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Abstract: This paper describes the development and application of a numerical model that can predict the delamination of the polymer coating from the steel substrate during deep-drawing. Experimentally characterized cohesive zones are used to describe the interface between the polymer and the steel and are capable of modelling delamination or a prior partial loss of adhesion during an axisymmetric deep-drawing simulation. A parameter is proposed that quantifies the interfacial integrity and is used to assess the influence of the tooling radii, the clearance between the punch and the die and the coating thickness on the interfacial integrity. [Copyright &y& Elsevier]

Abstract: Interfacial fibrilation is a typical mechanism that frequently occurs during delamination of a polymer coating from a steel substrate. It involves large displacements at the interface as well as large deformations in the bulk material. Classical small displacement cohesive zone formulations fail to describe such large deformations correctly. Therefore, a generic cohesive zone model is introduced that is suitable to describe both uniform and non-uniform fracture at an interface with large deformations in the delaminating bulk and large displacements at the crack tip. [Copyright &y& Elsevier]