Modelling of damage evolution in the vicinity of frictional interfaces in metal forming

Conventional ductile fracture criteria are not applicable in the vicinity of maximum friction surfaces for several rigid plastic material models because the equivalent strain rate (second invariant of the strain rate tensor) approaches infinity near such surfaces. In the present paper, a non-local ductile fracture criterion generalizing the modified Cockroft-Latham ductile fracture criterion is proposed to overcome this difficulty with the use of conventional local ductile fracture criteria. The final form of the new ductile fracture criterion involves the strain rate intensity factor which is the coefficient of the principal singular term in a series expansion of the equivalent strain rate in the vicinity of maximum friction surfaces. When the velocity field is not singular, the new ductile fracture criterion reduces to the modified Cockroft-Latham criterion. The strain rate intensity factor cannot be found by means of commercial finite element packages since the corresponding velocity field is singular. In the present paper, the new fracture criterion is illustrated with the use of an approximate semi-analytical solution for plane strain drawing. It is shown that the prediction is in qualitative agreement with physical expectations.