Fracture and Structural Integrity e-ISSN 1971-8993 Open access
Integrity of materials and structures Vol. 20, No. 75 (2026)

Optimization of austenitic and ferritic steels for deep drawing. Part 2: FEM analyses with damage development.

Author and affiliation details
  • Andrea Casaroli Department of Mechanical Engineering, Politecnico di Milano, via La Masa 1, 20156 Milano, Italy
  • Edoardo Scabini Corresponding author Department of Mechanical Engineering, Politecnico di Milano, via La Masa 1, 20156 Milano, Italy ORCID iD0009-0005-4487-912X edoardo.scabini@polimi.it
  • Marco Virginio Boniardi Department of Mechanical Engineering, Politecnico di Milano, via La Masa 1, 20156 Milano, Italy
  • Riccardo Andreotti Callens® AREA3, Via Merini 37 21100 Varese, Italy ORCID iD0000-0003-2472-9448
  • Barbara Rivolta Department of Mechanical Engineering, Politecnico di Milano, via La Masa 1, 20156 Milano, Italy
DOI
10.3221/IGF-ESIS.75.13
Pages
179-199
Published
Licence
CC BY 4.0
Published inVol. 20, No. 75 (2026)Go to the issue

Abstract

Deep drawing of sheet metal is a crucial industrial process due to its high productivity and low cost per unit produced. Stainless steels are ideal for this process, given their high deformability compared to other steels. Despite its apparent simplicity, understanding how the material deforms during deep drawing is essential to predict the final result. From this point of view, simulation via finite element modelling (FEM) represents a rapid and cost-effective alternative to experimental testing. When properly calibrated, FEM models allow for analysing stress and strain distribution, identifying areas at risk of failure, calculating final wall thickness, and optimizing die geometry. This research led to the development of a FEM model capable of simulating deep drawing under different operating conditions, steel types (AISI 304 and AISI 430) and lubrication. The model was calibrated and validated by comparing the numerical results with those obtained from a series of Erichsen tests. To ensure the accuracy of the true stress-strain curves, the steels were thoroughly characterized through tensile tests, Erichsen tests, and metallographic analyses. A specific method was also developed to represent the true stress-strain curve beyond necking, up to physical failure of the steel. The experiment was conducted according to the principles of DoE (Design of Experiments), combined with statistical analysis using the ANOVA technique.

Keywords

Article history

  1. ReceivedUntil the next stage: 5 days
  2. AcceptedUntil the next stage: 1 day
  3. Published

How to cite

APA

Casaroli, A., Scabini, E., Boniardi, M. V., Andreotti, R., & Rivolta, B. (2025). Optimization of austenitic and ferritic steels for deep drawing. Part 2: FEM analyses with damage development. Fracture and Structural Integrity, 20(75), 179–199. https://doi.org/10.3221/IGF-ESIS.75.13

IEEE

A. Casaroli, E. Scabini, M. V. Boniardi, R. Andreotti, and B. Rivolta, “Optimization of austenitic and ferritic steels for deep drawing. Part 2: FEM analyses with damage development.,” Fracture and Structural Integrity, vol. 20, no. 75, pp. 179–199, 2025, doi: 10.3221/IGF-ESIS.75.13.

MLA

Casaroli, Andrea, et al. “Optimization of austenitic and ferritic steels for deep drawing. Part 2: FEM analyses with damage development.” Fracture and Structural Integrity, vol. 20, no. 75, 2025, pp. 179–199. https://doi.org/10.3221/IGF-ESIS.75.13.

Chicago

Casaroli, Andrea, Edoardo Scabini, Marco Virginio Boniardi, Riccardo Andreotti, and Barbara Rivolta. 2025. “Optimization of austenitic and ferritic steels for deep drawing. Part 2: FEM analyses with damage development.” Fracture and Structural Integrity 20 (75): 179–199. https://doi.org/10.3221/IGF-ESIS.75.13.

Harvard

Casaroli, A., Scabini, E., Boniardi, M.V., Andreotti, R. and Rivolta, B. (2025) ‘Optimization of austenitic and ferritic steels for deep drawing. Part 2: FEM analyses with damage development.’, Fracture and Structural Integrity, 20(75), pp. 179–199. doi: 10.3221/IGF-ESIS.75.13.

Vancouver

Casaroli A, Scabini E, Boniardi MV, Andreotti R, Rivolta B. Optimization of austenitic and ferritic steels for deep drawing. Part 2: FEM analyses with damage development. Fracture and Structural Integrity. 2025;20(75):179-199. doi:10.3221/IGF-ESIS.75.13

BibTeX

@article{casaroli2025, author = {Casaroli, Andrea and Scabini, Edoardo and Boniardi, Marco Virginio and Andreotti, Riccardo and Rivolta, Barbara}, title = {Optimization of austenitic and ferritic steels for deep drawing. Part 2: FEM analyses with damage development.}, journal = {Fracture and Structural Integrity}, year = {2025}, volume = {20}, number = {75}, pages = {179--199}, doi = {10.3221/IGF-ESIS.75.13}, url = {https://doi.org/10.3221/IGF-ESIS.75.13}, issn = {1971-8993} }

RIS

TY - JOUR AU - Casaroli, Andrea AU - Scabini, Edoardo AU - Boniardi, Marco Virginio AU - Andreotti, Riccardo AU - Rivolta, Barbara TI - Optimization of austenitic and ferritic steels for deep drawing. Part 2: FEM analyses with damage development. JO - Fracture and Structural Integrity T2 - Fracture and Structural Integrity PY - 2025 DA - 2025/10/25 VL - 20 IS - 75 SP - 179 EP - 199 DO - 10.3221/IGF-ESIS.75.13 UR - https://doi.org/10.3221/IGF-ESIS.75.13 SN - 1971-8993 ER -

Licence

Creative Commons Attribution 4.0 International

May be shared and adapted, provided appropriate credit is given. Copyright © 2025 Andrea Casaroli, Edoardo Scabini, Marco Virginio Boniardi, Riccardo Andreotti, Barbara Rivolta.

Copyright 
Authors are allowed to retain both the copyright and the publishing rights of their articles without restrictions.  

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