Finite element simulation of magnesium alloy sheet forming at elevated temperatures

The use of lightweight magnesium (Mg) alloy offers significant potential to improve automotive fuel efficiency. However, the application of formed magnesium alloy components in auto-body structures is restricted due to this material’s low formability at room temperature and lack of knowledge for processing magnesium alloys at elevated temperature. In this study, non-isothermal finite element (FE) simulation has been conducted for forming round cups and rectangular pans from Mg alloy AZ31B sheet at elevated temperatures. The results were compared with experiments, conducted at the Technical University, Hanover. Simulation and experiments predicted increase in limiting draw ratio (LDR) with increase in temperature. Maximum LDR was obtained at the forming temperature of 200 °C. FE simulation results agreed well with experimental observations.