Bridging laboratory and industrial practices in sheared edge ductility evaluation

Abstract Mechanical shearing introduces a material limit lower than the onset of local necking. This new limit is critical for understanding and predicting material performance in industrial forming applications. The sheared edge condition, influenced by strain hardening and microstructural damage, reduces ductility in the shear-affected zone, posing challenges for reliable characterization and numerical prediction. This study presents an approach that integrates finite element modelling (FEM) with geometric shape matching to establish a practical, simulation-compatible material limit for sheared-edge formability. Instead of relying on localized strain measurements, the methodology determines the punch displacement in FEM simulations that best replicates the experimentally observed deformed geometry of Hole Expansion Capacity (HEC) test specimens, along with the corresponding maximum deformation of elements at the stretched edges. The method proves effective for industrial forming processes, enhancing FEM-based edge failure prediction and providing a valuable tool for process optimization and defect troubleshooting in sheet metal forming.