• A multi-scale modeling framework integrating crystal plasticity finite element (CPFE) with the evolutionary Yld2000-2d yield function accurately predicts plastic anisotropy and distortional strain hardening in 0.1-mm-thick CP-Ti sheets.
• The virtual modeling approach overcomes the lack of standardized mechanical testing methods for ultra-thin sheets, enabling reliable characterization under multiaxial stress states.
• Validation against limiting dome height tests confirms the framework's predictive capability for sheet forming simulations.
• The model supports precise manufacturing of metallic bipolar plates, contributing to lightweight fuel cell systems with improved efficiency.