Modeling of Sheet Metal Fracture via Cohesive Zone Model And Application to Spot Welds

Even though the cohesive zone model (CZM) has been widely used to analyze ductile fracture, it is not yet clearly understood how to calibrate the cohesive parameters including the specific work of separation (the work of separation per unit crack area) and the peak stress. A systematic approach is presented to first determine the cohesive values for sheet metal and then apply the calibrated model to various structure problems including the failure of spot welds. Al5754-O was chosen for this study since it is not sensitive to heat treatment so the effect of heat-affected-zone (HAZ) can be ignored. The CZM has been applied to successfully model both mode-I and mode-III fracture for various geometries including Kahn specimens, single-notch specimens, and deep double-notch specimens for mode-I and trouser specimens for mode-III. The mode-I fracture of coach-peel spot-weld nugget and the mixed-mode fracture of nugget pull-out have also been well simulated by the CZM. Using the mode-I average specific work of separation of 13 kJ/m2 identified in a previous work and the mode-III specific work of separation of 38 kJ/m2 found in this thesis, the cohesive peak stress has been determined to range from 285 MPa to 600 MPa for mode-I and from 165 MPa to 280 MPa for mode-III, depending on the degree of plastic deformation. The uncertainty of these cohesive values has also been examined. It is concluded that, if the specific work of separation is a material constant, the peak stress changes with the degree of plastic deformation and is therefore geometry-dependent.