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REFERENCE: Dilmec, Murat, Selcuk Halkaci, H., Ozturk, Fahrettin, and Turkoz, Mevlut, “Detailed Investigation of Forming Limit Determination
Standards for Aluminum Alloys,” Journal of Testing and Evaluation, Vol. 41, No. 1, 2013, pp. 1–12, doi:10.1520/JTE104356. ISSN 0090-3973.
ABSTRACT: In this study, experimental studies were conducted to evaluate the differences between the ASTM E2218-02 and ISO 12004-2
standards that are used for construction of the forming limit curve (FLC) and that made various assumptions, which create dissimilar FLCs for the same
material. The comparison was made for two materials which have moderate brittle and ductile characteristics, AA2024-T4 and AA5754-O alloys,
respectively. The effects of a specimen’s geometry, lubrication condition, and determination methods of limit strains on FLCs were considered and com-
pared. Because the same strain evaluation method should be used for the standards, so as to be able to investigate the effect of only standards, a simple
method in the computer grid analysis system was used. To test the validity and the reliability of the method, limit strains on the same specimens were
also determined with using a real-time measurement method for the ISO experiments, and the results reveal that the method is reliable. Failure mecha-
nisms were inspected for further investigation. The Nakajima specimens formed with the two standards showed different failure mechanisms. Finally,
conducting the case studies, it was concluded that ISO 12004-2 yields more reliable and reproducible results than the ASTM standard.
KEYWORDS: ASTM E2218-02, ISO 12004-2, forming limit curve, failure
C 2012 by ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959.
Copyright V 1
2 JOURNAL OF TESTING AND EVALUATION
TABLE 1—The chemical compositions of the materials (wt. %). geometry, lubrication condition, and limit strain evaluation methods
on FLCs were investigated. Failure mechanisms were inspected
Alloy % Cu % Mg % Mn % Fe % Si % Zn % Ti % Cr
and case studies were carried out for further investigation.
AA2024 4.44 1.29 0.6 0.123 0.068 0.092 0.027 0.002
AA5754 0.006 3.1 0.16 0.287 0.135 <0.02 0.022 0.064
FIG. 1—FLC test specimens according to (a) ASTM E 2218-02, and (b) ISO 12004-2 standards.
DILMEC ET AL. ON DETAILED INVESTIGATION OF FORMING LIMIT 3
respectively, were studied. AA2024-T4 sheet is widely used in FIG. 3—A typical sample which the dye on the it is was removed with acetone.
commercial and military aircraft for make fuselage and wing
skins. AA5754-O is especially used in automobile inner-body The test specimens were prepared by laser cutting machine at
panels often requiring a deep-drawn cross-section application rolling direction. AA2024 specimens were solution heat treated at
because of its superior formability. The chemical compositions of 493 C for 30 min. Then they were quenched in cold water and
the materials are given in Table 1. The mechanical properties of were allowed to be naturally aged at room temperature for 7 days
the materials were determined by the tensile test according to and so the mechanical properties of the material have a substan-
ASTM E8M-04 standard. tially stable condition (T4). AA5754 was annealed at 380 C dur-
The FLC test specimens were prepared according to both ing 4 h and it becomes O temper.
standards. The specimen’ geometries are shown in Fig. 1(a) and To measure strains, a 2.5-mm square grid pattern was printed
1(b). Different strain paths can be created by using various speci- by silk-screening method on the specimens. The detail of the pro-
men widths. The specimens having 1 mm thickness and 25 mm, cess is given in the authors’ earlier study [23]. The grid pattern
50 mm, 75 mm, and 100 mm widths have an hourglass shapes on has high accuracies and resolutions and was resisted against defor-
the narrow section for the both standards to eliminate failure at the mation and operating processes such as friction and lubrication.
blank holder area. The names of the specimens were denoted by w Then the specimens were deformed until the failure by using the
plus the specimen width. The Nakajima specimens specified in the formability test system as shown in Fig. 2. A 200-kN clamping
ASTM and the ISO standards differ from each other in terms of force was found to be suitable for the process. When necking or
geometry. The main differences of the specimens are the shaft fracture occurs, the forming process is automatically stopped. The
lengths as shown in the figure. The shaft lengths are about 9 mm punch speed was about 60 mm=min and each test has been
and 25 mm for ASTM and ISO, respectively. In addition to the repeated at least three times.
regular test specimens, four additional widths from w127 to w133 It is specified that the evaluation area must be nearly friction-
were also formed to improve the accuracy of the position of the less in ISO 12004-2. The standard mentions that the distance from
lowest major strain. the apex of the dome to the fracture should not exceed a maximum
FIG. 4—The section where the limit strain values are determined in the simple method.
4 JOURNAL OF TESTING AND EVALUATION
Yield strength Ultimate strength True strain Strain hardening exponent Strength coefficient Normal anisotropy Planar anisotropy
Material rY (MPa) rU (MPa) e n K (MPa) rm Dr
Note: All values are the mean of the three repeats and for 1 mm and 0 direction.
15 % of the punch diameter. If this condition is not satisfied, the Limit Strain Determination Methods
test must be repeated. The lubrication systems may not be
changed during the construction of a particular FLC. Paraffin wax FLCs were constructed according to ASTM E2218-02 and ISO
(lubrication 1) was used as lubricant between the interface of the 12004-2 standards. For conducting the ISO experiments, limit
punch and the sheet for all the widths in the ISO standard. In the strains were determined by using a real-time strain measurement
ASTM standard, only square samples were lubricated with method that determines the limit strains according to the cross-
0.3-mm thick polyethylene film with five layers þ SAE 10 mineral section method denoted in the ISO. Because double necking prob-
oil lubricant (lubrication 2). The other widths were formed under lems occur in the formed specimens following the ASTM, limit
dry conditions. strains cannot be determined by using the cross-section method.
In addition to the comparison of each standard’s own proper- Therefore, a simple method in a computer grid analysis system
ties for both materials, the effects of the specimen geometry and was used for the ASTM experiments. To be able to investigate the
the lubrication condition were investigated for only AA2024 ma- effects of the experimental standards, the same evaluation method
terial. The best curve was fitted to the strains obtained from all the should be used. The limit strains obtained from a specimen with
widths and repeats using the Microsoft Excel software. To see the using the both strain measurement methods must be in a good
repeatability of each standard, the w25 and w100 samples were agreement. To test the validity and the reliability of the simple
tested by many repeats. The standard deviations of all the strains method, the limit strains were determined with both methods
were calculated using the shortest distances of the strains to their using the same specimen.
own fitting curves.
Real-Time Strain Measurement Method—Because
the cross-section method is very complicated and time consuming,
ARAMIS a real-time measurement system was used for the deter-
mination of the limit strains according to ISO 12004-2. The ARA-
MIS can automatically determine the limit strains on the surface
of a specimen according to the cross-section method. This system
utilizes digital image processing and uses high-resolution CCD
cameras, which can measure the strains on the surface of a speci-
men has speckle pattern during deformation process. The CCD
cameras track the changes of the speckles taking photographs dur-
ing forming process. Photograph of an undeformed specimen is
taken as reference. While forming is in progress, ARAMIS com-
pares instantaneous photographs with the reference and calculates
the deformations and displacements. After the completion of the
image processing, three or five sections over the fracture region
are drawn. The measured strain distribution along these cross sec-
tions is analyzed. The strain points in the fracture area are deter-
mined by an objective mathematical criterion defined by the ISO.
A new strain distribution is reconstructed using these strain points
and a second order parabola is fitted the remaining part of the
strain distribution. The resulting values at the crack position indi-
cate the limit strains.
To measure the limit strains on the same specimens using the
both methods before creating speckle pattern, a 2.5-mm square
grid pattern was first applied on it. After the real-time measure-
ments, the dye on the dome-shaped specimens was removed with
acetone without disappearing of the grid pattern (Fig. 3). Then
the strains on the specimens were also determined by the
FIG. 5—An example formed Nakajima specimen according to (a) ISO, and (b) simple method to see the difference between two measurement
ASTM. methods.
DILMEC ET AL. ON DETAILED INVESTIGATION OF FORMING LIMIT 5
FIG. 6—Typical strain distributions in formed Nakajima specimens following to (a) ASTM, and (b) ISO.
FIG. 7—The strain distribution through most critical section of formed specimens following to both standards.
6 JOURNAL OF TESTING AND EVALUATION
Grid Analysis Method—In the ASTM standard, calcula- Results and Discussion
tion method for the limit strains is not specified. The strain distri-
Mechanical properties of the materials are given in Table 2.
bution on the specimens was obtained using a computer grid
analysis method, which is ASAME software. In this software, the
deformations of the grids on a deformed specimen were measured
by means of at least two photographs taken at different angle
Nakajima Experiments
using a reference target cube through photographs. There is not a All of the specimens were formed until necking or fracture
reliable limit strain determination method for all the materials in occurred. Necking was not observed for any of the samples
this software. Therefore, a simple method was used to determine because of the brittle nature of AA2024-T4, but AA5754-O for
the limit strains according to the ASTM. the both standards. In the ISO experiments, samples were frac-
The strain distributions for the specimens were quite uniform tured in such a way that the distance from the apex of the dome to
for Nakajima specimens formed following to the ISO. When the the fracture was not exceeded a maximum 15 % of the punch di-
strain distribution has been evaluated in the range of 1 %, it was ameter. In fact, many of the samples were fractured very close to
seen that the maximum strain region always covers at least four the apex of the dome as shown in Fig. 5(a). However, the frac-
grids. A section was drawn to covers at least four grids parallel to tures were far away (about 25 35 mm) from the apex of the
the fracture line as shown in Fig. 4 and the means of the major dome in the ASTM experiments (Fig. 5(b)). Thus, a double neck-
and minor strain values in this section were specified as limit ing problem occurs in the formed specimens according to the
strain values. ASTM as shown in Fig. 6(a). When the distance from the apex of
FIG. 10—The comparison of the repeatability of limit strains obtained following ASTM and ISO.
the dome to the fracture did not exceed a maximum 15 % of the were graded according to the color in such a way that the grade of
punch diameter, the problem of double necking was drastically major strain is about 1 %. Whereas the changing of the maximum
reduced (Fig. 6(b)). Thus, the evaluation of the strains is more strain value occurs in eight grids in the ISO samples, this change
easer and accurate. occurs in only two grids in the ASTM samples, as in these cases
In a typical sample, strain distributions through most critical and the usual.
section that pass the apex of the dome and perpendicular to the frac-
ture are given in Fig. 7 for both standards. It is clearly seen that the
determination of an accurate limit strain is easy in the ISO. Reliability of Grid Analysis Method
Because the geometry of the specimens in the ISO standard is For the validity of the simple method, it is required that the FLC
circular and the shaft length (25 mm) where the deformation is obtained from this method is in good agreement with that of the
localized is bigger than the ASTM, the strain distribution on the cross section method. The FLCs obtained from the same samples
deformed specimens according to the ISO is more uniform than by using both methods for AA2024-T4 and AA5754-O are given
that of the ASTM (9.4 mm) as shown in Fig. 6(a)–6(b). For the Fig. 8 and Fig. 9, respectively. It is obvious that the FLCs obtained
comparison of the strain distributions, the strains on the specimens by using the two methods are in a good agreement for the both
FIG. 11—The obtained FLCs following to ASTM and ISO standards for AA2024-T4.
8 JOURNAL OF TESTING AND EVALUATION
FIG. 12—The obtained FLCs following to ASTM and ISO standards for AA5754-O.
materials. So the validity and the reliability of the simple method The difference between the obtained FLCs following to the
were obviously proved. In that case, this method can be confidently ISO and the ASTM standards for AA2024-T4 and AA5754-O
used to provide a more accurate comparison of the standards. materials are shown in Figs. 11 and 12, respectively. In the ISO
and the ASTM standards, the lubrication 1 and 2, respectively,
Effect of Limit Strain Determination Standards was used as lubricant. In the ASTM standard, only the square
The effect of the used standards on the repeatability is shown in samples were lubricated and the other widths were formed under
Fig. 10 for some specimens. For the w25 specimen, the limit strain the dry condition.
values obtained following the ASTM change within 0.03 strain The curves are considerably different from each other, particu-
and have a standard deviation of 0.0095, these values are 0.013 larly for the plane strain and the equi-biaxial strain fields. The
and 0.0065, respectively, for the ISO. For the w100 specimen, FLC level obtained following to the ISO is higher than from the
these values are 0.023, 0.0085, 0.012, and 0.006, respectively. ASTM for the uniaxial tension and the equi-biaxial fields.
The overall uncertainty values of the construction of the FLCs are Although the major strains obtained following to the ASTM are
6r % 0.0095 and 0.006 strain for the ASTM and the ISO, respec- bigger than these of the ISO, the minor strains are smaller because
tively. It is obvious that the ISO standard enhances the repeatabil- of friction effect in the ASTM experiments for the plane strain. In
ity. Similar results were obtained for the other geometries too. As this case, all of the possible combinations cannot be obtained. In
a result, the conducted experiment following to the ISO gives the other words, the constructed curve do not represent to all the
more accurate and the reproducible results. The lowest error bands forming processes. All these negatives were eliminated in the
should be used as safe FLCs. ISO. Because the strain distribution on the deformed specimens
following to the ISO is more uniform than that of the ASTM, the Effect of Specimen Geometry
strain values obtained from the ASTM are lower than that of the
ISO for the uniaxial tension and the equi-biaxial fields [24]. After the comparison with own all properties of the standards for
the both materials, the effect of the specimen geometry was
FIG. 15—The thickness strain distributions of the ASTM and ISO specimens for (a) w25, and (b) w175.
10 JOURNAL OF TESTING AND EVALUATION
FIG. 16—The necking behaviors of the Nakajima specimens for AA2024-T4 with 1 mm and 0 direction.
investigated for AA2024 material. The specimens in both stand- Failure Mechanisms
ards were lubricated with the paraffin and the effect of the geome-
try on the FLC is shown in Fig. 13. The failure mechanisms (the thickness distribution and the neck-
It can be seen that whereas two curves are in a good agreement ing behavior) of the Nakajima specimens were inspected to
with each other for the biaxial stress, there is a significant differ- explain more detail the differences in the obtained FLCs following
ence between the curves for the tension tensile. The level of the to the both standard. The thickness distributions were measured
curve obtained using the ASTM specimens is lower than that of with a profile projector at intervals of 1 mm, 20 scale factor,
the ISO as much 0.01 strain. This difference may be important in and 0.002 mm accuracy and the necking behaviors were observed
the forming processes. with the scanning electron microscopy (SEM). The thickness dis-
Whereas the deformation is localized at approximately the tributions through the most critical section of the w25 (uniaxial
shaft length of 9 mm for the specimens having hourglass shape in tension) and the w175 (equi-biaxial stretching) specimens that
the ASTM experiments, it is distributed through a longer length pass the apex of the dome and perpendicular to the fracture were
(25 mm) for the ISO. Then it is expected that the strain distribu- given in Fig. 15 for both standard. It is obvious that the double
tion on the deformed specimens following to the ISO is more uni- necking problem occurs in the ASTM specimens. The thickness
form than that of the ASTM. Moreover the periphery of the ISO strain on the ISO deformed specimens is more uniform than these
specimens is circular provide the uniform strain distribution. In of the ASTM. So the bigger limit thickness strain values can be
this case, the limit strain where the deformation concentration obtained. The thickness strain values can be also calculated with
occurs for the ASTM is lower and more scattered than that of the using the constant volume assumption. It was seen that the differ-
ISO as shown in the figure. As a result, it is concluded that use of ence between the measured and the calculated thickness strains
the ISO specimens is more suitable. for the FLC’s various fields are about 0.01 0.03 strain.
The SEM photographs of the most critical section of the sam-
ples are given in Fig. 16 with the aim of visually investigation of
Effect of Lubrication
the necking behaviors of the samples. The fractures occur in a
To inspect the effect of only the lubrication condition, all the ISO way to make about 45 angle with the thickness direction because
specimens was formed with dry and paraffin wax for AA2024 and of shear stresses for all of the samples. Whereas the localized
the obtained FLCs were given in Fig. 14. This situation is similar to necking is observed for the ASTM samples, particularly w25 and
the comparison with own all the properties of the standards. It is w175, the diffuse necking is sighted for the ISO samples.
expected that the difference in the dashed curves in Figs. 11 and 14
is approximately equal to the effect of the specimen geometry for
the same thickness. Consequently, it was seen that the lubrication
Case Study
condition affects significantly the FLC [25]. Case studies should be To test the validity of the FLCs obtained following both standards,
conducted so as to determine which curve is reliable. the case studies were experimentally conducted for the both
DILMEC ET AL. ON DETAILED INVESTIGATION OF FORMING LIMIT 11
FIG. 17—The case studies for (a) AA2024-T4, and (b) AA5754-O.
• If the Nakajima specimen’s geometry specified in the ISO is [8] Graf, A. and Hosford, W. F., “Calculations of Forming
used, the strain distribution on the formed samples is more Limit Diagrams,” Metall. Trans. A, Vol. 21A, 1990, pp.
uniform than that of the ASTM. Moreover, because the ge- 87–94.
[9] Raghavan, K. S., “A Simple Technique to Generate in-Plane
ometry of the ISO specimens is circular, the strain distribu-
Forming Limit Curves and Selected Applications,” Metall.
tion is more uniform. Therefore, the usage of the geometries Mater. Trans. A, Vol. 26A, 1995, pp. 2075–2084.
and the experimental methods designated in the ISO is more [10] Ayres, R. A., “Aids for Evaluating Sheet Metal Formability:
suitable from the ASTM. The Limiting Dome Height (LDH) Test and the Cir. Grid
• The friction between the interface of the punch and the Analyzer,” Novel Techniques in Metal Deformation Testing,
sheet is fairly effective on the FLCs. To obtain more reliable R. H. Wagoner, Ed., TMS, 1983, pp. 47–64.
FLCs, the coefficient of friction should be minimized as far [11] Lewison, D. J., 1999, “An Assessment of Different Experi-
as possible as stated in the ISO standard. mental Methods for Determination of Forming Limits,”
• It was observed that the localized necking occurs for the Master’s thesis, Rensselaer Polytechnic Institute, Troy,
ASTM samples, the diffuse necking is sighted for the ISO NY.
samples. [12] Ghosh, A. K. and Hecker, S. S., “Stretching Limits in Sheet
Metals: In-Plane Versus out-of-Plane Deformation,” Metall.
• Conducting the case studies, it was concluded that the ISO
Trans., Vol. 5, 1974, pp. 2161–2164.
curves give more reliable results for both brittle and ductile [13] Djavanroodi, F. and Derogar, A., “Experimental and Numer-
materials and the usage of the ISO curves in the FEA is ical Evaluation of Forming Limit Diagram for Ti6Al4V Tita-
more confident. nium and Al6061-T6 Aluminum Alloys Sheets,” Mater.
Design, Vol. 31, 2010, pp. 4866–4875.
Acknowledgments [14] ASTM E2218-02, 2008, “Standard Test Method for Deter-
mining Forming Limit Curves,” Annual Book of ASTM
This work is supported by The Scientific and Technological Standards, Vol. 03.01, ASTM International, West Consho-
Research Council of Turkey (TUBITAK), Project No. 108M516, hocken, PA.
Project Title: “Adding Drawbead to the Blank Holder for Enhanc- [15] ISO 12004-2, 2008, “Metallic Materials-Sheet and Strip-
ing Formability of Aluminum Alloy Sheets with Hydroforming Determination of Forming-Limit Curves-Part 2: Determina-
Process.” This work is also supported by the Research Project tion of Forming-Limit Curves in the Laboratory.”
[16] Jahromi, S. J., Nazarboland, A., Mansouri, E., Abbasi, S.,
Unit (BAP) of Selcuk University under Project No. 09101005.
“Investigation of Formability of Low Carbon Steel Sheets by
TÜBITAK, Selcuk University, and Metal Forming Laboratory in
Forming Limit Diagrams,” Iranian J. Sci. Technol., Trans.
Nigde University, and Metal Forming Center of Excellence in Ati- B, Eng., Vol. 30, No. B3, 2006, pp. 377–385.
lim University are profoundly acknowledged. [17] Narayanasamy, R. and Sathiya Narayanan, C., “Forming,
Fracture and Wrinkling Limit Diagram for Steel Sheets of
Different Thickness,” Mater. Design, Vol. 29, 2008, pp.
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