Distortional hardening revisited: Advanced strength prediction model after multi-directional forming

•The HEXAH model is first applied in industrial problems, pipe forming processes.•A novel numerical algorithm for HEXAH is developed for finite element analysis.•HEXAH-FE predicts accurate strengths with superposed yield surface distortions. This study presents the first in-depth evaluation of the Extended Homogeneous Anisotropic Hardening (HEXAH) model for industrial-scale applications, particularly in multi-axial pipe forming processes. Building upon the Homogeneous Anisotropic Hardening (HAH) models, the HEXAH model addresses the limitations of HAH models, including “rotation singularity”, by incorporating multiple microstructure deviators to resolve physical discrepancies. This enhancement enables more reliable modeling of material response under cross-loading conditions. The HEXAH model was implemented into finite element (FE) analysis through a novel fully implicit stress update algorithm within ABAQUS, utilizing a user material subroutine (UMAT)—the HEXAH-FE framework. A comparative analysis was conducted in an industrial context, predicting the mechanical strength of the steel plate after multi-directional pipe forming processes. As a main result, only the HEXAH model accurately predicted yield strength along the hoop direction (HD), especially under cross-loading conditions where other HAH models fell short. The HEXAH model's ability to allow superposed distortions highlights its superiority in representing anisotropic hardening even under complex loading conditions. This study introduces the first application and validation of the HEXAH framework to real-world, industrial-scale problems with its implementation. Our work bridges the gap between theoretical advancements in material modeling and practical industrial applications. [Display omitted]