Fracture and wrinkling are two main failure modes in deep drawing of a coated metal sheet. With the development of damage mechanics and finite element modeling, it is possible to exactly predict the failure mode of a material during deep drawing. In this paper, a coated metal sheet during deep drawing is studied by finite element simulation and dimensional analysis. Based on a few dimensionless process parameters, a failure map is established, which can be divided into three regions including fracture, wrinkling, and success.
