scholarly journals The Sheet Metal Formability of AA-5083-O Sheets Processed by Friction Stir Processing

2015 ◽  
Vol 2015 ◽  
pp. 1-21
Author(s):  
G. F. Miori ◽  
E. C. Bordinassi ◽  
S. Delijaicov ◽  
G. F. Batalha
Keyword(s):  
Sheet Metal ◽  
Friction Stir Processing ◽  
Forming Limit Diagram ◽  
Tensile Tests ◽  
Forming Limit ◽  
Sheet Metals ◽  
Close Approximation ◽  
Nonlinear Fem ◽  
Friction Stir ◽  
Software Products

The aim of this study is to determine the sheet metal formability of AA-5083-O sheets processed by the Friction Stir Processing (FSP). The FSP process was studied and a FSP tool was built. Processing quality was verified by the metallography in the processing region, which established the voids presence. Tensile tests were carried out on FSP and non-FSP specimens, and the results showed that FSP specimens have 30% greater resistance than non-FSP ones. The formability of FSP sheets was produced in MSC-MARC and Abaqus and these software products were compared by using the nonlinear FEM code. The Forming Limit Diagram was built with the results from both software products. A device to process FSP sheet metals was developed and the sheets were processed to validate the results from the software. The tools made for the bulge tests were circular and ellipse-shaped. After the bulge tests, the commercial sheets showed close approximation to those obtained from the software. The FSP sheets broke when inferior pressure was applied because of the defects in the FSP process. The results of the FSP presented the same formability of commercial sheets, however, with 30% greater strength.

Investigations on Influence of Geometric Parameters in Drawing of Perforated Sheet Metals

2016 ◽  
Vol 852 ◽  
pp. 229-235 ◽  
Author(s):  
G. Venkatachalam ◽  
J. Nishanth ◽  
M. Mukesh ◽  
D.S. Pavan Kumar
Keyword(s):  
Sheet Metal ◽  
Software Package ◽  
Parametric Analysis ◽  
Forming Limit Diagram ◽  
Simulation Software ◽  
Geometric Parameters ◽  
Forming Limit ◽  
Sheet Metals ◽  
Open Area ◽  
Perforated Sheet

Forming Limit Diagram (FLD) is a resourceful tool to study the formability of sheet metals. Research on the formability of Perforated Sheet Metal is growing over the years as perforated sheet metal finds its applications in various fields. But finding FLD of perforated sheet metals is complex due to the presence of holes. Also, the hole size, shape and pattern, ligament ratio, thickness of the blank, percentage of open area influence the formability of a perforated sheet metal.In the present scenario, various simulation softwares have made the process of plotting FLD much easier, saving time and money. This paper is an attempt to predict the formability of mild steel perforated sheet metal through simulation software package LS Dyna. Also, Parametric analysis is performed to determine the influence of geometric parameters on the drawability of the perforated sheet metal.

Optimization of Sheet Metal Process Parameters of a Shield Case Piece Using Computer Simulation

2006 ◽  
Vol 510-511 ◽  
pp. 330-333
Author(s):  
M.C. Curiel ◽  
Ho Sung Aum ◽  
Joaquín Lira-Olivares
Keyword(s):  
Sheet Metal ◽  
Thickness Distribution ◽  
Forming Limit Diagram ◽  
Forming Limit ◽  
Physical Processes ◽  
Forming Process ◽  
Element Analysis ◽  
One Step ◽  
Range Of Values ◽  
Principal Strains

Numerical simulations based on Finite Element Analysis (FEA) are widely used to predict and evaluate the forming parameters before performing the physical processes. In the sheet metal industry, there are basically two types of FE programs: the inverse (one-step) programs and the incremental programs. In the present paper, the forming process of the shield case piece (LTA260W1-L05) was optimized by performing simulations with both types of software. The main analyzed parameter was the blankholding force while the rest of the parameters were kept constant. The criteria used to determine the optimum value was based on the Forming Limit Diagram (FLD), fracture and wrinkling of the material, thickness distribution, and the principal strains obtained. It was found that the holding force during the forming process deeply affects the results, and a range of values was established in which the process is assumed to give a good quality piece.

Comparison of different welding methods on mechanical properties and formability behaviors of tailor welded blanks (TWB) made from AA6061 alloys

2020 ◽  
pp. 095440622095250
Author(s):  
Behrouz Bagheri ◽  
Mahmoud Abbasi ◽  
Reza Hamzeloo
Keyword(s):  
Mechanical Properties ◽  
Laser Welding ◽  
Co2 Laser ◽  
Forming Limit Diagram ◽  
Dome Height ◽  
Forming Limit ◽  
Welding Parameters ◽  
Friction Stir ◽  
Tailor Welded Blanks ◽  
Different Characteristics

A tailor welded blank (TWB) includes two or more blanks joined together in order to make a single blank. Different welding methods are used to join blanks with different characteristics and form TWBs. In this study, a comparison is made among the effects of three different welding methods namely CO2 laser welding, friction stir welding (FSW), and friction stir vibration welding (FSVW) on mechanical and formability properties of developed TWBs. AA6061 alloy sheets with different thicknesses (1.2 and 0.8 mm) are joined to get TWBs. The forming limit diagram (FLD) and limiting dome height (LDH) are applied to assess the formability. The Taguchi method is applied to find the optimum values of welding parameters. It is concluded that TWBs made by FSVW have higher mechanical properties and formability compared to TWBs made by FSW and CO2 laser welding. The results also indicate that FLD for TWBs made by FSW is higher than FLD for TWBs made by CO2 laser welding and FLD0, for TWBs made by FSVW, increases as vibration frequency increases.

Incremental Sheet Forming with an Industrial Robot – Forming Limits and Their Effect on Component Design

2005 ◽  
Vol 6-8 ◽  
pp. 457-464 ◽  
Author(s):  
L. Lamminen
Keyword(s):  
Sheet Metal ◽  
Industrial Robot ◽  
Forming Limit Diagram ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Point Of View ◽  
Forming Limit ◽  
Forming Process ◽  
3D Cad ◽  
Component Design

Incremental sheet forming (ISF) has been a subject of research for many research groups before. However, all of the published results so far have been related to either commercial ISF machines or ISF forming with NC mills or similar. The research reported in this paper concentrates on incremental sheet forming with an industrial robot. The test equipment is based on a strong arm robot and a moving forming table, where a sheet metal blank is attached. The tool slides on the surface of the sheet and forms it incrementally to the desired shape. The robot is capable of 5-axis forming, which enables forming of inwards curved forms. In this paper the forming limit diagram (FLD) for ISF with the robot is presented and it is compared with conventional forming limit diagrams. It will be shown that the conventional FLD does not apply to incremental forming process. Geometrical accuracy of sample pieces is also studied. Cones of different shapes are formed with the robot equipment and their correspondence with the 3D CAD model is evaluated. The results are compared with other results of accuracy of incremental sheet forming, reported earlier by other researchers. The third issue covered in this article is a product development point of view to incremental sheet forming. In addition to fast prototyping and low volume production of sheet metal parts, ISF brings new possibilities to sheet metal component design and manufacturing. These possibilities can only be exploited if design rules, that will take the possibilities and limitations of the method into account are created for ISF.

Integrated Hydraulic Bulge and Forming Limit Testing Method and Apparatus for Sheet Metals

2014 ◽  
Vol 626 ◽  
pp. 171-177 ◽  
Author(s):  
Yan Yo Chen ◽  
Yu Chung Tsai ◽  
Ching Hua Huang
Keyword(s):  
Forming Limit Diagram ◽  
Close Correlation ◽  
Biaxial Stress ◽  
Forming Limit ◽  
Hydraulic Pressure ◽  
Sheet Metals ◽  
Stress Strain ◽  
Testing Method ◽  
Hydraulic Bulge ◽  
Strain Relationship

This paper proposes an integrated hydraulic bulge and forming limit testing method and apparatus for sheet metals. By placing a PU (Polyurethane) plate between molds and uniformly applying hydraulic pressure to sheet metals, a biaxial stress-strain relationship and forming limit diagram (FLD) displaying both left and right sides were acquired using the same apparatus. An uniaxial tension test and traditional drawing test were conducted to compare the results obtained from the proposed hydraulic bulge and forming limit testing methods, respectively. A close correlation between the results of the stress-strain relationship and FLD in both comparisons verified the feasibility and capability of this integrated hydraulic testing method and apparatus for use with sheet metals.

Microstructure Control and Mechanical Properties of 7075 Aluminum Alloy by Means of Multi-Pass Friction Stir Processing

2011 ◽  
Vol 409 ◽  
pp. 281-286
Author(s):  
Yutaka Matsuda ◽  
Goroh Itoh ◽  
Yoshinobu Motohashi
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Friction Stir Processing ◽  
Microstructural Characterization ◽  
Tensile Tests ◽  
7075 Aluminum Alloy ◽  
Tensile Direction ◽  
Friction Stir ◽  
Electron Microscopies ◽  
7075 Alloy

Friction stir processing (FSP) is a method for controlling the microstructure that has been proposed by applying friction stir welding, FSW. In this study, microstructure and mechanical properties of a 7075 aluminum alloy subjected to multi-pass FSP, MP-FSP, are assessed to obtain fundamental knowledge for improving the plasticity of aluminum alloys. The MP-FSP has been applied to 7075 alloy plates with T6 and O tempers, and microstructural characterization has been made by means of optical and scanning electron microscopies together with EDX and EBSD analyses, while mechanical properties were measured by means of micro hardness and tensile tests at room and high temperatures. From microstructural observation, a new zone, PBZ, has been discovered between stir zones, SZs. The PBZ is composed of two types of (fine and coarse) grains, where the coarse grain contains many sub-grains. Hardness in PBZ is intermediate between that in BM and SZ both in T6 and O specimens; hardness generally decreases and increases in T6 and O specimens, respectively, by MP-FSP. In accord to the hardness change, strength at room temperature is decreased by MP-FSP in T6 specimen, and increased in O specimen. Elongation at 773K is increased both in T6 and O specimens because of superplastic deformation. However, local elongation is smaller in PBZ than in SZ, which can be attributed to the microstructural change by the deformation: grain shape remains equiaxed in SZ while it becomes elongated in the tensile direction in PBZ.

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