Forming parameters for incremental forming of aluminium alloy sheet metal

2002 ◽  
Vol 216 (10) ◽  
pp. 1367-1371 ◽  
Author(s):  
J Jeswiet ◽  
E Hagan ◽  
A Szekeres
Keyword(s):  
Aluminium Alloy ◽  
Sheet Metal ◽  
Incremental Forming ◽  
Tensile Tests ◽  
Alloy Sheet ◽  
Strain Hardening Exponent ◽  
Strain Measurements ◽  
Forming Parameters ◽  
Plane Strain Compression Test ◽  
Sine Law

The forming parameters for incremental forming of aluminium alloy 3003 sheet are presented. Using two shapes for testing (a conical shape and a pyramid shape) and forming the sheet to various draft angles, the following data have been assembled: tensile tests, strain measurements, strength coefficient K and strain-hardening exponent n. The method of analysis of stress-strain diagrams used by Ford in the plane strain compression test are shown to be applicable. Relationships such as the sine law for spinning have been applied to the data and are presented.

scholarly journals Behaviour modelling of aluminium alloy sheet for single point incremental forming

2008 ◽  
Vol 1 (S1) ◽  
pp. 1151-1154 ◽  
Author(s):  
N. Decultot ◽  
V. Velay ◽  
L. Robert ◽  
G. Bernhart ◽  
E. Massoni
Keyword(s):  
Aluminium Alloy ◽  
Incremental Forming ◽  
Single Point ◽  
Alloy Sheet ◽  
Single Point Incremental Forming ◽  
Behaviour Modelling

scholarly journals Influence of Forming Parameters on the Mechanical Behavior of a Thin Aluminum Sheet Processed through Single Point Incremental Forming

Metals ◽  
2020 ◽  
Vol 10 (11) ◽  
pp. 1461
Author(s):  
Muhammad Ilyas ◽  
Ghulam Hussain ◽  
Haris Rashid ◽  
Mohammed Alkahtani
Keyword(s):  
Mechanical Properties ◽  
Yield Strength ◽  
Residual Stresses ◽  
Strain Hardening ◽  
Incremental Forming ◽  
Single Point ◽  
Strain Hardening Exponent ◽  
Single Point Incremental Forming ◽  
Forming Parameters ◽  
Tool Diameter

Incremental sheet forming (ISF) is an economical process for batch production. This paper investigates post-forming mechanical properties with an emphasis on the relationship between residual stresses, strengths, micro-hardness and the strain-hardening exponent. Moreover, the influence of important process parameters on the post-forming tensile properties and hardness is analyzed. A Taguchi statistical analysis method is applied to study the effect of forming parameters and identify the best combinations to enhance the mechanical properties of the commercial aluminum. The results reveal that direct relationships exist for the plots of: (i) the strain-hardening exponent vs. the post-necking strain and (ii) difference of post-forming strengths vs. the strain-hardening exponent. Furthermore, the post-forming yield strength can be enhanced by 66.9% through the Single Point Incremental Forming (SPIF). Similarly, the ductility can be doubled by conducting the SPIF after performing the annealing of the as-received rolled sheet. In the present study, parts formed at a wall angle (θ) of 40° with a tool diameter (d) of 6 mm exhibit the highest strength. Moreover, most ductile parts will be obtained at ω = 1500 rpm, d = 22 mm and θ = 20°. It has also been shown that the compressive residual stresses are favorable for higher yield strength and improve hardness of the formed parts.

scholarly journals Investigation on Fracture of a 6014-T4 Aluminum Alloy Sheet in the Flanging and Hemming Process Based on Numerical and Experimental Methods

Metals ◽  
2020 ◽  
Vol 10 (1) ◽  
pp. 81
Author(s):  
Zhengwei Gu ◽  
Gang Wang ◽  
Ge Yu
Keyword(s):  
Aluminum Alloy ◽  
Uniform Elongation ◽  
Natural Aging ◽  
Strain Ratio ◽  
Tensile Tests ◽  
Alloy Sheet ◽  
Uniaxial Tensile ◽  
Strain Hardening Exponent ◽  
Plastic Strain Ratio ◽  
Aging Period

The fracture of a flat-surface straight-edge hemmed component of aluminum alloy sheets was investigated in this study. The specimen was made of 1 mm thick 6014-T4. Natural aging characteristics of 6014-T4 were studied via uniaxial tensile tests. The results show that the yield stress and ultimate tensile strength increased while the uniform elongation, strain hardening exponent, and plastic strain ratio decreased during the natural aging period, which worsened the formability. The sheet was biaxially stretched to obtain a pre-strain before the flanging and hemming operation. The influence of the flanging radius on the fracture was evaluated using experimental and numerical methods, and the optimum values were obtained. The comparison between the roller hemming and die hemming process proved that the former tends to produce better formability.

scholarly journals Parametric Effects of Single Point Incremental Forming on Hardness of AA1100 Aluminium Alloy Sheets

Materials ◽  
2021 ◽  
Vol 14 (23) ◽  
pp. 7263
Author(s):  
Sherwan Mohammed Najm ◽  
Imre Paniti ◽  
Tomasz Trzepieciński ◽  
Sami Ali Nama ◽  
Zsolt János Viharos ◽  
...  
Keyword(s):  
Aluminium Alloy ◽  
Incremental Forming ◽  
Sheet Material ◽  
Single Point ◽  
Alloy Sheet ◽  
Single Point Incremental Forming ◽  
Regression Equations ◽  
Effective Parameters ◽  
Forming Process ◽  
Tool Diameter

When using a unique tool with different controlled path strategies in the absence of a punch and die, the local plastic deformation of a sheet is called Single Point Incremental Forming (SPIF). The lack of available knowledge regarding SPIF parameters and their effects on components has made the industry reluctant to embrace this technology. To make SPIF a significant industrial application and to convince the industry to use this technology, it is important to study mechanical properties and effective parameters prior to and after the forming process. Moreover, in order to produce a SPIF component with sufficient quality without defects, optimal process parameters should be selected. In this context, this paper offers insight into the effects of the forming tool diameter, coolant type, tool speed, and feed rates on the hardness of AA1100 aluminium alloy sheet material. Based on the research parameters, different regression equations were generated to calculate hardness. As opposed to the experimental approach, regression equations enable researchers to estimate hardness values relatively quickly and in a practicable way. The Relative Importance (RI) of SPIF parameters for expected hardness, determined with the partitioning weight method of an Artificial Neural Network (ANN), is also presented in the study. The analysis of the test results showed that hardness noticeably increased when tool speed increased. An increase in feed rate also led to an increase in hardness. In addition, the effects of various greases and coolant oil were studied using the same feed rates; when coolant oil was used, hardness increased, and when grease was applied, hardness decreased.

scholarly journals Mechanical clinching and self-pierce riveting for sheet combination of 780-MPa high-strength steel and aluminium alloy A5052 sheets and durability on salt spray test of joints

2021 ◽  
Vol 113 (1-2) ◽  
pp. 59-72
Author(s):  
Yohei Abe ◽  
Ken-ichiro Mori
Keyword(s):  
Aluminium Alloy ◽  
High Strength Steel ◽  
Salt Spray ◽  
High Strength ◽  
Alloy Sheet ◽  
Galvanized Steel ◽  
Load Reduction ◽  
Minimum Thickness ◽  
Steel Sheets ◽  
Mechanical Clinching

AbstractTo increase the usage of high-strength steel and aluminium alloy sheets for lightweight automobile body panels, the joinability of sheet combinations including a 780-MPa high-strength steel and an aluminium alloy A5052 sheets by mechanical clinching and self-pierce riveting was investigated for different tool shapes in an experiment. All the sheet combinations except for the two steel sheets by self-pierce riveting, i.e., the two steel sheets, the two aluminium alloy sheets, and the steel-aluminium alloy sheets, were successfully joined by both the joining methods without the gaps among the rivet and the sheets. Then, to show the durability of the joined sheets, the corrosion behaviour and the joint strength of the aged sheets by a salt spray test were measured. The corrosion and the load reduction of the clinched and the riveted two aluminium alloy sheets were little. The corrosion of the clinched two steel sheets without the galvanized layer progressed, and then the load after 1176 h decreased by 85%. In the clinched two galvanized steel sheets, the corrosion progress slowed down by 24%. In the clinched steel and aluminium alloy sheets, the thickness reduction occurred near the minimum thickness of the upper sheet and in the upper surface on the edge of the lower aluminium alloy sheet, whereas the top surface of the upper sheet and the upper surface of the lower sheet were mainly corroded in the riveted joint. The load reduction was caused by the two thickness reductions, i.e., the reduction in the minimum thickness of the upper sheet and the reduction in the flange of the aluminium alloy sheet. Although the load of the clinched steel without the galvanized coating layer and aluminium alloy sheets decreased by about 20%, the use of the galvanized steel sheet brought the decrease by about 11%. It was found that the use of the galvanized steel sheets is effective for the decrease of strength reduction due to corrosion.

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