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Warm forming processes have been successfully applied at laboratory level toovercome some important drawbacks of the Al-Mg alloys, such as poor formabilityand large springback. However, the numerical simulation of these processesrequires the adoption of coupled thermo-mechanical finite element analysis,using temperature-dependent material models. The numerical description of thethermo-mechanical behaviour can require a large set of experimental tests.These experimental tests should be performed under conditions identical to theones observed in the forming process. In this study, the warm deep drawing of acylindrical cup is analysed, including the split-ring test to assess thetemperature effect on the springback. Based on the analysis of the formingprocess conditions, the thermo-mechanical behaviour of the AA5086 aluminiumalloy is described by a rate-independent thermo-elasto-plastic material model.The hardening law adopted is temperature-dependent while the yield function istemperature-independent. Nevertheless, the yield criterion parameters areselected based on the temperature of the heated tools. In fact, the modelassumes that the temperature of the tools is uniform and constant, adopting avariable interfacial heat transfer coefficient. The accuracy of the proposedfinite element model is assessed by comparing numerical and experimentalresults. The predicted punch force, thickness distribution and earing profileare in very good agreement with the experimental measurements, when theanisotropic behaviour of the blank is accurately described. However, this doesnot guarantee a correct springback prediction, which is strongly influenced bythe elastic properties, namely the Young's modulus.

Thermo-mechanical finite element analysis of the AA5086 alloy under warm forming conditions