Modeling and Prediction of the Forming Limits of AA5052 Sheets Under Cryogenic Conditions Using a Modified M-K Model

Cryogenic forming overcomes room-temperature limitations by leveraging the enhanced strength–ductility synergy in Al alloys. To explore the forming limits of AA5052 sheet under cryogenic forming conditions, quasi-in situ tensile tests were conducted and digital image correlation techniques were employed to examine strain distribution, surface roughness evolution, and forming limit curves of the AA5052 sheet in the tensile deformation process. Experimental results show that the maximum equivalent forming limit at −196 °C increases to 50.7% from 19.9% at room temperature, representing a 250% increase. At the same time, the surface roughness evolution rate increases by 60% from 2713 nm at room temperature to 4414 nm at −196 °C. Cryogenic conditions suppress dislocation annihilation and dynamic recovery, enhancing strain hardening, resulting in higher forming limits. Additionally, intensified grain rotation and more dislocation slip accelerate surface roughening, which influences the development of the geometric heterogeneity coefficient. By introducing a strain-dependent surface roughening coefficient, the Marciniak–Kuczyński (M-K) model was modified and was used to quantitatively characterize the heterogeneity during deformation, and subsequently analyzes its impact on the prediction of forming limits for AA5052 from room temperature (25 °C) to cryogenic temperature (−196 °C). The modified model reduces the prediction standard deviation by more than 70% and the identified mechanisms offer theoretical guidance for optimizing cryogenic forming process parameters for Al alloy components with complex geometries.