Forming and fracture limits of aluminium alloy

Abstract

Forming and fracture limits of an AA 3104-H19 aluminium alloy sheet were studied by hydraulic bulging and Marciniak type deep drawing and tensile tests. The alloy appeared to be highly anisotropic, exhibiting distinctly different fracture patterns in the rolling and transverse directions. The preferred fracture direction was transverse to the rolling direction. In the tensile test, samples loaded in the rolling direction failed transverse to the rolling direction, but in the transverse direction, the fracture was inclined at ∼55° to the tensile axis. In some cases, two such competing fractures in the characteristic directions could be observed. Scanning electron microscopy studies revealed a typical ductile fracture pattern. The fracture occurred by shearing in the through thickness direction, and typical alternating shear lips in a direction inclined at ∼45° to the through thickness direction could be observed. Forming limit diagrams for both rolling and transverse directions were determined from the experiments. The measured limit strains in uniaxial tension were predicted well by the modified Rice–Tracey theory, but in equibiaxial tension, the theory overestimated the fracture limit strains.

Keywords:

• Forming limit diagram
• Fracture
• Aluminium

The authors would like to thank Dr J. W. Yoon and Alcoa Technical Center for providing the material for the experiments.