Various shear tests have been proposed over decades leading to the publication of the ASTM Standard B831-93 [ASTM B831-93: Standard Test Method for Shear Testing of Thin Aluminum Alloy Products, Annual Book of ASTM Standards, ASTM International, West Conshohocken, PA, 2011] and its latest revision B831-11 for shear test of aluminum alloy thin sheet materials. However, this standard only measures the shear strength of aluminum sheets. A new shear specimen design has been developed by Kang et al. [Kang, J., Wilkinson, D. S., Wu, P. D., Bruhis, M., Jain, M., Embury, J. D? and Mishra, R? "Constitutive Behavior of AA5754 Sheet Materials at Large Strains,” J. Eng. Mater. Technol., Vol. 130, No. 3, 2008, p. 031004], We propose using digital image correlation for shear strain measurements, which is impractical for conventional extensometry techniques. A new shear test method is then used to measure both the shear strength and shear stress-shear strain curves up to large strains. 3D finite element analysis (FEA) was carried out for both the standard and new shear specimen designs. The results show that simple shear state is reached within the shear zone. The results also reveal that the out-of-plane shear strain is significantly reduced to 5 % in new shear specimen design compared to that of over 12 % for the standard specimen design. The rotation of the end of the shear zone is, thus, prevented.
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