An Enhanced Strategy for Ductile Fracture Simulation under Large Deformation Incorporating Effective Element Size
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In this study, a strategy is proposed to dynamically adjust the damage criterion by introducing the concept of an effective element size, aiming at accurate and efficient simulation of ductile fracture under large deformation conditions. Ductile fracture in metallic materials is governed by strain-controlled mechanisms, and strain-based damage models inherently exhibit element-size dependence due to strain localization near crack tips. As a result, conventional strategies may lead to non-negligible prediction errors when applied to fracture problems involving large deformations. To mitigate this limitation, the effective element size is defined as a deformation-dependent variable along the crack propagation direction, which evolves during the fracture process. Based on this definition, a scale-consistent strategy is established to dynamically adjust the critical fracture strain according to the effective element size throughout the simulation. The proposed strategy: (i) reconstructs the ductility diagram as a function of the effective element size, (ii) relies only on two standard experiments, i.e., tensile and crack growth tests, and (iii) enables efficient and automated parameter identification within a systematic process. Numerical validations demonstrate markedly improved agreement with experimental observations compared with the conventional strategy, particularly under complex loading paths and large deformation regimes. These results indicate that the proposed strategy provides enhanced predictive capability while maintaining efficient parameter calibration with minimal experimental input, making it suitable for ductile fracture analyses under large deformation conditions.
