Ductile fracture in thin sheet metals is a common failure mechanism that governs many important industrial applications. A variety of simulation methods, ranging from the atomistic to continuum scales, have been proposed and demonstrated. To assess the capabilities of the existing simulation tools, a group of researchers presented their modeling predictions on the so-called Sandia Fracture Challenge problem at the 2012 ASME IMECE conference. The discrepancies between the simulation and experimental results, and among the experimental results themselves led to consensus that more needs to be done to improve the understanding of this complex phenomenon. Following the participation of the Sandia Fracture challenge, further simulations are performed to study the ductile failure in thin sheet metals with conditions that are commonly used for processing. It is shown that failure pattern and load are significantly influenced by the processing conditions.

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