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Investigating fracture failure in origami-based sheet metal bending

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Abstract

Origami-based sheet metal (OSM) bending is a promising new die-free folding technique for sheet metal. OSM bending principle is based on deforming the material along a pre-defined fold line, which is determined using material discontinuity (MD) produced by laser or waterjet cutting. The objective of this work is to study and evaluate the fracture in OSM bending under the influence of various MD types, kerf-to-thickness (k/t) ratios, and sheet thicknesses. The research goal is to provide information on selecting an optimized k/t ratio and type of MD that allows for fracture-free bending. Four different ductile fracture criteria (DFC) are used and calibrated from experimental data to forecast fracture. The DFC calibration is used to produce a set of critical damage values (CDV) for assessing the possibility of fracture in the OSM bending. In addition, the study provides fracture evaluation using finite element analysis (FEA) integrated with experimental cases for a broader range of OSM bending parameters and MDs. The results demonstrated that an MD with a higher k/t ratio is less likely to fracture during the OSM bending, whereas a higher sheet thickness increases the possibility of fracture. Furthermore, the study identifies the k/t ratio limit that ensures successful bending without fracture and categorizes MD types into two groups based on fracture likelihood. The fracture in the first group is dependent on the limiting k/t ratio, whereas the possibility of fracture in the second group is independent of the k/t ratio due to its topology.

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Abbreviations

2-D:

Two-dimensional

3-D:

Three-dimensional

CDV:

Critical damage value

D i (i = CL, B, A, RT):

Damage values corresponding to each of these DFC

DFC:

Ductile fracture criteria

DV:

Damage value

ε̅ p :

Equivalent plastic strain

\({\overline{\varepsilon }}_{p}^{f}\) :

Equivalent plastic strain at fracture

ϵ:

True strain

\({\upepsilon }_{u}\) :

Ultimate true strain

FFLD:

Fracture forming limit diagram

FEA:

Finite element analysis

FLD:

Forming limit diagrams

g :

Punch placement

k/t ratio:

Kerf-to-thickness ratio

MD:

Material discontinuity

OSM:

Origami-based sheet metal

R p :

Punch radius

s :

Offset distance

SSE:

Error sum of squares

σ :

True stress

σ i (i = 1,2,3):

Principal stresses

σ eq :

Equivalent stress

σ h :

Hydrostatic stress

σ u :

Ultimate true stress

W :

Weight factor

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Funding

This work was partially supported by Hellman Fellow Fund.

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Authors and Affiliations

  1. Mechanical Engineering Department, University of California, Merced, 5200 Lake Rd, Merced, CA, 95343, USA

    Muhammad Ali Ablat, Ala’aldin Alafaghani & Jian-Qiao Sun

  2. Mechanical Engineering, The Pennsylvania State University, The Behrend College, Erie, PA, 16563, USA

    Chetan Nikhare

  3. Mechanical, Industrial & Manufacturing Engineering Department, The University of Toledo, 2801 W. Bancroft St, Toledo, OH, 43606, USA

    Ala Qattawi

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  1. Muhammad Ali Ablat
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  5. Ala Qattawi
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Correspondence to Ala Qattawi.

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Ablat, M.A., Alafaghani, A., Sun, JQ. et al. Investigating fracture failure in origami-based sheet metal bending. Int J Adv Manuf Technol 119, 5335–5363 (2022). https://doi.org/10.1007/s00170-021-08576-0

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