Multi-Scale Modeling in Forming Limits Analysis of SUS430/Al1050/TA1 Laminates: Integrating Crystal Plasticity Finite...

Numerical simulations of the forming limit diagram (FLD) for SUS430/Al1050/TA1 laminated metal composites (LMCs) are conducted through the crystal plasticity finite element (CPFE) model integrated with the Marciniak-Kuczyński (M-K) theory. Representative volume elements (RVEs) that reconstruct the measured crystallographic texture, as characterized by electron backscatter diffraction (EBSD), are developed. The optimal grain number and mesh density for the RVE are calibrated through convergence analysis by curve-fitting simulated stress-strain responses to the uniaxial tensile data. The established multi-scale model successfully predicts the FLDs of the SUS430/Al1050/TA1 laminated sheet under two stacking sequences, namely, the SUS layer or the TA1 layer in contact with the die. The Nakazima test results validate the effectiveness of the proposed model as an efficient and accurate predictive tool. This study extends the CPFE-MK framework to multi-layer LMCs, overcoming the limitations of conventional single-layer models, which incorporate FCC, BCC, and HCP crystalline structures. Furthermore, the deformation-induced texture evolution under different loading paths is analyzed, establishing the relationship between micro-scale deformation mechanisms and the macro-scale forming behavior.