Investigation of the Forming Limit Curves Development for Failure Behavior Prediction

The modern automotive industry emphasizes environmental sustainability, necessitating the
selection of lightweight yet high-strength materials to improve fuel efficiency and reduce energy
consumption. Compliance with international environmental standards further reinforces the need for
innovative manufacturing techniques. Additionally, the industry faces intense competition, where cost
efficiency plays a crucial role. To address these challenges, the finite element method (FEM) is widely
employed to minimize trial-and-error processes in material forming. A key aspect of sheet metal
formability is the Forming Limit Curve (FLC), which defines the relationship between major and minor
strains and helps predict material behavior during forming operations. This study determines the FLC
using the Nakajima stretch-forming test in accordance with standardized procedures. The experimentally
obtained Forming Limit Diagram (FLD) is compared with an established model, integrating advanced
hardening laws and yield criteria to enhance accuracy. Furthermore, the effectiveness of FEM is
validated through deep drawing simulations of an industrial component, ensuring precise material
behavior predictions. The findings contribute to optimizing metal forming processes, reducing
manufacturing costs, and improving the overall efficiency of automotive production.