Numerical and experimental study of three-layered Al 1050/Mg AZ31B/ Al 1050 sheets formability considering strain and stress conditions through single point incremental forming

This article examines the formability of 3-layer Al 1050/Mg-AZ31B /Al 1050 sheets experimentally and numerically. Mg AZ31B, with its high strength-to-weight ratio, and Al 1050, with its formability and lightweight, are attractive industrial metals. In the experimental method, the forming limit diagram (FLD), the Forming limit angle (FLA), and the fracture depth were investigated for the 3-layer and base samples with two pyramid and cone geometries. The results showed that the ductility in the cone geometry is higher than that of the pyramid. Also, by comparing the FLD of the 3-layer sample to the base sample, the results showed that the formability of the 3-layer sample increased compared to the Mg-AZ31B base sample. In contrast, the formability decreased compared to the base sample of Al 1050. Numerical studies for predicting the FLD using the SPIF method were carried out using Abaqus software. The numerical techniques considered the second deviation minor strain (SDMIS), second deviation effect strain (SDEF), second deviation thickness (SDT), and second deviation major strain (SDMS). The results showed that the highest accuracy occurred for the SDT method compared to other numerical methods. To remove the effect of the strain path on the numerical analysis for predicting the FLD (from the stress analysis method), a second deviation of von Mises stress (SDVMS) was used. By examining the results, it was found that the results of numerical methods considering stress could be highly accurate.