Forming Limit Stress Diagram Prediction of Aluminum Alloy 5052 Based on GTN Model Parameters Determined by In Situ Tensile Test

The conventional forming limit diagram (FLD) is described as a plot of major strain versus minor strain. However, FLD is dependent on forming history and strain path. In the present study, a forming limit stress-based diagram (FLSD) has been adopted to predict the fracture limit of aluminum alloy (AA) 5052-O1 sheet. Nakazima test is simulated by plastic constitutive formula derived from the modified Gurson-Tvergaard-Needleman (GTN) model. An in situ tensile test with scanning electron microscope (SEM) is proposed to determine the parameters in GTN model. The damage evolution is observed and recorded, and the parameters of GTN model are identified through counting void fraction at three damage stages of AA5052-O1. According to the experimental results, the original void volume fraction, the volume fraction of potential nucleated voids, the critical void volume fraction, the void volume fraction at the final failure of material are assigned as 0.002 918, 0.024 9, 0.030 103, 0.048 54, respectively. The stress and strain are obtained at the last loading step before crack. FLSD and FLD of AA5052-O1 are plotted. Compared with the experimental Nakazima test and uniaxial tensile test, the predicted results show a good agreement. The parameters determined by in situ tensile test can be applied to the research of the forming limit for ductile metals.