Analytical Prediction of Limit Strains and Limit Stresses in Hydroforming of Anisotropic Aluminum Tubes

Forming limit diagram (FLD) shows the formability of metal sheets under different loading conditions before that necking is taken place. In this paper, the application of plastic instability criterion for prediction of necking and also FLD has been investigated. Using Balart’s anisotropic yield function and plastic instability criterion in different strain ratios, limit strains have been calculated, and then the limit strains have been converted to limit stresses. To verify the analytical results, a free bulge setup with the ability of applying the axial feeding has been fabricated. Tubes have been undergone different loading paths and different plane strain conditions have been induced to obtain FLD. FLDs which have been obtained using plastic instability criterion have been compared with experimental results. The results show that swift instability criterion for tubes have the best prediction of FLD in tube hydroforming process.