Journal of Computational & Applied Research in Mechanical Engineering (JCARME)

Articles in Press

Document Type : Research Paper

Authors

¹ Department of Mechanical Engineering, University of Birjand, Birjand, South Khorasan, 97175-376, Iran

² Department of Mechanical and Materials Engineering, Birjand University of Technology, South Khorasan, Birjand, 9719866981, Iran

https://doi.org/10.22061/jcarme.2026.12353.2702

Abstract

This study investigates crack formation and rupture in a newly developed "SCDA expansion forming", which utilizes the pressure generated by a soundless chemical demolition agent (SCDA). The research integrates experimental analysis and finite element analysis (FEA) to examine the forming of a 1 mm thick St12 low-carbon steel sheet into a dome shape. The experimental phase involved using Green Rock SCDA within a rigid steel die under test conditions of 75°C temperature, 25% water content, and 300 g mixture mass. The corresponding FEA was performed in Abaqus, applying the forming limit diagram (FLD) damage model criteria to predict necking instability and crack formation. The results from both the simulation and the experimental tests demonstrated that rupture occurs in the areas between the dome's center and its corners. FEA revealed that the maximum plastic strain and stress are concentrated in these central regions, leading to localized thinning and eventual failure. The experimental findings confirmed the location of the crack, thereby validating the accuracy of the numerical model. Analysis of the fracture surface via scanning electron microscopy (SEM) indicated a ductile fracture mechanism, characterized by dimples formed through a combination of shear and tensile modes.

Graphical Abstract

Keywords

Main Subjects

Forming

References

[1] A. Awasthi, K. K. Saxena and V. Arun, “Sustainable and smart metal forming manufacturing process”, Mater. Today Proc., Vol. 44, No. 1, pp. 2069-2079, (2021).

[2] S. A. Alavi, S. M. H. Seyedkashi and M. Rakhshkhorshid, “A novel expansion forming process using soundless chemical demolition agent”, J. Mater. Eng. Perform., Vol. 34, No. 22, pp. 1-11, (2025).

[3] R. Li, Y. Yan, Z. Jiang, W. Zheng and G. Li, “Impact of hole parameters and surrounding constraint on the expansive pressure distribution and development in soundless chemical demolition agents”, Constr. Build. Mater., Vol. 307, No. 8, p. 124992, (2021).

[4] D. F. Laefer, A. S. Natanzi and S. M. I. Zolanvari, “Impact of thermal transfer on hydration heat of a soundless chemical demolition agent”, Constr. Build. Mater., Vol. 187, pp. 348–359, (2018).

[5] M. B. Étkin and A. E. Azarkovich, “Effect of non-explosive splitting compounds and rational work parameters”, Power Technol. Eng., Vol. 40, No. 5, pp. 287–292, (2006).

[6] J. Xu, “Investigation of non-explosive expansion material in roof caving field application”, Int. J. Rock Mech. Min. Sci., Vol. 120, pp. 50–57, (2019).

[7] A. S. Natanzi, D. F. Laefer and L. Connolly, “Cold and moderate ambient temperatures effects on expansive pressure development in soundless chemical demolition agents”, Constr. Build. Mater., Vol. 110, pp. 117–127, (2016).

[8] Y. Gui, Z. Jiang, C. Dai and Q. Zhang, “Enhanced effect of self-propagating subsequent heating on the expansive pressure on soundless chemical demolition agent”, Constr. Build. Mater., Vol. 364, p. 129866, (2023).

[9] X. Li, X. Xu, C. Wang, Z. Liu, Y. Chang and Q. Wang, “Experimental investigation of the static expansion tensile behavior of concrete after exposure to elevated temperatures”, Fire Technol., Vol. 59, No. 6, pp. 3667-3687, (2023).

[10] J. Hinze and J. Brown, “Properties of soundless chemical demolition agents”, J. Constr. Eng. Manag., Vol. 120, No. 4, pp. 816–882, (1994).

[11] M. P. Huynh, Investigation of crack propagation due to expansion agents, M.S. thesis, University College Dublin, Dublin, Ireland, (2012).

[12] D. F. Laefer, N. Ambrozevitch-Cooper, M. P. Huynh, J. Midgette, S. Ceribasi and J. Wortman, “Expansive fracture agent behaviour for concrete cracking”, Mag. Concr. Res., Vol. 62, No. 6, pp. 443–452, (2010).

[13] Y. F. Yapan, H. G. Korkmaz, S. Toros and M. Türköz, “Experimental and numerical investigation of the damage state of Ti-6Al-4V alloy sheet in the tensile test, hydraulic bulging, and hydroforming processes”, Int. J. Adv. Manuf. Tech., Vol. 132, No. 9, pp. 4585-4605, (2024).

[14] A. Hashemi, M. Hoseinpour Gollo and S. M. H. Seyedkashi, “Bimetal cup hydroforming of Al/St and Cu/St composites: adaptive finite element analysis and experimental study”, J. Mech. Sci. Technol., Vol. 30, No. 5, pp. 2217-2224, (2016).

[15] R. Hambli, “Comparison between Lemaitre and Gurson damage models in crack growth simulation during blanking process”, Int. J. Mech. Sci., Vol. 43, No. 12, pp. 2769-2790, (2001).

[16] A. A. El-Aty, Y. Xu, W. Xie, L. L. Xia, Y. Hou, S. Zhang, M. M. Ahmed, B. Alzahrani, A. Ali, X. Huang and A. S. Sobh, “Finite element analysis and experimental study of manufacturing thin-walled five-branched AISI 304 stainless steel tubes with different diameters using a hydroforming process”, Materials., Vol. 17, No. 1, p. 104, (2024).

[17] F. A. Ahamed and P. Chinnaiyan, “Studies on finite element analysis in hydroforming of nimonic 90 sheet”, Mathematics., Vol. 11, No. 11, p. 2437, (2023).

[18] M. Alizad-Kamran, M. Hoseinpour-Gollo, A. Hashemi and S. M. H. Seyedkashi, “Determination of critical pressure in analyzing of rupture instability for hydromechanical deep drawing using advanced yield criterion”, Arch. Civ. Mech. Eng., Vol. 18, No. 1, pp. 103-113, (2018).

[19] A. Hashemi, M. Hoseinpour Gollo and S. M. H. Seyedkashi, “Process window diagram of conical cups in hydrodynamic deep drawing assisted by radial pressure”, Trans. Nonferrous Met. Soc. China, Vol. 25, No. 9, pp. 3064−3071, (2015).

[20] L. Jebri, T. Lazghab, M. Toumi and M. Soula, “The behavior and forming performance of vapor hydroforming process of thin aluminum sheets: Numerical and experimental analysis”, Adv. Mech. Eng., Vol. 14, p. No. 4, p. 16878132221089380, (2022).

[21] D. Marquez-Monje, R. Escribano-Garcia and O. Zubiri, “Characterization and finite element modeling of microperforated titanium grade 2”, Appl. Sci., Vol. 14, No. 17, p. 7903, (2024).

[22] K. Komori and K. Matsushima, “Predicting ductile fracture during biaxial sheet stretching using an ellipsoidal void model”, Theor. Appl. Fract. Mech., Vol. 118, p. 103215, (2022).

[23] F. Xue, Y. Yan and J. Kang, “Predicting forming limit diagrams for AZ31 magnesium alloy and 7050 aluminum alloy by numerical simulation”, J. Strain Anal. Eng. Des., Vol. 56, No. 8, pp. 598-608, (2021).

[24] A. Jalil, M. H. Hosseinpour Gollo, and S. M. H. Seyedkashi, “Process analysis of hydrodynamic deep drawing of cone cups assisted by radial pressures”, Proc. Inst. Mech. Eng. Pt. B J. Eng. Manuf., Vol. 231, No. 10, pp. 1793-1802, (2017).

[25] M. L. R. Meragalge and P. Gamage, “Finite element simulation model to predict the formability of AA 2014 T6 aluminum sheets at elevated temperatures”. Proc. 10^th Int. Conf. Inf. Autom. Sustainability (ICIAfS), Negambo, Sri Lanka, pp. 542-547, (2021).

[26] A. Nakwattanaset and S. Suranuntchai, “Formability analysis on ultra-high strength steel for automotive parts using finite element simulation”, Mater. Sci. Forum., Vol. 1018, pp. 137-144, (2021).

[27] M. M. Shahzamanian, M. Parsazadeh, and P. D. Wu, "Numerical and analytical analyses of the formability and fracture of AA7075-O aluminum sheets in hemispherical punch tests," Int. J. Solids Struct., Vols. 286–287, p. 112558, 2024.

[28] J. Zhang, "Numerical analysis and application of Marciniak and Nakazima experimental model on the formability of 304l Sheet," J. Phys. Conf. Ser., Vol. 2834, p. 012152, (2024).

[29] T. S. Yang and J. Y. Huang, "Forming limit analysis of magnesium alloy sheet metal forming process at elevated temperatures," J. Phys. Conf. Ser., Vol. 2878, p. 012022, (2024).

[30] Y. Guo, T. L. Burnett, S. A. McDonald, M. Daly, A. H. Sherry, and P. J. Withers. "4D imaging of void nucleation, growth, and coalescence from large and small inclusions in steel under tensile deformation." J. Mater. Sci. Technol., Vol. 123, pp. 168-176, (2022).

Name *

Email Address *

Affiliation *

Comments *

Security Code *

CAPTCHA Image

Journal of Computational & Applied Research in Mechanical Engineering (JCARME)

Articles in Press, Accepted Manuscript
Available Online from 27 July 2026

Files

Share

How to cite

Statistics

Article View: 6
PDF Download: 2