A closed-form expression of a ductile Fracture Limit Surface (FLS) for general plane stress deformation paths

Ductile fracture in metals is a complex phenomenon caused by the nucleation, growth, and aggregation of micron-sized voids. Existing theoretical models for fracture use experimentally determined Fracture Limit Curves (FLCs) in two-dimensional strain space, which require multiple curves to account for anisotropic effects. This paper proposes a practical closed-form analytical function for a Fracture Limit Surface (FLS) which has a conical shape in the Elastic Distortional Deformation Space (EDDS). The EDDS is a space generated by the components of the elastic distortional metric of the microstructural vectors that characterize elastic distortional deformations and the orientations of anisotropy. The FLS is determined by simulating only four experimental FLCs using a large deformation Eulerian formulation of the microstructural vectors and it depends only on the current state of elastic distortional deformation. It is shown that the failure limit points predicted by the FLS agreed very well with those predicted using a popular evolution equation for damage-based ductile fracture. Path-independence of the FLS is also examined using experimental data. In addition, the example of a B-pillar forming process is presented to show that the FLS can be applied to practical engineering problems with material points that experience general loading paths.