Prediction of forming limit curve for AA6061-T6 at room and elevated temperatures

Abstract Forming Limit Curve (FLC) has been widely adopted as a practical criterion for evaluating the formability of sheet metals. Predicting a reliable FLC by a virtual methodology could lead to robust process optimization before expensive tool manufacturing. In order to increase the predictive capabilities of the virtual forming tools, an accurate modeling of the forming limit curve should be considered at room and elevated temperatures. In this work, the isothermal forming limit curves of 6000 series aluminum alloy sheet metal are predicted by performing numerical simulations of Nakajima test. A stress triaxiality and Lode angle based ductile fracture criterion is used to determine the forming limit curve. Also, the ductile fracture criterion is extended to add the impact of temperature on ductile fracture prediction. The hybrid experimental-numerical approach is used to calibrate the ductile fracture criterion. The forming limit curve of AA6061-T6 sheet metal, with a thickness of 1 mm, is predicted using the calibrated ductile fracture criterion at room and elevated temperatures. Numerical simulations are performed in 3D with the finite element code Abaqus. The limit strains are determined for specimens undergoing deformation under different strain paths. Influence of temperature on the predicted forming limit curve is discussed.