Prediction of limit strains in hot forming of aluminium alloy sheets

Theoretical analysis for the prediction of the limit strains of AA5083 aluminium alloy sheets deformed at room and elevated temperatures are presented and discussed in relation to experimental limit strains. The AA5083 forming limit strain curves, FLC, were predicted by employing D-Bressan and Marciniak–Kuczynski macroscopic concept models and were compared with the experimental FLC from Nakazima tests performed at room and high temperatures. In order to calibrate the models, tensile tests on specimens cut at 0°, 45° and 90° with respect to the rolling direction were carried out in a wide rage of temperatures and strain rates in order to obtain the coefficients of plastic anisotropy as well as material strain and strain rate hardening behaviour at different temperatures. The applied critical shear stress rupture criterion and strain gradient evolution models showed to give a satisfactory agreement with the forming limit strain curves of AA5083 aluminium sheet, proving the suitability of a novel concept of shear stress rupture and local necking evolution in sheet metals deformed at room and elevated temperatures. The correlation of M–K predicted FLC-N curve with the experimental points for room and high temperatures was also fairly good.