Formability Analysis of the Mg/Al Composite Plate Based on Cupping Test

ZHANG Jian; MA Lifeng; SONG Yaohui; ZHANG Ruifeng

doi:10.3969/j.issn.1674-6457.2026.09.021

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (9) : 205-218. DOI: 10.3969/j.issn.1674-6457.2026.09.021

Composites Forming

Formability Analysis of the Mg/Al Composite Plate Based on Cupping Test

ZHANG Jian^1,*, MA Lifeng¹, SONG Yaohui², ZHANG Ruifeng³

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Abstract

The work aims to explore the effect mechanism of strain rate and temperature on the forming process of Mg/Al laminated composite plates, and combine with Abaqus finite element numerical simulation to elaborate on the evolution behavior of stress, strain, and crack propagation during deformation, providing a basis for the plastic forming of Mg/Al laminated composite plates. The EBSD microstructure characterization of the samples prepared with different allometric ratios was carried out. Combined with the cupping test of Mg/Al laminated composite plates at room temperature, the evolution of microstructure and forming properties of Mg/Al laminated composite plates with different allometric ratios was studied. By analyzing the characteristics of load-stroke curve changes during the stamping process of cupping tests at different forming temperatures, the mechanism by which temperature affected load bearing capacity and indentation endurance (IE) was revealed. Then, by combining with the Abaqus finite element numerical simulation, the distribution of equivalent stress, the evolution of equivalent plastic strain, and the crack propagation pattern during the deformation process of the cupping test sample were obtained, enabling a precise analysis of the essence of its deformation and fracture behavior. When the allometric ratio was 0.65, the Mg/Al composite plate experienced the maximum shear deformation. Under strong shear forces, the degree of recrystallization of magnesium alloy grains was enhanced, leading to the highest level of grain refinement in the Mg and Al matrices, thereby improving the effect of grain refinement strengthening. When the allometric ratio was 0.65, the Mg/Al laminated composite plate could withstand a maximum load of 9 949.45 N and a cupping value of 3.93 mm at room temperature, indicating the best formability under this condition. This indicated that the allometric ratio improved the formability of Mg/Al laminated composite plates by altering the rolling force and thereby affecting the microstructure. Under non-room temperature conditions, when the cupping temperature was 200 ℃, the Mg/Al composite plate exhibited a significant cupping value (IE=6.84 mm) and could withstand the maximum ultimate load (12 840.43 N). The effect mechanism of the allometric ratio and forming temperature on the cupping forming behavior of Mg/Al composite plates is comprehensively investigated from three aspects: macroscopic forming performance, microstructure, and numerical simulation. The final results indicate that an allometric ratio of 0.65 and a forming temperature of 200 ℃ constitute the optimal process combination for cupping forming of Mg/Al composite plates. This research method can also effectively guide the optimization design of the forming process for Mg/Al laminated composite plates.

Key words

Mg/Al laminated composite plate / cupping test / fracture

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ZHANG Jian, MA Lifeng, SONG Yaohui, ZHANG Ruifeng. Formability Analysis of the Mg/Al Composite Plate Based on Cupping Test[J]. Journal of Netshape Forming Engineering. 2026, 18(9): 205-218 https://doi.org/10.3969/j.issn.1674-6457.2026.09.021

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