Development and validation of an advanced material model for high-temperature blow forming of AA5083 parts

High-temperature blow forming processes are increasingly used in industry due to their ability to produce near-net-shape, lightweight components in a single forming operation. To accurately identify the forming limits in high-temperature blow forming and two-stage forming processes, a new phenomenological material model is proposed to model the viscous, hardening and softening behaviour associated with creep deformation. The model is developed based on tensile tests conducted on AA5083 at 450°C across five strain rates ranging from 0.001 to 0.3 s ‐1 . The material constants for the model are selected and further calibrated through iterative finite element analysis. Validation of the model, implemented via an LS-DYNA user subroutine, achieved a validation metric greater than 96% in predicting the force/displacement tensile behaviour even up to localized necking. Furthermore, blow-forming trials of a benchmark part confirmed the model’s predictive accuracy for sheet thinning, with errors within 5%. This approach provides a reliable numerical framework for optimizing high-temperature forming processes and advancing lightweight manufacturing technologies.