Study and Modify the Forming Limit Curves for Predicting a Fracture Behavior in Deep Drawing Process of AA5754-O in Automotive Parts

The forming limit curve (FLC) is a curve that describes the relationship between major and minor strains. It can be used as a criterion to evaluate the formability of sheet metal. In this research, was studied and generated the FLC using the Keeler-Beizer equation to predict areas where damage or failure might occur in the deep drawing process of the aluminum alloy grade 5754-O (AA5754-O) sheets with a thickness of 1.5 mm to produce motorcycle fuel tank components. The FLC was used in conjunction with finite element analysis methods. Test the AA5754-O material with tensile test for use the results for make the FLC. In this study, the deep drawing process of the motorcycle fuel tank was simulated using the PAM-STAMP software, and three variations of the Keeler-Beizer equation, namely Keeler-Beizer Modified (Original), Keeler-Beizer Modified I and Keeler-Beizer Modified II, were used as criteria to predict and compare potential failure locations in the formed components. This approach allowed for the assessment of feasibility in forming various components using different materials, based on the manufacturer's requirements, before creating the actual production dies.