An integrated experimental–numerical approach for characterizing deformation behavior of high-strength steels

This study aims to establish an integrated experimental–numerical framework for characterizing the deformation behavior of DP590 high-strength steel sheet. The framework combines experimental uniaxial tensile and Nakajima tests with finite element (FE) simulations to provide a comprehensive assessment of forming limits and fracture behavior. Forming limit curves (FLCs) and forming limit stress curves (FLSCs) were determined with the integrated approach and then validated numerically using the Hill’48 yield criterion together with both Swift and Voce hardening laws. Model calibration incorporated experimental data on directional mechanical properties to ensure that material anisotropy was accurately represented. The FE simulations demonstrated strong agreement with the experimental data across uniaxial, plane-strain, and biaxial loading paths. The Swift hardening law consistently predicted higher forming limit stresses and more accurate drawing-depth estimates than the Voce law, particularly under biaxial and plane-strain conditions. The novelty of this work lies in the simultaneous validation of both strain- and stress-based forming limits, combined with the quantitative prediction of drawing depths, which has rarely been reported for DP590 grade. The proposed framework improves the predictive accuracy of forming simulations and provides practical guidelines for material characterization and process optimization in the automotive and related manufacturing industries.