Effects of sheet thickness and anisotropy on forming limit curves of AA2024-T4

In this study, the effects of sheet thickness and anisotropy of AA2024-T4 on forming limit curve (FLC) are experimentally investigated according to ISO 12004-2 standard. A new limit strain measurement method is proposed by using the grid analysis method so as to determine limit strains conveniently and reliably. In addition to the regular test specimens, various widths are added to enhance the FLC’s accuracy at the plane strain condition (PSC). The accuracy and reliability of the proposed method are verified for different materials. Results illustrate that an increase in the sheet thickness increases the FLC level. The additional experiments for additional widths improve the accuracy of the FLC at the PSC, and the position of the lowest major strain value differs from the literature. However, the effect of anisotropy on the FLC is found to be insignificant. Finally, experimental and numerical case studies are carried out for conventional deep drawing, stretch drawing, and hydraulic bulge processes. Results reveal that different FLCs are necessary for different thicknesses for accurate predictions.