Warm forming process for an AA5754 train window panel

2021 ◽  
pp. 1-32
Author(s):  
Antonio Piccininni ◽  
Andrea Lo Franco ◽  
Gianfranco Palumbo
Keyword(s):  
Material Characterization ◽  
Room Temperature ◽  
Warm Forming ◽  
Railway Vehicle ◽  
Fe Model ◽  
Forming Process ◽  
Vehicle Component ◽  
Mechanical Approach ◽  
Thermal Simulations ◽  
Critical Regions

Abstract A warm forming process is designed for AA5754 to overcome low room temperature formability. The solution includes increased working temperature and is demonstrated with a railway vehicle component. A Finite Element (FE) based methodology was adopted to design the process taking into account also the starting condition of the alloy. In fact, the component's dent resistance can be enhanced if the yield point is increased accordingly: the stamping process was thus designed considering the blank in both the H111 (annealed and slightly hardened) and H32 (strain-hardened and stabilized) conditions that were preliminarily characterized. Tensile and formability tests were carried out at different temperature and strain rate levels, thus providing the data to be implemented within the FE model (Abaqus/CAE): the stamping was at first simulated at room temperature to evaluate the blank critical regions. Subsequently, the warm forming process was designed by means of an uncoupled thermo-mechanical approach. Thermal simulations were run to properly design the heating strategy and achieve an optimal temperature distribution over the blank deformation zone (according to the results of the material characterization). Such a distribution was then imported as a boundary condition into the mechanical step (Abaqus/Explicit) to determine the optimal process parameters and obtain a sound component (strain severity was monitored implementing an FLD-based damage criterion). The simulation model was validated experimentally with stamping trials to fabricate a sound component using the optimized heating strategy and punch stroke profile.

Flow Stress Experimental Determination for Warm-Forming Process

2011 ◽  
Author(s):  
Ting Fai Kong ◽  
Luen Chow Chan ◽  
Tai Chiu Lee
Keyword(s):  
Stainless Steel ◽  
Flow Stress ◽  
Room Temperature ◽  
Warm Forming ◽  
Recrystallization Temperature ◽  
Process Conditions ◽  
Compression Tests ◽  
Forming Process ◽  
Forming Temperature ◽  
Flow Stress Data

Warm forming is a manufacturing process in which a workpiece is formed into a desired shape at a temperature range between room temperature and material recrystallization temperature. Flow stress is expressed as a function of the strain, strain rate, and temperature. Based on such information, engineers can predict deformation behavior of material in the process. The majority of existing studies on flow stress mainly focus on the deformation and microstructure of alloys at temperature higher than their recrystallization temperatures or at room temperature. Not much works have been presented on flow stress at warm-forming temperatures. This study aimed to determine the flow stress of stainless steel AISI 316L and titanium TA2 using specially modified equipment. Comparing with the conventional method, the equipment developed for uniaxial compression tests has be verified to be an economical and feasible solution to accurately obtain flow stress data at warm-forming temperatures. With average strain rates of 0.01, 0.1, and 1 /s, the stainless steel was tested at degree 600, 650, 700, 750, and 800 °C and the titanium was tested at 500, 550, 600, 650, and 700 °C. Both materials softened at increasing temperatures. The overall flow stress of stainless steel was approximately 40 % more sensitive to the temperature compared to that of titanium. In order to increase the efficiency of forming process, it was suggested that the stainless steel should be formed at a higher warm-forming temperature, i.e. 800 °C. These findings are a practical reference that enables the industry to evaluate various process conditions in warm-forming without going through expensive and time consuming tests.

Low Temperature Warm Forming of Magnesium ZEK 100 Sheets for Automotive Applications

2014 ◽  
Vol 783-786 ◽  
pp. 431-436 ◽  
Author(s):  
Xiao Ping Niu ◽  
Tim Skszek ◽  
Mark Fabischek ◽  
Alex Zak
Keyword(s):  
Mechanical Properties ◽  
Low Temperature ◽  
Process Parameters ◽  
Room Temperature ◽  
Warm Forming ◽  
Automotive Applications ◽  
Forming Process ◽  
Stamping Die ◽  
Automotive Parts ◽  
Volume Production

Cosma R&D investigated a low temperature warm forming process by which a magnesium ZEK 100 door inner part with a single-stage draw depth of 144 mm was successfully formed. The warm forming process is comprised of three steps: 1) heating pre-lubricated blanks in an oven at temperatures ranging from 215°C to 260 °C, 2) robotic transfer of the heated blank to a mechanical stamping press, 3) forming of the panel in room temperature stamping die at speed of about 160 mm/s. The effect of process parameters on the formability of the part, as well as, the post-forming properties including the mechanical properties, microstructure evolution and deformation thinning are also presented. The result indicates that Magnesium ZEK 100 exhibits superior low temperature warm formability over Magnesium AZ31B, and the developed warm forming process is promising and potential for volume production of magnesium automotive parts.

FEM-Based Simulation and Gripper Jaw Trajectory Fitting of Stretch-Bending Process for a Bending Beam of Railway Vehicles

2013 ◽  
Vol 372 ◽  
pp. 661-665
Author(s):  
Sheng Man Wang ◽  
Xin Hua Yang ◽  
Xing Lu
Keyword(s):  
Control Method ◽  
Die Design ◽  
Railway Vehicle ◽  
Fe Model ◽  
The Finite Element Method ◽  
Forming Process ◽  
Stretch Bending ◽  
Bending Process ◽  
Design Requirements ◽  
Displacement Control Method

The bending beam of railway vehicle is made of thin stainless steel, with large sizes and unsymmetrical section, and prone to defects during stretch-bending forming process, such as wrinkling, cross-section distortion and so on. A reasonable trajectory of gripper jaws could make for mitigating the mentioned defects. The Finite Element Method was employed to fit the trajectory as well as simulate the forming process. The FE model was built by using the commercial FE software Hypermesh and ABAQUS/CAE. The analysis was carried out based on dynamic explicit and displacement control method. On this basis, the actual stretch bending process was developed according to the fitted trajectory and simulated process. The actual production process indicates that the formed beam can meet the design requirements, and the method is feasible and economical, as well as can contribute to a better understanding of stretch bending process and die design.

Coupled Thermo-Mechanical FEA of Three-Roll Cross Rolling Process for Rings with Small-Hole and Deep Groove

2012 ◽  
Vol 560-561 ◽  
pp. 846-852 ◽  
Author(s):  
Qi Ma ◽  
Lin Hua ◽  
Dong Sheng Qian
Keyword(s):  
Rolling Process ◽  
Small Hole ◽  
Fe Model ◽  
Forming Process ◽  
Software Environment ◽  
Cross Rolling ◽  
Design And Optimization ◽  
Forming Technology ◽  
Deep Groove ◽  
Plastic Forming

Ring parts with small-hole and deep groove such as duplicate gear and double-side flange, are widely used in various engineering machineries. Three-roll cross rolling (TRCR) is a new advanced plastic forming technology for the processing of rings with small-hole and deep groove. In this paper, a 3D coupled thermo-mechanical FE model for TRCR of ring with small-hole and deep groove is established under ABAQUS software environment. By simulation and analysis, the evolution and distribution laws of strain and temperature in the forming process are revealed, and the effects of the key process parameters on the deformation uniformity are explored. The results provide valuable guideline for the technological parameter design and optimization.

Finite Element Simulation and Experimental Study on Blow Forming of Plastic Cups

2011 ◽  
Vol 148-149 ◽  
pp. 1319-1322
Author(s):  
Xiao Hu ◽  
Yi Sheng Zhang ◽  
Hong Qing Li ◽  
De Qun Li
Keyword(s):  
Finite Element ◽  
Thickness Distribution ◽  
Viscoelastic Model ◽  
Engineering Practice ◽  
Fe Model ◽  
Thin Wall ◽  
Forming Process ◽  
Element Simulation ◽  
Physically Based ◽  
Set Up

Blow forming process of plastic sheets is simple and easy to realize, thus, it is widely used for plastic thin-wall parts. In the practical production, an effective method is needed for the preliminary set-up of process parameters in order to achieve accurate control of thickness distribution. Thus, a finite element method (FEM) code is used to simulate blow forming process. For better description of complex material theological characteristics, a physically based viscoelastic model (VUMAT forms Buckley model) to model the complex constitutive behavior is used. Nonlinear FE analyses using ABAQUS were carried out to simulate the blow forming process of plastic cups. The actual values at different locations show a satisfactory agreement with the simulation results: as a matter of fact the error along the cell mid-section did not exceed 0.02 mm on average, corresponding to 5% of the initial thickness, thus the FE model this paper can meet the requirements of the engineering practice.

Material Characterization for Sheet-Bulk Metal Forming

2012 ◽  
Vol 504-506 ◽  
pp. 1029-1034 ◽  
Author(s):  
Bernd Arno Behrens ◽  
Kathrin Voges-Schwieger ◽  
Anas Bouguecha ◽  
Jens Mielke ◽  
Milan Vucetic
Keyword(s):  
Metal Forming ◽  
Material Characterization ◽  
Cyclic Load ◽  
Material Behavior ◽  
Forming Force ◽  
Forming Process ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Metal Forming Process

Sheet-bulk metal forming is a novel manufacturing technology, which unites the advantages and design solutions of sheet metal and bulk metal forming. To challenge the high forming force the process is superimposed with an oscillation in the main flow of the process. The paper focuses on the characterization of the material behavior under cyclic load and the effects for the sheet bulk metal forming process.

Process-adapted temperature application within a two-stage rivet forming process for high nitrogen steel

2022 ◽  
pp. 146442072110686
Author(s):  
C-M Kuball ◽  
B Uhe ◽  
G Meschut ◽  
M Merklein
Keyword(s):  
Room Temperature ◽  
Temperature Management ◽  
High Nitrogen Steel ◽  
High Nitrogen ◽  
Forming Process ◽  
Two Stage ◽  
Nitrogen Steel ◽  
Temperature Application ◽  
Stage 1 ◽  
Forming Behaviour

Mechanical joining technologies like self-piercing riveting are gaining importance with regard to environmental protection, as they enable multi-material design and lightweight construction. A new approach is the use of high nitrogen steel as rivet material, which allows to omit the usually necessary heat treatment and coating and thus leads to a shortening of the process chain. Due to the high strain hardening, however, high tool loads must be expected. Thus, appropriate forming strategies are needed. Within this contribution, the influence of applying different temperatures for each forming stage in a two-stage rivet forming process using the high nitrogen steel 1.3815 is investigated. The findings provide a basic understanding of the influence of the temperature management when forming high nitrogen steel. For this purpose, the rivets are not formed at the same temperature in each stage, but an elevated temperature is applied selectively. Different process routes are investigated. First, cups are manufactured in stage 1 at room temperature, followed by stage 2 at 200°C. Second, cups are formed in stage 1 at 200°C and used for stage 2 at room temperature. By comparing the findings with results when applying the same temperature in both stages, it is shown that the temperature during the first forming operation has an effect on the forming behaviour during the second forming stage. The required forming forces and the resulting rivet hardness can be influenced by process-adapted temperature application. Furthermore, the causes for the temperature impact on the residual cup thickness in stage 1 are evaluated by a cause and effect analysis, which provides a deeper process understanding. The thermal expansion of the tool and the billet as well as the improved forming behaviour at 200°C are identified as the main influencing causes on the achieved residual cup thickness.

scholarly journals New Numerical Model of Composite Fabric Behaviour: Simulation of Manufacturing of thin Composite Part

2000 ◽  
Vol 9 (3) ◽  
pp. 096369350000900 ◽  
Author(s):  
J.L. Billoet ◽  
A. Cherouat
Keyword(s):  
Mechanical Properties ◽  
Tensile Tests ◽  
Woven Fabrics ◽  
Woven Fabric ◽  
Forming Process ◽  
Composite Part ◽  
Initial Shape ◽  
Shaping Process ◽  
Mechanical Approach ◽  
Behaviour Simulation

The present study concerns the modelling of the behaviour of pre-impregnated woven fabric during the forming process. The mechanical approach is based on a mesostructural model. It allows us to take into account the mechanical properties of fibres and resin and the various dominating mode of deformation of woven fabrics during the forming process. Shear and tensile tests of composite fabric specimens are proposed and compared with the experimental results in order to demonstrate the efficiency of our approach. Different numerical simulations and experiments of shaping process have been carried out in order to validate the proposed computational formulation. The various forming parameters examined have included the initial shape of fabric, fibre orientations and viscosity of resin.

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