FE simulations of gas blow forming and prediction of forming limit diagram of AZ31 magnesium sheet

FE simulation of elliptical bulge forming of AZ31 automotive magnesium sheet has been carried out based on a recent experimental study where a new method of simultaneously bulging of two clamped blanks of different geometries was successfully employed to experimentally obtain tension–compression side of the FLD. The present study complements the earlier experimental study by providing insight into material plastic flow and strain localization for various ‘double blank’ configurations. In addition, FE simulation results are utilized to predict the FLD of AZ31 sheet at 300°C based on a recently proposed strain localization criterion and other material model assumptions. Good agreement has been observed between the experimental and predicted FLDs.