A limit theorem of plasticity has been developed to investigate the hemisphere punch hydroforming process. The limit theorem of plasticity is used to predict the upper and lower bounds of the permissible fluid pressure. Loci representing the critical fluid pressures which result in the rupture and wrinkling are presented. The property of the sheet metal is governed by Hill’s quadratic yield criterion with a power-law hardening for anisotropic material. The premature failure is avoidable if the fluid pressure path is restricted to travel only within the suggested bounds. The theoretical results which include the failure prediction and wrinkling distribution are verified by conducting a serial of hydroforming experiments. The experimental data agrees well with the computed results and demonstrates the technological usefulness of the results.

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