Surface roughness influences on localization and damage during forming of DP1000 sheet steel

Sebastian Münstermann, Peerapon Wechsuwanmanee, Wenqi Liu, Junhe Lian

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Surface roughness strongly influences the occurrence of edge cracks in metal forming processes. Recently, a sub-modelling approach has therefore been presented that is capable of predicting whether an edge forming process could be performed without failure events, but the macroscopic load-deformation behavior could not be predicted. This approach is extended to consider roughness induced micro damage even on the macroscopic scale. The concept is based on the idea to define an individual set of material parameters for those elements that are located at the sample´s surface. In order to calibrate the required set of parameters for these surface elements, sub-models are created which geometrically represent the roughness profiles that were determined experimentally before the bending tests were conducted. The procedure is demonstrated for the example of bending tests performed on samples made of steel DP1000 that have undergone two different surface treatments to adjust roughness conditions - fine grinding and polishing in the one extreme case and grinding with 80-grit sand paper in the other one. Experimental results reveal significant differences between the two sample configurations: while the samples with smooth surfaces remain free from cracks during the entire duration of the experiment, the samples with rough surfaces show fracture events. For both cases, the new simulation framework allows to reproduce both the macroscopic load-deflection curves and the individual damage and fracture behaviours.
Original languageEnglish
Title of host publication18th International Conference on Sheet Metal, SHEMET 2019, New Trends and Developments in Sheet Metal Processing
Publication statusPublished - 2019
MoE publication typeA4 Conference publication
EventInternational Conference on Sheet Metal - Leuven, Belgium
Duration: 15 Apr 201917 Apr 2019
Conference number: 18

Publication series

NameProcedia Manufacturing
ISSN (Electronic)2351-9789


ConferenceInternational Conference on Sheet Metal
Abbreviated titleSHEMET


  • Surface Roughness
  • Strain Localization
  • Stress State Effects
  • Ductile Damage Accumulation


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