| Summary: | The temperature and strain rate have significant effect on the formability of Al-Mg alloy sheet during warm forming process. Forming limit curve (FLC) is widely used for predicting sheet failure in warm forming simulation. However, the current simulation and optimization may lead to non-robust results, due to not considering the variation of FLC caused by the randomness of sheet temperature and deformation velocity, etc. In this study, a theoretical approach is developed to predict the temperature and strain rate dependent FLC. Backofen constitutive equation is extended, in which the material parameters are fitted as a function of temperature and strain rate by response surface method (RSM). Based on the M-K theory and Logan-Hosford yield criterion, the FLCs of 5083 Al-Mg sheet under different temperature and strain rate conditions are predicted and compared with the experimental results. By integrating the theoretical approach and Monte-Carlo simulation, the temperature and strain rate uncertainties are involved in FLC prediction to reflect manufacturing reality. The upper and lower margins of the FLC variation band are established, which covers the dispersion of the limit strains propagate from temperature and strain rate fluctuation. It is shown that under the combination of a higher temperature and a lower strain rate, the FLC of 5083 Al-Mg sheet is quite sensitive to small fluctuation of temperature or strain rate. In a particular temperature range (413 K–453 K), the FLC of 5083 Al-Mg alloy sheet becomes less sensitive to the fluctuation of temperature or strain rate. All these findings will advance the understanding of the design quality and robustness of the warm forming process.
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