Assessment of aluminium alloys’ formability by elevated temperature testing

Abstract This work presents an investigation of the warm formability of AA7075-T6 aluminium alloy sheets using both experimental and numerical methods. Forming limit diagrams (FLDs) can be created by plotting the failure criteria on a graph with two axes representing major and minor strains. Sheets with a grid can be used to quantify both large and minor strains. General techniques available for the grid involve regular patterns of circles in this experiment. Experiments were conducted at various temperature levels, including room temperature, 100, 120, 140, 160, and 180 °C, as well as different strain rates. The investigation has revealed a significant impact of temperature on formability, while the effect of forming speed is quite insignificant across the whole range studied. At an ageing temperature of 140 °C, the distribution of precipitates is evenly balanced, resulting in improved mechanical strength. To offer accurate numerical models for warm-forming processes, a proposed constitutive model is introduced for aluminium alloy sheets. The present model incorporates plastic anisotropy and the effects of temperature and strain rate dependence. An investigation was conducted on the stress-strain behaviour of thin sheets composed of AA7075-T6 aluminium alloy under elevated temperatures and different strain rates. The objective was to ascertain the appropriate fitting parameters. It was associated with ABAQUS finite element modelling. The recommended material model was utilized to build finite element models, which were subsequently compared to the experimental data. The findings obtained from simulated isothermal uniaxial tensile tests were compared to the empirical measurements. The models used in the tensile test accurately predicted the material’s mechanical response. The predicted failure location, punch forces, and strain distributions for all three forming processes were found to be in close agreement with the experimental results. During deep draw operation, the warm forming limit curves were utilized to precisely predict both the pierce depth at which failure occurs and the precise location where the failure initiates.