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Forming limit strain curves of conventional aluminium alloy AA6014 sheets after loading with non-linear strain paths are presented and compared with D-Bressan macroscopic model of sheet metal rupture by critical shear stress criterion. AA6014 exhibits good formability at room temperature and, thus, is mainly employed in car body external parts by manufacturing at room temperature. According to Weber et al., experimental bi-linear strain paths were carried out in specimens with 1mm thickness by pre-stretching in uniaxial and biaxial directions up to 5%, 10% and 20% strain levels before performing Nakajima testing experiments to obtain the forming limit strain curves, FLCs. In addition, FLCs of AA6014 were predicted by employing D-Bressan critical shear stress criterion for bi-linear strain path and comparisons with the experimental FLCs were analyzed and discussed. In order to obtain the material coefficients of plastic anisotropy, strain and strain rate hardening behavior and calibrate the D-Bressan model, tensile tests, two different strain rate on specimens cut at 0°, 45° and 90° to the rolling direction and also bulge test were carried out at room temperature. The correlation of experimental bi-linear strain path FLCs is reasonably good with the predicted limit strains from DBressan model, assuming equivalent pre-strain calculated by Hill 1979 yield criterion. [ABSTRACT FROM AUTHOR]

Present work examines mathematical models to predict the onset of localized necking in sheet metal forming of interstitial free steel, such as biaxial stretching and deep drawing. Forming Limit Curve, FLC, which is an essential material parameter necessary to numerical simulation by FEM, of IF steel sheet was assessed experimentally by Nakajima testing and ASAME software. The "Map of Principal Surface Limit Strains - MPLS", shows the experimental FLC which is the plot of principal true strains in the sheet metal surface (ε1, ε2), occurring at critical points obtained in laboratory formability tests or in the fabrication process of parts. Two types of undesirable rupture mechanisms can occur in sheet metal forming products: localized necking and rupture by induced shear stress. Therefore, two kinds of limit strain curves can be plotted in the forming map: the local necking limit curve FLC-N and the shear stress rupture limit curve FLC-S. Localized necking is theoretically anticipated to occur by two mathematical models: Marciniak-Kuczynski modeling, hereafter named M-K approach, and D-Bressan modeling. In the M-K approach, local necking originates at an initial sheet thickness heterogeneity or defect f0 = tob/toa. The strain state inside the evolving groove moves to plane strain and the limit strain si* is attained when the strain sia outside the groove or neck stop to increase. In the D-Bressan model, local necking is proposed to initiate at the instability point of maximum load, at a thickness defect (λ/μ)diffuse inside the grooved sheet thickness. The inception of visible grooving on the sheet surface evolves from instability point to localized necking (λ/μ)crit and final rupture, during further sheet metal straining. Work hardening law is defined for a strain and strain-rate material by the effective current stress. The average experimental hardening law curve for tensile tests at 0°, 45° and 90°, assuming normal anisotropy, was used to analyze the plasticity behavior during the biaxial stretching of sheet metals. Theoretical predicted curves of local necking limits are plotted in the positive and negative region of MPLS for different defect values f0 and λ/μ. parameters. Limit strains are obtained from a software developed by the authors. Experimental results of FLC obtained from experiments for IF steel sheets were compared with the theoretical predicted curves: the correlation is reasonable good in the positive quadrant, but the predicted values are above the experimental points in the negative quadrant due to punch friction, non-linear strain path and grid measurements. [ABSTRACT FROM AUTHOR]