Predicting plastic behavior of magnesium alloy tube bending with comprehensive constitutive models

Abstract

This paper aims to predict defects occurring in magnesium alloy tube bending through finite element simulations. Deformation tests were conducted to identify and characterize plastic anisotropy, tension-compression asymmetry, and anisotropic hardening behaviors of extruded Mg–Al–Zn-RE alloy rectangular tubes. Limited by size, the deformation tests along the wall thickness of specimens were conducted through crystal plasticity analysis. To thoroughly investigate the material constitutive features affecting bending, two constitutive models, Yoon2014 and Hill48, were established and calibrated. The non-associative flow rule was adopted, and anisotropic hardening was depicted using the yield-surface interpolation method. In comparison, the Yoon2014 model accurately predicted the strain distribution and tube shape collapse of the bent tube with negligible deviation from the experimental data, prior to the Hill48 model. This underscores the necessity of considering comprehensive plasticity models in tube bending simulations.