Designing superplastic forming process of a developmental AA5456 using pneumatic bulge test experiments and FE-simulation

2012 ◽  
Vol 6 (3) ◽  
pp. 219-228 ◽  
Author(s):  
Jens Kappes ◽  
Mathias Liewald ◽  
Simon Jupp ◽  
Christoph Pirchl ◽  
Roman Herstelle
Keyword(s):  
Fe Simulation ◽  
Superplastic Forming ◽  
Bulge Test ◽  
Forming Process ◽  
Pneumatic Bulge Test

New Strategy for the Prediction of the Gas Pressure Profile of Superplastic Forming of Al-5083 Aluminium Alloy

2012 ◽  
Vol 735 ◽  
pp. 204-209 ◽  
Author(s):  
Nagore Otegi ◽  
Lander Galdos ◽  
Iñaki Hurtado ◽  
Sean B. Leen
Keyword(s):  
Strain Rate ◽  
Constant Strain Rate ◽  
Superplastic Forming ◽  
Pressure Profile ◽  
Bulge Test ◽  
Forming Process ◽  
Optimum Pressure ◽  
New Approach ◽  
Superplastic Alloy ◽  
New Strategy

This paper describes a new approach for identification of the optimum pressure history for SPF processes, based on mechanisms-based hyperbolic constitutive equations. This equation set has been modified to incorporate the effect of the damage behaviour the material suffers due to the cavitational evolution of Al-5083 superplastic alloy. A large deformation, multiaxial formulation of the constitutive equation set is implemented and applied to finite element modelling of a bulge test forming process to characterise the cavitation evolution behaviour in the bulge test, using conventional (constant strain rate) and the newly proposed (variable strain rate) strategy.

Instrumentation and Control of a Bulge Test on a Superplastic Pb-Sn Alloy

2012 ◽  
Vol 735 ◽  
pp. 224-231
Author(s):  
Erick Petta Marinho ◽  
Alberto Sakata ◽  
Erika Fernanda Prados ◽  
Gilmar Ferreira Batalha
Keyword(s):  
Strain Rate ◽  
Superplastic Forming ◽  
Uniaxial Tensile ◽  
Bulge Test ◽  
Uniaxial Tensile Test ◽  
Biaxial Test ◽  
Biaxial Testing ◽  
Forming Process ◽  
Set Up ◽  
And Control

Superplasticity is characterized by high elongations under a high strain rate sensibility, and it’s variation with strain rate, temperature and grain size. This parameter is often obtained from uniaxial tensile test. However, superplastic deformation is a biaxial process; hence there is a need to develop a way to get this parameter in a biaxial test. This work aims to set up the instrumentation to record and control a biaxial superplastic forming in a Pb-Sn alloy. The control system project has been divided into tracking variables: strain and pressure. The instrumentation is able to predict the breaking point at the beginning of the superplastic forming process from biaxial testing.

scholarly journals Deformation Characteristics and Microstructure Analysis of Aluminum Alloy Component with Complex Shape by Cold Orbital Forming

Metals ◽  
2021 ◽  
Vol 11 (5) ◽  
pp. 808
Author(s):  
Wei Feng ◽  
Chaoyi Jin ◽  
Jiadong Deng ◽  
Wuhao Zhuang
Keyword(s):  
Aluminum Alloy ◽  
Complex Shape ◽  
Fe Simulation ◽  
Effective Strain ◽  
Electron Back Scatter Diffraction ◽  
Main Body ◽  
Deformation Characteristics ◽  
Alloy Component ◽  
Forming Process ◽  
Orbital Forming

This work aimed to study the deformation characteristics and microstructure of AA6063 aluminum alloy component with complex shape manufactured by cold orbital forming processing. The material flowing behavior was analyzed by Finite Element (FE) simulation and forming experiments were carried out using bar blank with different lengths. The microstructure of the boss zone cut from the formed samples was observed using scanning electron microscopy (SEM) and electron back-scatter diffraction (EBSD). FE simulation and experiment results both showed the aluminum base can be formed using cold orbital forming process. The distributions of the effective strain of the component with different blank lengths were almost the same, and the effective strain was bigger at the boss and the flash as the forming finished. The material flow is complex, especially in the boss, and the folding defect was observed at the root of the boss. The distribution of Mg2Si strengthening precipitate is more homogeneous in the matrix, has a different shape, and shows directivity at different position of boss zone. The grains are elongated, and the extent is different at different positions of the boss zone after cold orbital forming, and the crystal orientation discrepancy is smaller in the component main body and bigger in the boss zone. Subsequent forming process and blank optimization need to be further researched to improve forming quality.

Design in Superplastic Forming Process by Rigid Visco Plastic Shell FEM

1996 ◽  
Vol 243-245 ◽  
pp. 735-738 ◽  
Author(s):  
Kai Feng Zhang ◽  
Z.R. Wang ◽  
Xiao Ming Lai ◽  
G.L. Kan
Keyword(s):  
Superplastic Forming ◽  
Plastic Shell ◽  
Forming Process

scholarly journals Optimization of Superplastic Forming Process of AA7075 Alloy for the Best Wall Thickness Distribution

2021 ◽  
Vol 6 (4) ◽  
pp. 251-261
Author(s):  
Manh Tien Nguyen ◽  
Truong An Nguyen ◽  
Duc Hoan Tran ◽  
Van Thao Le
Keyword(s):  
Wall Thickness ◽  
Deformation Temperature ◽  
Numerical Optimization ◽  
Thickness Distribution ◽  
Superplastic Forming ◽  
Forming Process ◽  
Wall Thickness Distribution ◽  
Surface Method ◽  
Series Of Experiments ◽  
The Relationship

This work aims to optimize the process parameters for improving the wall thickness distribution of the sheet superplastic forming process of AA7075 alloy. The considered factors include forming pressure p (MPa), deformation temperature T (°C), and forming time t (minutes), while the responses are the thinning degree of the wall thickness ε (%) and the relative height of the product h*. First, a series of experiments are conducted in conjunction with response surface method (RSM) to render the relationship between inputs and outputs. Subsequently, an analysis of variance (ANOVA) is conducted to verify the response significance and parameter effects. Finally, a numerical optimization algorithm is used to determine the best forming conditions. The results indicate that the thinning degree of 13.121% is achieved at the forming pressure of 0.7 MPa, the deformation temperature of 500°C, and the forming time of 31 minutes.

Numerical and Experimental Investigation on the Hybrid Superplastic Forming of the Conical Mg Alloy Component

2018 ◽  
Vol 385 ◽  
pp. 391-396
Author(s):  
Mei Ling Guo ◽  
Ming Jen Tan ◽  
Xu Song ◽  
Beng Wah Chua
Keyword(s):  
Electron Backscatter Diffraction ◽  
Thickness Distribution ◽  
Superplastic Forming ◽  
Test Results ◽  
Forming Process ◽  
Hyperbolic Sine ◽  
Coarse Grains ◽  
Hot Drawing ◽  
Material Forming ◽  
Backscatter Diffraction

Hybrid superplastic forming (SPF) is a novel sheet metal forming technique that combines hot drawing with gas forming process. Compared with the conventional SPF process, the thickness distribution of AZ31B part formed by this hybrid SPF method has been significantly improved. Additionally, the microstructure evolution of AZ31 was examined by electron backscatter diffraction (EBSD). Many subgrains with low misorientation angle were observed in the coarse grains during SPF. Based on the tensile test results, parameters of hyperbolic sine creep law model was determined at 400 oC. The hybrid SPF behavior of non-superplastic grade AZ31B was predicted by ABAQUS using this material forming model. The FEM results of thickness distribution, thinning characteristics and forming height were compared with the experimental results and have shown reasonable agreement with each other.

Superplastic Forming Formula for Aluminum Channel Panels

2005 ◽  
Author(s):  
Frank G. Lee ◽  
M. David Hanna
Keyword(s):  
Finite Element ◽  
Aspect Ratio ◽  
Superplastic Forming ◽  
Forming Process ◽  
Taguchi Design Of Experiment ◽  
Forming Parameters ◽  
Physical Experiments ◽  
Element Simulation ◽  
Experiment Method ◽  
Sectional Analysis

A parametric study was conducted to determine how the design features and forming parameters affect part thinning and forming time in the Superplastic Forming Process (SPF). Explicit formulas, describing the maximum percent thinning and the forming time for channel parts formed by the SPF process as a function of eight designs and forming parameters, were derived. The formulas are good approximations of those obtained by finite element simulation analyses and physical experiments. Thinning of the channels was influenced most by the component aspect ratio (height versus width) and entry radius at top of the channel forming tool. The forming time was most influenced by strain rate, aspect ratio and tool bottom radius. A design domain can be established to avoid excessive thinning. The Taguchi design-of-experiment method was applied to select parameter combinations, and the MARC finite element code was used to conduct sectional analysis for various combinations.

An Experimental Study on Elevated Temperature Biaxial Bulge Test

2012 ◽  
Vol 430-432 ◽  
pp. 539-542 ◽  
Author(s):  
Ho Sung Lee ◽  
Jong Hoon Yoon ◽  
Joon Tae Yoo
Keyword(s):  
Elevated Temperature ◽  
Strain Rate ◽  
Rate Sensitivity ◽  
Metal Sheet ◽  
Bulge Test ◽  
Nickel Base Superalloy ◽  
Test Results ◽  
Forming Process ◽  
Uniaxial Test ◽  
Nickel Base

By using biaxial bulge test, it is possible to predict sheet metal forming behavior during hot forming process. The purpose of this study is to obtain materials parameters for elevated temperature forming condition during biaxial bulge test of a nickel base superalloy in hemispherical die. At constant gas pressure, the strain rate in which the metal sheet experiences varies and therefore the strain rate sensitivity can be obtained in a single loading. Biaxial bulge tests on superalloy metal sheet were performed and results are in satisfactory agreement with uniaxial test results at elevated temperature.

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