Multiscale investigation of deformation mechanisms and microstructural evolution in deep drawing of AA5052 thin-walled box-shaped parts

Deep drawing of thin-walled AA5052 aluminum alloy (AA5052) box-shaped parts is susceptible to thinning, wrinkling, and fracture. This study investigated deformation mechanisms and microstructural evolution under complex stress paths using integrated finite element (FE) simulations and electron backscatter diffraction (EBSD) characterization. An FE model employing the Hill’48 anisotropic yield criterion and the forming limit diagram (FLD) was established and validated through uniaxial tensile tests and Erichsen cupping tests. To address the thinning-wrinkling trade-off under constant blank holder force (BHF), a blank holder displacement evolution strategy was proposed. This approach reduced the maximum thinning rate from 26.30% to 18.65% and lowered the FLD damage initiation criterion (FLDCRT) from 0.950 to 0.733, which expanded the forming window. Springback predictions showed good agreement with experimental measurements. EBSD characterization revealed distinct texture evolution in regions with contrasting stress–strain states. The sidewall region, under a compression-dominated stress state, developed ordered fibrous grains with Brass and S textures. In contrast, the corner radius region experienced a biaxial tension-dominated stress state, resulting in a pronounced strengthening of the Cube texture to 26.90% and severe dislocation entanglement. Hardness in the corner radius region increased from the raw material value of 60.41 HV to 91.72 HV, attributed to dislocation entanglement, texture strengthening, and work hardening. This multiscale process-stress-microstructure-property linkage provides a theoretical basis for precision forming of thin-walled aluminum alloy parts.