress ratio (α) is close to zero for narrow sheets. Stress ratio is nothing but the major stress to minor stress ratio. This delays the growth and coalescence of micro-voids as the volumetric strain and stress triaxiality (pressure/effective stress) decrease. On the other hand, ductility decreases with increase in α for wider sheets. Fracture bending strain is calculated and, as expected, it increases with decrease in the width/thickness ratio. Furthermore, a brief study is performed to understand the effect of superimposed hydrostatic pressure on fracture strain for various sheet metals with different width/thickness ratios. It is found that the superimposed hydrostatic pressure increases the ductility, and that the effect of the width/thickness ratio in metals on ductility is as significant as the effect of superimposed hydrostatic pressure. Numerical results are found to be in good agreement with experimental observations.

It is generally accepted that the superimposed hydrostatic pressure increases fracture strain in sheet metal and mode of fracture changes with applying pressure. Void growth is delayed or completely eliminated under pressure and the shear damage mechanism becomes the dominant mode of fracture. In this study, the effect of superimposed hydrostatic pressure on the ductility of sheet metal under tension is investigated using the finite element (FE) method employing the modified Gurson–Tvergaard–Needleman (GTN) model. The shear damage mechanism is considered as an increment in the total void volume fraction and the model is implemented using the VUMAT subroutine in the ABAQUS/Explicit. It is shown that ductility and fracture strain increase significantly by imposing hydrostatic pressure as it suppresses the damage mechanisms of microvoid growth and shear damage. When hydrostatic pressure is applied, it is observed that although the shear damage mechanism is delayed, the shear damage mechanism is dominant over the growth of microvoids. These numerical findings are consistent with those experimental results published in the previous studies about the effect of superimposed hydrostatic pressure on fracture strain. The numerical results clearly show that the dominant mode of failure changes from microvoid growth to shear damage under pressure. Numerical studies in the literature explain the effect of pressure on fracture strain using the conventional GTN model available in the ABAQUS material behavior library when the mode of fracture does not change. However, in this study, the shear modified GTN model is used to understand the effect of pressure on the shear damage mechanism as one of the individual void volume fraction increments and change in mode of fracture is explained numerically.

The effects of cladding layers of rate-sensitive materials on the ductility and fracture strain of compressed rings are numerically investigated by using the finite element method (FEM) and employing the Johnson–Cook (J–C) model. The results show that ductility is governed by the behavior of the material that is located at the ring outer wall regardless of the volume fraction of the core and clad materials. However, as the number of layers increases, this influence becomes less noticeable. Moreover, as barreling increases at the outer wall and decreases at the inner wall, fracture strain increases. Furthermore, the effects of ring shape factor and bonding type of clad and core materials are numerically evaluated. The numerical results show that less force per unit volume is required to fracture narrower rings and that using a noise diffusion pattern at the interface of the materials is more suitable to simulate crack propagation in the compressed rings and functionally graded materials (FGMs). Additionally, delamination has a direct relation to layer thickness and can occur even in the presence of perfect bonding conditions owing to differences among the material and fracture parameters of laminated layers.

There has been an increasing interest in fabricating automotive components from copper (Cu)–lean 7xxx-series aluminum (Al) alloys to produce structural components to achieve higher in-service strength and to reduce weight and cost (compared to steel). Wit