Predicting edge fracture in dual-phase steels : Significance of anisotropy-induced localization

While experimental methods for characterizing edge fracture have advanced significantly, current modeling approaches often neglect factors like anisotropy evolution and localization, limiting their ability to accurately predict edge fracture across various tests. In the present study, we investigate the anisotropic deformation, localization, and fracture behavior of a dual-phase (DP1000) steel during hole expansion tests using an advanced evolving anisotropic model coupled with a hybrid damage mechanics model. The anisotropic plasticity model is calibrated by tensile tests along different loading directions and is capable of describing both anisotropic hardening and r-value evolution, while the fracture model is calibrated by tests under several stress states. To illustrate the impact of anisotropy, an isotropic version of the model is also included for comparison. The novelty of the investigation is that it originally found the edge fracture of the DP1000 steel is anisotropic and triggered by through-thickness localization induced by material anisotropy. Therefore, only the model with anisotropy can provide a satisfactory prediction of the hole expansion ratio as well as the location of the edge fracture, while the isotropic model overestimates the experiments significantly. The findings provide an in-depth understanding of the importance of anisotropy in evaluating edge fracture behavior, which not only improves the modeling accuracy but also adds a design concept to enhance the edge formability of materials.