Edge crack sensitivity of lightweight materials under different load conditions

Tsoupis I, Merklein M (2016)

Publication Type: Journal article

Publication year: 2016


Publisher: Institute of Physics Publishing

Book Volume: 159

Pages Range: 1-8

Journal Issue: 1

DOI: 10.1088/1757-899X/159/1/012017


This study addresses the analysis of edge crack sensitivity of DP800 steel and AA5182 aluminum alloy in dependency of punching and machining operation as well as load case of subsequent forming. The inserting of a round hole by punching with defined punch-to- die-clearance, milling and drilling is compared. Subsequent forming is performed by standardized hole expansion test and by Nakajima-tests with three different specimen geometries. Local strain distribution at the surface for Nakajima-tests is measured by optical strain measurement technique and investigated in order to evaluate local deformation before failure. Additionally, resulting hole expansion ratio λ is determined. Significant higher X as well as local strain values ϵ max are achieved by machined holes. This is directly coupled to higher local formability and stretchability for both materials. Furthermore, the load condition has a strong impact on the edge crack sensitivity of the material. Prior failure is observed with changing stress conditions using different specimen geometries also influencing the reachable maximum failure strain. Higher edge crack sensitivity is observed for DP800, which is in good accordance to the material properties in terms of ductility and strength. These data in dependency of the process parameter can be used for the design of automotive components.

Authors with CRIS profile

Additional Organisation(s)

How to cite


Tsoupis, I., & Merklein, M. (2016). Edge crack sensitivity of lightweight materials under different load conditions. IOP Conference Series: Materials Science and Engineering, 159(1), 1-8. https://doi.org/10.1088/1757-899X/159/1/012017


Tsoupis, Ioannis, and Marion Merklein. "Edge crack sensitivity of lightweight materials under different load conditions." IOP Conference Series: Materials Science and Engineering 159.1 (2016): 1-8.

BibTeX: Download