Prediction of forming limit diagrams based on shear failure criterion

Maximum shear stress theory, also called the ‘Third Strength Theory’, is a classical theory used to predict the failure of common metal, but it cannot be used directly to predict sheet metal failure due to anisotropy and the loading path. Therefore, this paper proposes a maximum shear stress calculating method, which has been named “shear failure criterion” for the purpose of this paper. In order to validate the shear failure criterion, a general program was developed, and two typical materials, steel, and aluminum alloy, were used to study the new shear failure criterion in this study. The two materials were modeled by advanced constitutive models, including Hill1948 and Yld2000-2d yield functions and several types of isotropic hardening models. Experimental validation has indicated the accuracy of predicted FLD using shear failure criterion, which is able to provide a new alternative method to numerically predict FLD.