The influence of cut edge heterogeneity in complex phase steel sheet edge cracking: An experimental and numerical investigation

This study investigated how geometrical variations along the perimeter of sheared edges influenced the formability of advanced high-strength steel sheets during hole expansion. A combined numerical and experimental approach was employed, based on the standardised ISO 16630 Hole Expansion Test. The shear cutting process prior to cut edge forming was modelled using the Particle Finite Element Method, which enabled accurate prediction of edge morphology and deformation within the shear affected zone. The resulting geometries and residual fields were transferred to three-dimensional blank meshes for hole expansion simulations. A cold-rolled complex-phase steel was used, processed with varying cutting clearances to produce distinct edge conditions. Circumferential heterogeneities, including burr-to-no-burr transitions and irregular burnish patterns, were shown to significantly reduce edge formability and promote early crack initiation. These effects were found to be more detrimental than damage distributed through the thickness of the sheared edge. To represent such irregularities in numerical modelling, a hybrid meshing strategy was introduced, incorporating three-dimensional microscopy data into the simulation workflow. This approach improved the accuracy of predicted hole expansion ratios and allowed reproduction of experimentally observed fracture patterns. Stress analysis showed that geometric imperfections around the hole perimeter elevated local stress triaxiality and accelerated damage development. The findings emphasised the importance of achieving uniform cut edge quality to ensure reliable forming performance and reduce the risk of edge cracking during manufacturing.