Numerical and analytical analyses of the formability and fracture of AA7075-O aluminum sheets in hemispherical punch tests

In this study, numerical simulations and experimental validations of the simulation of hemispherical punch tests for AA7075-O aluminum sheets with various sample widths are presented. It is convincingly believed in literature that a finite element (FE) based forming limit diagram (FLD) can be predicted very well using various time-dependent criteria. This matter has been investigated and securitized deeply and the FE-based FLD was predicted using three time-dependent criteria and compared with the experimental FLD. Results show that two of the three criteria could predict the relatively appropriate shape of the FLD while one of them has failed to match. Aside from using FE simulation to predict the FLD, an analytical method, namely, Marciniak-Kuczynski (M-K) was also used to make a better evaluation about the capability of the finite element method (FEM) to predict FLD. Among the FE-based FLDs, the one predicted using the Martinez-Donaire et al., 2014 was found to be close to the one predicted using the M-K method. Although, the main objective of this paper is to investigate the capability of the FEM to predict an FLD for AA7075-O aluminum sheets, the fracture behavior for each case was predicted using a unified fracture model. Several computer runs were executed to perform the tests and reproduce the experimental results. The aim of this study was to discuss the simulation of hemispherical punch tests and analyze the numerical results and compare them with the experimental and analytical methods. It was observed that the experimental FLD can be reproduced using various time-dependent criteria in a relatively appropriate manner but with limitations especially at the equibiaxial stress state. These limitations were scrutinized and discussed in detail by comparing the results with experimental and analytical calculations.