Enhancing the deep drawing process by predicting damage initiation and progression using the anisotropic Lemaitre damage model

Abstract The originality of the approach proposed in this work lies in the integration of the effect of plastic anisotropy on the initiation and propagation of ductile damage via the modified Lemaitre damage model. The main objective is to improve the deep drawing of sheet metal during forming, particularly DC04 steel. The proposed model adopts a coupling between anisotropic plasticity, described by Hill’s plasticity criterion (1948), and a direction-dependent damage propagation law, identified experimentally. For this purpose, a comprehensive experimental campaign was conducted using monotonic and cyclic tensile tests (loading-unloading), at different orientations (0°, 45°, and 90°) relative to the rolling direction. Strain gradient measurements were obtained using digital image correlation, while damage propagation was quantified by the degradation of Young’s modulus. In addition, a model simulation based on ( FEM ) was validated by implementing these parameters, identified via Abaqus/Explicit using a VUMAT subroutine. Compared to classical isotropic damage models, the proposed new correlation methodology significantly improves the prediction of damage initiation, localization, and critical thresholds. The model accurately reproduces the greater sensitivity to damage observed at 45°, associated with lower Lankford coefficients and improved strain localization. The integration of anisotropy in plasticity and damage evolution enables more realistic simulations of deep drawing processes and provides a reliable tool for industrial forming applications.