Weight reduction is a primary concern in the automotive and electrical industries because of the intensive requirements of energy conservation and emission reduction. As the lightest structural metal, magnesium (Mg) alloys are widely used in the automotive and aerospace industries. However, the current industrial application of this material is mainly limited to pressure casting parts due to its poor formability at room temperature. Therefore, identifying the factors that affect the formability of Mg alloy is highly important. In this study, forming limits of Mg alloy sheet under electromagnetic forming (EMF) condition were analyzed at different temperatures based on the Johnson–Cook constitutive model and the failure model. The complete forming limit diagrams of AZ31 Mg alloy at different temperatures and high strain rates were established. The effects of voltage, capacitance, and temperature on the forming limit of AZ31 Mg alloy under EMF were systematically investigated. Results showed that increased discharge voltage and temperature can effectively improve the EMF limit of Mg alloy. The effect of increasing capacitance on the formability of Mg alloy was not obvious.
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