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A new thermo-elasto-viscoplastic (TEV) crystal plasticity constitutive formulation is developed and implemented in the well-known Marciniak-Kuczynski analysis to predict the formability of aluminum alloys (AA) 5754 and 3003 at elevated temperatures. The model takes into account the temperature dependence of the single crystal elastic coefficients, single slip hardening parameters, thermal softening and slip rate sensitivity. Temperature dependent single slip hardening parameters are determined from uniaxial tension simulations at room and elevated temperatures. The new model is able to accurately predict the experimental forming limit diagrams (FLDs) without the need for further curve fitting. The effects of elastic constants and thermal softening on FLD predictions are discussed, and a new expression to represent the temperature dependence of the initial imperfection (for the M-K analysis) is developed to enable the model to successfully predict the FLDs for any temperature in the warm forming regime prior to recrystallization.

A New Thermo-Elasto-Viscoplastic Crystal Plasticity Framework to Predict the Formability of Aluminum Alloys at Elevated Temperatures