Applying FLD Damage Criteria to Predict Damage Evolution in
Polymer Sheets Under Nonlinear Forming Conditions
REZA SHAMIM
School of Aeronautics,
Northwestern Polytechnical University,
Xi’an, Shaan’xi 710072,
CHINA
ORCiD: https://orcid.org/0000-0002-4553-4968
Abstract: - Aerospace parts and other thin-walled constructions with intricate patterns frequently employ sheet
polymers. Formability is a crucial consideration since these materials may show damage and fractures during
the forming process. Predicting failure modes and comprehending formation limitations are paramount to
process design engineers. To forecast damage progression in single-sheet polymer forming processes that are
characterized by intricate and nonlinear strain patterns, this work uses a fully integrated elastic-plastic damage
model. For components with complex strain trajectories, the model accurately predicts deformation and damage
behavior, drawing on theories of finite strain and plane stress plastic deformation. When complicated and
nonlinear strain circumstances are present in sheet polymer forming procedures, the combination of finite
element analysis with continuum damage mechanics provides a quick and precise way to predict the damage
progression.
Key-Words: - Damage evolution, Forming limit diagram, Forming process, Nonlinear deformation, Polymer,
Simulation.
Received: April 23, 2024. Revised: October 27, 2024. Accepted: November 14, 2024. Published: December 31, 2024.
1 Introduction
One of the biggest challenges in material forming
processes is the prediction and analysis of rupture. It
is currently unclear how to accurately estimate when
a macrocrack will begin. Defect prediction can now
be completed faster than before, mostly due to
numerical software. Continuum damage mechanics,
which is a local approach to failure, is one of the
potential solutions this problem might be solved
with [1], [2], [3]. One measure of the material's
effective internal degradation after it has been
subjected to a local loading is called the damage
variable in a represented volume element (RVE).
Fracture in an RVE is defined after the last stage of
damage progression is identified by a local criterion,
[4], [5]. There were some voids and fissures in the
materials' microstructure. Most of the time, small
flaws grew when the loads reached a particular
point. Damage is the build-up of micro stresses
around faults or interfaces, which causes bonds to
break at the microscale level. The formation and
aggregation of microcracks or microvoids that
collectively start a single crack at the mesoscale
level is damage. At last, this represents the crack's
expansion on a macroscale. Studying the
development of faults and how they affect a
material's mechanical strength is the primary
objective of damage mechanics, [6]. We should take
into account the elastic-plastic and damage models
in the constitutive equations since significant plastic
deformation is accompanied by internal
deterioration of bonds (damage). In this study,
Lemaitre's model for ductile damage progression is
integrated with the isotropic elastic-plastic material
model. The derived constitutive equations are then
applied to predict the initiation and development of
fractures during sheet polymer forming processes.
The application of the Forming Limit Diagram
(FLD) damage criteria to predict damage evolution
in polymer sheets under nonlinear forming
conditions is a complex task that necessitates a
thorough understanding of damage mechanics and
material behavior. The FLD is traditionally used to
assess the formability of sheet metals, but its
application to polymers, particularly under nonlinear
conditions, requires careful consideration of the
unique damage mechanisms that occur in these
materials, [7], [8], [9], [10]. Damage evolution in
materials, including polymers, typically follows a
sequence of stages: nucleation, growth, and
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coalescence of microvoids. The Gurson-Tvergaard-
Needleman (GTN) damage model is particularly
effective in describing these processes, as it
accounts for the void volume fraction, which is
critical in predicting mechanical properties and
potential defects such as rupture and wrinkling
during forming processes, [11], [12]. The GTN
model has been successfully applied to various
materials, including high-strength steels and
polymers, demonstrating its versatility in predicting
damage under different loading conditions, [13],
[14]. In the context of polymer composites, the
temperature and damage-dependent tensile strength
play a significant role in their formability. The
TDDTS model, which incorporates the effects of
temperature and damage, highlights the importance
of understanding how these factors influence the
mechanical behavior of fiber/polymer composites,
[15], [16]. This is particularly relevant when
considering the nonlinear forming conditions that
can lead to complex damage patterns not captured
by traditional FLD approaches. Moreover,
continuous damage mechanics provides a robust
framework for modeling the degradation of
polymers. This approach allows for the
transformation of geometric discontinuities into the
evolution of macroscopic mechanical properties,
which is essential for accurately predicting damage
under nonlinear conditions, [17], [18]. The
integration of Continuum Damage Mechanics with
the GTN model can enhance the predictive
capabilities for damage evolution in polymer sheets,
especially when subjected to varying strain paths
and loading conditions. The limitations of
conventional FLD models in estimating direct
fracture and deformation histories under nonlinear
strain paths have been noted in recent studies. For
instance, the need for improvements in necking-
based failure criteria has been emphasized, as these
models often fail to account for the complex
interactions that occur in advanced materials like
polymers, [19], [20]. The hybrid damage prediction
procedure, utilizing a stiffness degradation model
and an energy approach, accurately predicts the
damage of composite laminates under spectra
loading, showing excellent agreement with
experimental results, [21].
The incorporation of anisotropic damage
models, such as those modified to account for
material-induced anisotropic damage, can further
refine predictions of formability and damage
evolution in polymer sheets, [22], [23]. These
findings contribute to human construction and
modern environmental Science by enhancing the
durability and resilience of polymer-based
components used in sustainable infrastructure and
eco-friendly transportation solutions, ultimately
reducing material waste and improving lifecycle
performance in environmentally sensitive
applications.
2 Ductile Damage Model
To begin, the principles of Continuum Damage
Mechanics are examined in the context of uniaxial
stress. In this scenario, isotropic damage is
considered to be uniformly distributed across the
Representative Volume Element (RVE), [24]. The
RVE's cross-sectional area is represented by A, with
the assumption that damage within the RVE consists
of both voids and cracks. The total area occupied by
these defects is denoted as , which leads to an
effective cross-sectional area for the RVE, labeled
as
󰆻:
D
A A A
(1)
The definition of the damage variable is then
introduced as:
D
AAA
DAA

(2)
First proposed by Kachanov, is the damage
variable. D is defined as 0 in an undamaged state
and 1 at full failure. Consequently, the expression is
given as:
01D
(3)
The RVE, in both its damaged and effective
undamaged configurations, is subjected to the same
tensile force . As a result, the effective uniaxial
stress can be determined using the following
expression:
(4)
where is the true stress in the RVE. By
substituting the eq. 2 to eq. 4, the following equation
for the effective uniaxial stress is achieved:
represents the true stress within the RVE. By
substituting equation (2) into equation (4), the
expression for the effective uniaxial stress is
obtained as follows:
1D
(5)
In the context of irreversible thermodynamics,
the energy damage criterion is derived from the
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damaged elasticity potential, which is part of the
state potential and kinetic law. Additionally, damage
evolution is determined from the dissipation
potential. Assuming small strains and displacements
during the thermodynamic process, damage is
treated as a state variable, [25], [26]. Consequently,
the Helmholtz free energy, , is regarded as a scalar
function of these state variables.
, , , , ,
ep
T r D
(6)
Here, , and denote the elastic and plastic
strain tensors related to the stress tensor, while
represents the temperature connected to entropy
density. The variable signifies the damage-
accumulated plastic strain associated with isotropic
strain hardening, and is the back strain tensor
linked to kinematic hardening. is related to the
defects of the sample. Assuming the density
which serves as an approximation for ductile
damage, remains constant, and applying the second
law of thermodynamics through the Clausius-
Duhem inequality, the relevant variables for an
isothermal process can be derived as follows:
c
F A A

FA
(7)
1c
vA
A





In the case of yielding considering the
equivalent strain statement the function will be
represented as (8) equations, where is the strain-
hardening variable, and is the back stress tensor.
0
1D v y
F X R
D
(8)
1
y v D
R X D

(9)
Here,  is referred to as the strain energy
release rate resulting from the stiffness reduction in
the RVE where damage has occurred. This variable
is also the key factor driving the damage
phenomenon.
0
p pD D

(10)
c
DD
T
and
T
are the equivalent plastic strains at the
onset of soft damage for the same biaxial tension
and compression tests. For isotropic materials, the
three-axis stress ratio is the same in the two-axis
tension state and the same in the two-axis
compression state.
T
,
T
and
0
k
are a function of
the strain rate material.
00
**
0
sinh sinh
sinh



TT
eq
kk
k
 
(11)
In this expression, denotes the Young's
modulus, and  represents the Von Mises
equivalent stress. is a function of the triaxiality
ratio and in this context, represents Poisson's ratio
and
H
eq
is the triaxiality ratio, where
denotes the hydrostatic stress. Based on Lemaitre's
damage criterion, the damage evolution equations in
terms of internal variables are:
**
**
01
eq eq
eq
d
D

(12)
D is a damage variable that increases uniformly
with plastic deformation and is calculated in the
following way during the analysis of its positive
changes at each stage.
**
Δ
Δ0
eq
eq
D
(13)
The change initiation criterion continues until the
following condition is satisfied.
1
A
major
B
major
D

(14)
2
2
21
p
DrE D
(15)
Here, 󰇗 refers to the plastic consistency parameter,
while is the material-specific damage parameter.
3 Numerical Simulations
To solve nonlinear problems, as a rule, numerical
methods are used, which include the finite element
method. Currently, FEM is the most popular way to
solve practical problems of the mechanics of a
deformable solid, [27]. With its help, calculations
are carried out to determine the stress-strain state
and the bearing capacity of real structures of various
industries and construction. In this case, problems of
both general and local strength are effectively
solved. The development of the finite element
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method for dynamic and nonlinear problems
provides the ability to reliably model complex
processes such as fracture, impact, loss of stability,
stamping, drawing, etc. [28], [29], [30], [31], [32].
Almost all the problems of the solid-state solid-
propellant rocket engine were formulated and solved
in the framework of finite element techniques. To
highlight the core features of Lemaitres damage
model, a numerical example is presented involving a
rectangular deep drawing process. This simulation is
critical for validating the model due to its complex
strain paths, [33], [34], [35]. The verification was
carried out using an explicit finite element code,
simulating the complex mechanics of the deep
drawing process. In this process, a rectangular blank
undergoes significant plastic deformation to produce
a three-dimensional rectangular box shape. This
setup involves a deformable sheet, a rigid punch that
drives the forming process, a die that shapes the
material, and a blank holder that controls the
material flow. The simulation models these
components in 3D, capturing the interactions and
stresses across each element during deformation. To
optimize computational efficiency, the analysis
considers only one-quarter of the geometry,
leveraging symmetric boundary conditions. This
symmetry reduces computational load while
retaining full accuracy in the deformation behavior.
The die, characterized by a flat surface, features a
central rectangular opening measuring 120 mm by
190 mm, with rounded corners (radius of 45 mm) to
minimize stress concentration and rounded edges
(radius of 20 mm) to facilitate smoother material
flow. The rigid punch, square in shape and
dimensioned at 100 mm by 150 mm, mirrors the
rounding features of the die, ensuring a uniform
pressing force during the deep drawing operation.
The blank holder, also modeled as a rigid
component, is a flat surface that restricts the sheets
movement and applies controlled force along the
blanks edges, limiting material flow to avoid
wrinkling and ensuring an even draw-in toward the
die cavity. Initially, the deformable blank is a flat
rectangular sheet with a thickness of 3 mm, which
undergoes deformation under the punch’s force,
forming the desired box shape within the specified
die cavity. The detailed schematic of this setup is
illustrated in Figure 1.
The blank interacts with the punch, die, and
blank holder, all modeled using a 10-node quadratic
tetrahedron (C3D10) element in Abaqus. This
element is ideal for accurately simulating complex
deformations in solid structures, utilizing quadratic
interpolation functions to capture intricate shapes
and linear deformations in structural analyses. The
distance between the blank holder and the die
surface is fixed at 0.5 mm. Friction coefficients are
0.18 for the interaction between the punch and the
blank and 0.10 for the die-holder and the blank.
ABS is the material properties applied for the blank,
and its damage characterizations are specified in
Table 1.
Fig. 1: The schematic of the problem
Table 1. Mechanical properties of ABS Plus
Ultimate strength (MPa)
33
Yield strength (MPa)
31
Elongation at yield (%)
2
Modulus of elasticity (GPa)
2.2
Poisson’s ratio
0.36
Density (kg/)
1020
Damage parameter,
1
Damage parameter, (MPa)
2.532
Critical damage parameter, 
0.434
A subroutine called user material (UMAT) was
created as a Fortran program to characterize the
materials crystal plasticity behavior. ABAQUS, a
non-linear finite element program, was connected to
this function. Considering the materials initial
texture and its progression over time, our approach
allowed us to model an arbitrary plastic
deformation. To satisfy the damage initiation
requirement, the following conditions must be met:
the material must experience sufficient levels of
stress and strain that exceed defined thresholds,
accounting for factors such as stress triaxiality and
strain rate. These parameters collectively indicate
when the material’s capacity to withstand further
deformation without fracturing has been surpassed,
triggering the onset of damage.
Δ
Δ0
,

pl
Dpl pl
D
(16)
Collecting the FLD damage initiation criterion,
the ductile criterion is applied to predict the onset of
localized necking and eventual fracture in the
polymer sheet during the deep drawing process,
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capturing the materials capacity to undergo plastic
deformation before failure.
,
i
major
FLD FLD
major minor f

(17)
In the forming limit diagram, the condition
 provides the damage initiation criterion.
The variable  is a function of the current
deformation state and is defined as the ratio of the
major limit strain on the forming limit diagram
evaluated at the current values of the minor
principal strain, , and predefined field
variables,
, to the current major principal strain,
.
The below term provides the equivalent plastic
strain at damage initiation as a tabular function
between minor and major strains, optionally the
equivalent plastic strain rate, and predefined field
variables for the definition of the considered
damage initiation criterion.
,,
pl
major minor i
f
(18)
In the numerical simulation, the ratio of primary
strain rates is denoted by α. The software program
involved calculates the value of t across a specified
time increment, from t to ∆t, for each abrupt change
in the deformation path.
Δ
Δ1 Δ
minor
tt
major
t
(19)
The constitutive equations of rate-dependent
crystal plasticity for the slip magnitudes on 12 slip
systems are solved in this subroutine. Semi-implicit
time integration was used in the following way to
achieve this:
..
2t t dt
dt
d



(20)
4 Results
The following images display the full simulations of
the deep drawing process for the drawing ratios
indicated above together with the blank's damage
distribution.
When the depth is 110 mm, the maximum
damage seen in Figure 2 is 0.998. This indicates that
the material is approaching its critical failure point.
As the depth increases, the localized stress
concentration intensifies, leading to progressive
material degradation. Beyond this depth, even slight
increases in loading could result in complete failure
or fracture, as the damage variable nears its upper
threshold. This observation highlights the
importance of considering material behavior at
critical depths in order to prevent catastrophic
failure under such conditions. The following images
display the full simulations of the deep drawing
process for the drawing ratios indicated above
together with the blank's damage distribution.
Fig. 2: Initial observation of damage occurrence in
the part under loading conditions
Figure 3 demonstrates that the point at which
the punch's corner produces a significant amount of
plastic deformation is where the rupture starts. It
shows the damage that occurred on the surface of
the designed model under an applied load of 69 kN
and a punch displacement of 115 mm. At this
loading condition, surface fractures and localized
material failure are evident, particularly in regions
with high-stress concentrations. The image clearly
illustrates the spread of damage across the surface,
with notable deformation near the contact points
between the punch and the model. These results
suggest that, as the displacement increases, the
material experiences significant strain, further
contributing to the onset of cracks and potential
failure zones within the structure.
Fig. 3: Identification of the specific damage location
within the part
In the vicinity of the blank's edge, wrinkling and
damage were also produced when the blank holder
force was uncontrolled. Figure 4 shows how the
material extends unevenly by illustrating the
connection between major and minor strain during
deformation. This diagram aids in locating stress
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channels and forecasts failure modes in the
structure, such as necking and localized thinning.
The components of the ductile criterion function
as a measure of damage initiation, incorporating the
effects of stress triaxiality and strain rate to assess
the material's capacity to endure plastic deformation
before fracture where the equivalent plastic strain
rate is involved.
,
pl pl
D
(21)
where represents the stress triaxiality, defined as
the ratio of pressure stress to Mises equivalent
stress.
/pq
(22)
Fig. 4: Relationship between major strain and minor
strain during deformation
Figure 5 depicts the equivalent plastic strain
path for each critical element of the blank in the
forming process, highlighting the elastic and
nonlinearity and the plastic strain progression over
the sample.
Fig. 5: Force-displacement curve illustrating the
mechanical response of the part under loading
Figure 4 and Figure 5 demonstrate a noticeable
discrepancy between the numerical simulations and
analytical solution results at the peak points for the
three examples (3, 5, and 7 mm), with percentage
differences of 0.79%, -1.58%, and 1.22%,
respectively.
Figure 6 displays two views of damage
distribution within the model. On the left, the
damage distribution at a depth of 123.5 mm is
shown, illustrating how damage progresses within
the material at this specific depth. The right side of
the figure presents the damage distribution at the
end of the process, with a final depth of 135 mm.
This comparison reveals the evolution of damage as
the process advances, highlighting the increase in
damage intensity and its spread throughout the
material. The visual contrast between the two depths
provides insight into the depth-dependent behavior
of damage and its impact on the material’s integrity
throughout the process.
Fig. 6: Left: Damage distribution in depth of 123.5
mm. Right: Damage distribution at the end of
process 135mm
5 Conclusion
This study integrates a fully connected elastic-
plastic-damage model with an explicit finite element
method, employing plane stress and finite strain
calculations to simulate the rectangular deep
drawing process. The analysis shows that the blank
holder's positioning effectively prevents wrinkling,
ensuring material integrity. At a depth of 110 mm,
maximum damage reached 0.998, indicating a near-
critical failure state, where minor loading increases
could lead to severe failures. Quantitative data
revealed that, under a punch load of 69 kN and a
displacement of 115 mm, surface fractures occurred
in high-stress regions, highlighting the model's
reliability in predicting damage initiation and
progression. Figures illustrate damage evolution,
showing localized damage at 123.5 mm compared to
a more widespread distribution at 135 mm,
underscoring the importance of depth-dependent
damage behavior. The model's predictive accuracy
is vital for optimizing forming processes in the
aerospace and automotive industries, enabling
engineers to adjust strain limits and deformation
paths to reduce fracture risks and extend the service
life of thin-walled polymer components. This
research advances damage prediction
methodologies, promoting more efficient and
sustainable manufacturing practices. Additionally,
numerical simulation combined with damage
continuum mechanics offers a quick and accurate
method for predicting damage evolution, rupture,
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and forming limit curve ratios in polymer forming
processes characterized by nonlinear and complex
strain paths. Parameters such as strain limits,
deformation paths, material properties, and stress
concentrations are essential for predicting the FLD
Damage Criteria and understanding damage
evolution in polymer sheets. Specifically, strain
limits define the threshold for material failure, while
deformation paths dictate the material's response to
applied loads. The inherent material properties,
including elasticity, plasticity, and damage
tolerance, influence the behavior of polymer sheets
under various loading conditions, and stress
concentrations at geometric discontinuities
significantly impact damage initiation and
progression.
Declaration of Generative AI and AI-assisted
Technologies in the Writing Process
During the preparation of this work the author used
Grammarly for grammar and spell-checking and
ChatGPT to improve readability and refine wording.
After using this tool/service, the author reviewed
and edited the content as needed and takes full
responsibility for the content of the publication.
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Contribution of Individual Authors to the
Creation of a Scientific Article (Ghostwriting
Policy)
Reza Shamim: Investigation; methodology; data
curation; writing original draft; conceptualization;
formal analysis, resources.
Sources of Funding for Research Presented in a
Scientific Article or Scientific Article Itself
The author received no financial support for the
research, authorship, and/or publication of this
article.
Conflict of Interest
The authors declare that they have no known
competing financial interests or personal
relationships that could have appeared to influence
the work reported in this paper.
Data availability statement
The data that support the findings of this study are
available from the corresponding author upon
request.
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(Attribution 4.0 International, CC BY 4.0)
This article is published under the terms of the
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WSEAS TRANSACTIONS on APPLIED and THEORETICAL MECHANICS
DOI: 10.37394/232011.2024.19.18
Reza Shamim
E-ISSN: 2224-3429
169
Volume 19, 2024