This work provides numerical and experimental investigations of blanking process, where the shear-enhanced Lemaitre’s damage model is fully characterized and successfully applied in blanking process to predict the cutting force and cutting edge geometry under different blanking process parameters. Advanced high strength steel DP1000 and an aluminum alloy Al6082-T6 are selected for series of experiments. To obtain the damage parameters in Lemaitre’s damage model the flat rectangular notched specimens tensile test was conducted and the inverse parameter identification procedure was performed. For characterizing the crack closure parameter h in the shear enhanced Lemaitre’s damage model, an in-plane torsion test with novel specimen design was conducted. The finite element model (FEM) of this test was established with the minimum mesh size of 0.01 mm which was consistent with the minimum mesh size in the shear zone of the FEM for blanking process simulation. The longitudinal strain distributions of four kinds of initial notch radius or central-hole specimen were measured and compared with simulation results to validate the FEMs for these four tests. Deformation analysis of blanking of a circular work piece also was performed under three clearances. The effects of blanking conditions on sheared part morphology were detected. Stress triaxiality distribution of the blank sheet was revealed taking advantage of the successfully established FEM. The availability of the testing method and the determination method of the parameters was investigated.

这项工作提供了落料过程的数值和实验研究，其中剪切增强的Lemaitre的损伤模型得到了充分表征，并成功地应用于了落料过程中，以预测不同落料过程参数下的切削力和切削刃几何形状。一系列实验选择了高级高强度钢DP1000和铝合金Al6082-T6。为了在Lemaitre的损伤模型中获得损伤参数，进行了扁平矩形缺口样品的拉伸试验，并执行了逆参数识别程序。为了表征裂纹闭合参数h在剪切增强型Lemaitre的损伤模型中，进行了具有新颖标本设计的面内扭转试验。建立了该测试的有限元模型（FEM），最小网格尺寸为0.01 mm，这与用于冲裁过程模拟的FEM剪切区中的最小网格尺寸一致。测量了四种初始切口半径或中心孔试样的纵向应变分布，并将其与仿真结果进行比较，以验证这四种测试的有限元方法。还在三个间隙下对圆形工件的落料进行了变形分析。检测了落料条件对剪切零件形态的影响。利用成功建立的有限元方法揭示了空白板的应力三轴度分布。