Failure Prediction and Forming Behavior of AA5754 Sheets at Warm Temperature
The prediction of the warm forming behavior of aluminum alloy sheets is vital in the automotive industry to conceive and improvise the tool design to fabricate intricate thin-walled lightweight components without premature thinning or splitting. In this work, Marciniak–Kuczynski-based-forming limit diagram (MK-FLD) of AA5754-H22 sheet at 30 and 200 ℃ was successfully developed incorporating Hill48 anisotropic yield theory and Swift strain rate sensitive hardening law. Drastic improvement of FLD was noticed at 200 ℃ as the FLD0 was 1.35 times higher compared to that at 30 ℃. The developed FE models accurately captured the fracture location, maximum thinning, and strain localization region. The suitability of MK-FLD and FE simulations was demonstrated using the experimental data available from the literature. The strain path followed by the failure node during the deformation of Hasek, biaxial, and deep drawing samples was observed to follow tension–compression, tension–tension, and plane strain modes, respectively.
KeywordsWarm forming AA5754 Forming limit diagram FE modeling
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