ORIGINAL ARTICLE Modeling material behavior of AA5083 aluminum alloy sheet using biaxial tensile tests and its application in numerical simulation of deep drawing Ved Prakash 1 & D. Ravi Kumar 1 & Alexander Horn 2 & Hinnerk Hagenah 2 & Marion Merklein 2 Received: 19 February 2019 /Accepted: 21 October 2019 # Springer-Verlag London Ltd., part of Springer Nature 2019 Abstract Improvement in accuracy of the predicted results from numerical simulation results into a reduction of cost and time involved in tool design and experimental trials. However, the predicted results from finite element simulations are significantly affected by the chosen yield criterion and work hardening law. The selection of yield criterion and work hardening law depends on the characterization methods used for defining the material behavior. In this work, the mechanical behavior of AA5083-O aluminum alloy sheet is modeled by performing biaxial tensile tests using cruciform specimen and hydraulic bulging experiments in addition to uniaxial tensile tests. Biaxial to uniaxial yield stress ratios are determined using the equal plastic work principle from the flow curves obtained from these tests. The obtained ratios are used to find the coefficients of Yld2000-2d and Hill48 yield criteria which is then used in the numerical simulations of cylindrical cup deep drawing. Numerical simulations are also carried out using uniaxial and biaxial flow curves fitted with different isotropic hardening laws. Thickness distributions and the load- displacement curves are predicted and validated by performing cylindrical cup deep drawing experiments. Keywords Deep drawing . Aluminum alloy . Hydraulic bulge test . Cruciform specimen . Hardening laws . Yield criteria . Finite element simulation 1 Introduction The continuous demand for improvement in fuel efficiency and reduction in exhaust-out emissions is a major challenge for the automotive industry. One of the ways to meet these demands is a reduction in the weight of the vehicle, which can be achieved by replacing the conventional steel with some lightweight materials. Therefore, the importance of light- weight aluminum alloy sheet materials in automotive and aerospace industries is well known. AA5XXX aluminum– magnesium alloys are one of the promising substitutes for low carbon steel in the automotive industry without any sig- nificant compromise on strength and stiffness. These alloys also possess good welding characteristics, resistance to corro- sion, and good formability. Formability of the sheet metals manufactured by different manufacturers vary significantly even though they are of the same grade. To avoid change in tooling that becomes necessary due to variation in formability from one lot to another, virtual manufacturing is mandatory. Virtual manufacturing through finite element analysis (FEA) is widely used to save the cost and time involved in tooling and shop floor trials of sheet metal forming operations in- volved in the fabrication of end product [1]. In actual forming of a sheet metal component, the material undergoes multiaxial stressing. To validate the experimental results by FEA, results from standard tests performed under similar stress state are preferred. The accuracy of the results obtained in FEA is high- ly dependent on the characterization of sheet material proper- ties, yield criterion, and hardening law used in the finite ele- ment simulation [2]. The more accurate information in terms of geometrical features and post-forming characteristics of the formed part can be achieved by implementing advanced ma- terial models which can model forming behavior and forming limits in any process conditions [3]. A predominant biaxial state of stress prevails in most of the sheet metal forming * Ved Prakash ved227@gmail.com 1 Department of Mechanical Engineering, Indian Institute of Technology Delhi, New Delhi, India 2 Lehrstuhl für Fertigungstechnologie, Friedrich-Alexander-Universität, 91058 Erlangen, Germany The International Journal of Advanced Manufacturing Technology https://doi.org/10.1007/s00170-019-04587-0