Abstract: A simultaneous prediction of macroscopic deformation and microstructure evolution is critical for understanding the deformation mechanism of components. In this work, the hydro-bulging process of 2219 aluminum alloy sheet was investigated using cross-scale numerical modeling, in which the macroscopic finite element method (FEM) and crystal plasticity finite element method (CPFEM) were combined. The calculated texture evolution exhibits good agreement with the experimental results, and the stress error between the two scales is generally small. The effects of different strain states on texture evolution and slip mode are further discussed. As the strain ratio η increases, the volume fractions of the initial Rotated Copper texture component and γ-Fiber texture component decrease significantly, which tend to be stabilized at P texture component. The initial Rotated Cube texture component is inclined to rotate towards the Cube texture component, while the volume fraction of this orientation is relatively stable. The lower strain ratio can considerably enhance the activity of more equivalent slip systems, promoting a more uniform strain distribution over grains. The difficulty of grain deformation changes as the lattice rotates. The grain with easy-to-deform orientation can gradually rotate to a stable orientation during plastic deformation, which has a lower Schmid factor.

Key words: Cross-scale modeling, Crystal plasticity, Texture evolution, Aluminum alloy, Hydro-bulging forming