Numerical modelling of shear cutting in complex phase high strength steel sheets: A comprehensive study using the Particle Finite Element Method

The study examines the shear cutting process of Advanced High Strength Steel using the Particle Finite Element Method. Shear cutting, a crucial process in sheet metal forming, often leads to microcracks and plastic deformation that degrades the material performance in subsequent applications, such as cold forming, crashworthiness, and fatigue resistance. This work utilises the Particle Finite Element Method as an alternative to conventional Finite Element Methods to address the challenges of large deformation solid mechanics, offering high predictive accuracy in localised shearing deformation and fracture. The model was validated against experimental data from sheet punching tests, with evaluations at both macroscopic and mesoscopic levels, including cut edge profiles and microstructural deformation within the shear-affected zone. The Particle Finite Element Method approach demonstrated a high level of accuracy in predicting cut edge shape and shear-induced damage across various cutting conditions. As an unconventional numerical technique, usage of the Particle Finite Element Method advances modelling of large deformations solid mechanics and providing a robust tool for optimising manufacturing processes of materials sensitive to sheared edge damage.