Investigating Fracture Failure in Origami-based Sheet Metal Bending

Investigating Fracture Failure in Origami-based Sheet Metal Bending | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Investigating Fracture Failure in Origami-based Sheet Metal Bending Muhammad Ali Ablat, Ala’aldin Alafaghani, Jian-Qiao Sun, Chetan Nikhare, and 1 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-918505/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 15 Jan, 2022 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted 3 You are reading this latest preprint version Abstract Origami-based sheet metal (OSM) bending is a promising new die-free folding technique for sheet metal. OSM bending principle is based on deforming the material along a pre-defined fold line, which is determined using material discontinuity (MD) produced by laser or waterjet cutting. The objective of this work is to study and evaluate the fracture in OSM bending under the influence of various MD types, kerf-to-thickness (k/t) ratios, and sheet thicknesses. The research goal is to provide information on selecting an optimized k/t ratio and type of MD that allows for fracture-free bending. Four different ductile fracture criteria (DFC) are used and calibrated from experimental data to forecast fracture. The DFC calibration is used to produce a set of critical damage values (CDV) for assessing the possibility of fracture in the OSM bending. In addition, the study provides fracture evaluation using finite element analysis (FEA) integrated with experimental cases for a broader range of OSM bending parameters and MDs. The results demonstrated that an MD with a higher k/t ratio is less likely to fracture during the OSM bending, whereas a higher sheet thickness increases the possibility of fracture. Furthermore, the study identifies the k/t ratio limit that ensures successful bending without fracture and categorizes MD types into two groups based on fracture likelihood. The fracture in the first group is dependent on the limiting k/t ratio, whereas the possibility of fracture in the second group is independent of the k/t ratio due to its topology. Biotechnology and Bioengineering Sheet Metal Forming Finite Element Analysis (FEA) Ductile fracture Origami-based sheet metal (OSM) bending Full Text Cite Share Download PDF Status: Published Journal Publication published 15 Jan, 2022 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted Editorial decision: Major Revisions Needed 28 Oct, 2021 Reviews received at journal 17 Sep, 2021 First submitted to journal 16 Sep, 2021 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-918505","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":52898526,"identity":"c5643506-55f7-49d9-bb00-ffa72964ecb6","order_by":0,"name":"Muhammad Ali Ablat","email":"","orcid":"","institution":"University of California Merced","correspondingAuthor":false,"submittingAuthor":false,"prefix":"","firstName":"Muhammad","middleName":"Ali","lastName":"Ablat","suffix":""},{"id":52898527,"identity":"a14b7da6-3757-45cb-9355-40008920949c","order_by":1,"name":"Ala’aldin Alafaghani","email":"","orcid":"","institution":"University of California Merced","correspondingAuthor":false,"submittingAuthor":false,"prefix":"","firstName":"Ala’aldin","middleName":"","lastName":"Alafaghani","suffix":""},{"id":52898528,"identity":"b12f5d88-610e-4a9a-9f65-fcac446e0d43","order_by":2,"name":"Jian-Qiao Sun","email":"","orcid":"","institution":"University of California Merced","correspondingAuthor":false,"submittingAuthor":false,"prefix":"","firstName":"Jian-Qiao","middleName":"","lastName":"Sun","suffix":""},{"id":52898529,"identity":"dd5e8145-e65a-41f2-8c6b-d67d6419ff3a","order_by":3,"name":"Chetan Nikhare","email":"","orcid":"","institution":"University of California Merced","correspondingAuthor":false,"submittingAuthor":false,"prefix":"","firstName":"Chetan","middleName":"","lastName":"Nikhare","suffix":""},{"id":52898530,"identity":"6c2ecff8-e95e-446d-845b-6fe967917cbc","order_by":4,"name":"Ala Qattawi","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAA/0lEQVRIiWNgGAWjYDACdjiLsfEBkJRhYEgAUmx4tDCDSQMJoJZmA6BqHlK0MLBJEKWFv5n5AcObmj91/DOS26p5f9jw8LMnH2D4UHYYpxaJw2wGjHOOGUhI3Ehsu82TkMYj2fMsgXHGOdxaGA4zGDDzsAEddhus5TCPwY0cA2beNtxa5A+zf2Dm+WcgIQ/UUgzSYg/S8hePFgOgsUAzDSQMgFqYwbZIALUw4tFieJin4ODcPmPJjfcfNkvOSUvjkTjzLOFgz7l0nFrkjrdvfPDmmxy/3JnjDz+8sbGR429PPvjgR5k1bu8DwQEeDBG86kEAQ8soGAWjYBSMAmQAAGGJUXbhSRALAAAAAElFTkSuQmCC","orcid":"","institution":"University of California Merced","correspondingAuthor":true,"submittingAuthor":false,"prefix":"","firstName":"Ala","middleName":"","lastName":"Qattawi","suffix":""}],"badges":[],"createdAt":"2021-09-18 20:18:31","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-918505/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-918505/v1","draftVersion":[],"editorialEvents":[{"content":"https://doi.org/10.1007/s00170-021-08576-0","type":"published","date":"2022-01-15T07:53:48+00:00"}],"editorialNote":"","failedWorkflow":false,"files":[],"financialInterests":"","formattedTitle":"\u003cp\u003eInvestigating Fracture Failure in Origami-based Sheet Metal Bending\u003c/p\u003e","fulltext":[{"header":"Full Text","content":"This preprint is available for \u003ca href='/article/rs-918505/latest.pdf' target='_blank'\u003edownload as a PDF\u003c/a\u003e."}],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":false,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"Sheet Metal Forming, Finite Element Analysis (FEA), Ductile fracture, Origami-based sheet metal (OSM) bending","lastPublishedDoi":"10.21203/rs.3.rs-918505/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-918505/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"Origami-based sheet metal (OSM) bending is a promising new die-free folding technique for sheet metal. OSM bending principle is based on deforming the material along a pre-defined fold line, which is determined using material discontinuity (MD) produced by laser or waterjet cutting. The objective of this work is to study and evaluate the fracture in OSM bending under the influence of various MD types, kerf-to-thickness (k/t) ratios, and sheet thicknesses. The research goal is to provide information on selecting an optimized k/t ratio and type of MD that allows for fracture-free bending. Four different ductile fracture criteria (DFC) are used and calibrated from experimental data to forecast fracture. The DFC calibration is used to produce a set of critical damage values (CDV) for assessing the possibility of fracture in the OSM bending. In addition, the study provides fracture evaluation using finite element analysis (FEA) integrated with experimental cases for a broader range of OSM bending parameters and MDs. 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