Effect of non-associated flow rule on fracture prediction of metal sheets using a novel anisotropic ductile fracture criterion

•The ductile fracture behavior of anisotropic materials was studied and modeled by the uncoupled ductile fracture criterion for aluminum alloys 6016-AC200.•The non-associated flow rule was applied to increase the accuracy of onset of the anisotropic ductile fracture.•The fracture locus, fracture surface, and fracture forming limit diagram constructed by the proposed ductile fracture criterion were displayed for AA6016-AC200.•The proposed ductile fracture criterion can be utilized for predicting the onset of the anisotropic ductile fracture behavior in sheet metal forming. [Display omitted] The ductile fracture behavior of anisotropic materials was investigated and modeled by the uncoupled ductile fracture criterion for aluminum alloys 6016-AC200. The ductile fracture model takes into account micro-mechanisms of void nucleation, void growth, and evolution of void coalescence. The anisotropic yield function and non-associated flow rule were applied to increase the accuracy of the ductile fracture prediction. Series of uniaxial tensile tests, equi-biaxial tension test, and hydraulic bulge test were utilized to identify coefficients of the plasticity model. Various standard fracture tests covering a wide range of stress triaxiality from negative to moderate and high-stress triaxiality were used in order to calibrate the ductile fracture parameters for AA6016-AC200. The strain field on the surface of specimens was captured by the non-contact measurement DIC system for all tests. The fracture surface, fracture locus, and fracture forming limit diagram constructed by the proposed ductile fracture criterion were plotted. These basic fracture tests and a square cup drawing test were simulated by the ABAQUS/Explicit commercial software to verify the efficiency of the proposed fracture criterion and the advanced plastic model in predicting the onset of ductile fracture behavior. The results indicated that the proposed ductile fracture criterion can be utilized for predicting the onset of the anisotropic ductile fracture behavior in sheet metal forming.