Characterization of Tensile Properties, Limiting Strains, and Deep Drawing Behavior of AA5754-H22 Sheet at Elevated Temperature

Automotive industries are very much interested in characterization of formability improvement of aluminum alloys at elevated temperatures before designing tools, heating systems, and processing sequences for fabrication of auto-body panels by warm forming technology. In this study, tensile tests of AA5754-H22 aluminum alloy were carried out at five different temperatures and three different strain rates to investigate the deformation behavior correlating with Cowper-Symonds constitutive equation. Laboratory scale warm forming facilities were designed and fabricated to perform limiting dome height and deep drawing tests to evaluate forming limit strains and drawability of sheet metal at different tool temperatures. The forming limit strain and dome height improved significantly when both the die and punch were heated to 200 °C. Remarkable improvement in deep drawn cup depth was observed when die and punch temperatures were maintained at 200 and 30 °C, respectively, producing a non-isothermal temperature gradient of approximately 93 °C across the blank from flange to center. The forming behavior at different isothermal and non-isothermal conditions were predicted successfully using a thermo-mechanical FE model incorporating temperature-dependent properties in Barlat-89 yield criterion coupled with Cowper-Symonds hardening model, and the thinning/failure location in deformed cups were validated implementing the experimental limiting strains as damage model.