As a lightweight material, magnesium is being increasingly used for automotive parts. However, due to a hexagonal-closed-packed (hcp) crystal structure, in which only the basal plane can move, magnesium alloy sheets exhibit a low ductility and formability at room temperature. Press forming of magnesium alloy sheets is conventionally performed at elevated temperatures of 200°C to 250°C and thus is known as energy consumed forming. Therefore, in view of an energy saving forming technology, we study magnesium alloy sheet forming by a rotational incremental sheet forming (RISF) at room temperature, where the rotational tool generates local heat of specimen enough to accelerate plastic deformation. The flow curves of the magnesium alloy sheet are obtained and calculated at elevated temperatures, while the yield loci of the magnesium alloy sheet are measured at room temperature. Using RISF, a square cup of 80-mm width, 80-mm length, and 25-mm height is then formed from a magnesium alloy sheet at room temperature. In addition, the strain distribution is obtained and compared with the forming limit curve (FLC) by considering the effect of the tool radius and is found to effectively predict the forming limit of a magnesium alloy sheet in RISF.
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