scholarly journals The Process Design and Rapid Superplastic Forming of Industrial AA5083 for a Fender with a Negative Angle in a Small Batch

Metals ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 497
Author(s):  
Zhihao Du ◽  
Guofeng Wang ◽  
Hailun Wang
Keyword(s):  
Mechanical Properties ◽  
Elevated Temperatures ◽  
Thickness Distribution ◽  
Superplastic Forming ◽  
Optimized Design ◽  
Forming Process ◽  
Minimum Thickness ◽  
Rigid Plastic ◽  
Final Structure ◽  
Average Grain Size

A front automobile fender with a negative angle was trial produced via rapid superplastic forming (SPF) technology. The tensile test of industrial AA5083 was carried out at elevated temperatures, and the results showed that the maximum elongation was 242% at 480 °C/0.001 s−1. A rigid-plastic constitutive model of the SPF process was established. Initial dies of preforming and final forming were designed. The finite element method (FEM) was used to simulate the forming process and predict the thickness distribution of different areas. Furthermore, the dies were optimized to make the thickness distribution uniform. In the final structure, the maximum thinning ratio decreased from 83.2% to 63% due to the optimized design of the forming dies. The front automobile fender was then successfully fabricated by the preforming process and final forming process at 480 °C. A thickness measurement was carried out, and the minimum thickness of the preforming structure was 2.17 mm at the transverse tank, while that of the final structure was 2.49 mm near the edge of the lamp orifice. The average grain size grew from 20 to 35 μm. The grain growth led to the reduction of mechanical properties. Compared with the mechanical properties of the initial material, the maximum decrease in tensile strength for the material after superplastic forming was 5.78%, and that of elongation was 18.5%.

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.

Experimental Study of the Mechanical Properties at Elevated Temperatures in Commercial Mg-Al-Zn Alloys for Superplastic Forming

1999 ◽  
Vol 171-174 ◽  
pp. 337-342 ◽  
Author(s):  
Toshiji Mukai ◽  
H. Tsutsui ◽  
H. Watanabe ◽  
Ishikawa Kunio ◽  
Y. Okanda ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Experimental Study ◽  
Elevated Temperatures ◽  
Superplastic Forming ◽  
Zn Alloys

scholarly journals Performance of Thermo-Mechanically Processed AA7075 Alloy at Elevated Temperatures—From Microstructure to Mechanical Properties

Metals ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 884 ◽  
Author(s):  
Seyed Vahid Sajadifar ◽  
Emad Scharifi ◽  
Ursula Weidig ◽  
Kurt Steinhoff ◽  
Thomas Niendorf
Keyword(s):  
Mechanical Properties ◽  
Elevated Temperatures ◽  
Tensile Tests ◽  
Uniaxial Tensile ◽  
Forming Process ◽  
Softening Mechanism ◽  
Rate Dependent ◽  
Heat Treated ◽  
Different Temperatures ◽  
Die Forming

This study focuses on the high temperature characteristics of thermo-mechanically processed AA7075 alloy. An integrated die forming process that combines solution heat treatment and hot forming at different temperatures was employed to process the AA7075 alloy. Low die temperature resulted in the fabrication of parts with higher strength, similar to that of T6 condition, while forming this alloy in the hot die led to the fabrication of more ductile parts. Isothermal uniaxial tensile tests in the temperature range of 200–400 °C and at strain rates ranging from 0.001–0.1 s−1 were performed on the as-received material, and on both the solution heat-treated and the thermo-mechanically processed parts to explore the impacts of deformation parameters on the mechanical behavior at elevated temperatures. Flow stress levels of AA7075 alloy in all processing states were shown to be strongly temperature- and strain-rate dependent. Results imply that thermo-mechanical parameters are very influential on the mechanical properties of the AA7075 alloy formed at elevated temperatures. Microstructural studies were conducted by utilizing optical microscopy and a scanning electron microscope to reveal the dominant softening mechanism and the level of grain growth at elevated temperatures.

Effects of Specimen Diameter on Microstructure and Microhardness of Hot Extruded AZ31B Magnesium Alloy

2014 ◽  
Vol 1004-1005 ◽  
pp. 158-162 ◽  
Author(s):  
Xiang Ting Hong ◽  
Fu Chen ◽  
Fei Chen ◽  
Wang Yu ◽  
Bo Rong Sang ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Grain Size ◽  
Magnesium Alloy ◽  
Size Effects ◽  
Strain Distribution ◽  
Elevated Temperatures ◽  
Az31b Magnesium Alloy ◽  
Specimen Diameter ◽  
Average Grain Size ◽  
Micro Parts

Microstructures of metal micro parts after microforming at elevated temperatures must be evaluated due to mechanical properties depend on average grain size. In this work, the effects of specimen diameter on the microstructure and microhardness of a hot-extruded AZ31B magnesium alloy were studied. Obvious size effect on microstructure and microhardness of the alloy could be observed. The size effects could be explained by strain distribution and dislocation density differences between the two kinds of specimens.

Numerical Simulation of Bulging Process of Aluminum Alloy Sheet

2013 ◽  
Vol 327 ◽  
pp. 112-116 ◽  
Author(s):  
Mao Ting Li ◽  
Yong Zhang ◽  
Chui You Kong
Keyword(s):  
Aluminum Alloy ◽  
Material Flow ◽  
Thickness Distribution ◽  
Superplastic Forming ◽  
Alloy Sheet ◽  
Pressure Loading ◽  
Forming Process ◽  
Element Analysis ◽  
Danger Zone ◽  
Linear Finite Element

Basing on software MSC. Marc of non-linear finite element analysis, the article has studied the material flow in the process of aluminum alloy superplastic gas bulging forming. By analyzing of the thickness distribution of the molding member it confirm the danger zone in the forming process. By analyzing of pressure loading curve influence on forming part. Because the aluminum alloy is widely used in the industrial departments, it is supposed to improve the ability of forming ability of aluminum alloy by researching the superplastic forming.

Hybrid Superplastic Forming of Non-Superplastic AZ31 Mg Alloy

2016 ◽  
Vol 838-839 ◽  
pp. 534-539
Author(s):  
Mei Ling Guo ◽  
Ming Jen Tan ◽  
Xu Song ◽  
Beng Wah Chua
Keyword(s):  
Magnesium Alloy ◽  
Electron Backscatter Diffraction ◽  
Thickness Distribution ◽  
Superplastic Forming ◽  
Forming Process ◽  
Az31 Mg Alloy ◽  
Electron Backscatter ◽  
Hot Drawing ◽  
Backscatter Diffraction ◽  
First Contact

In this work, magnesium alloy sheets of non-superplastic grade AZ31 were successfully formed by a proposed hybrid superplastic forming at 400 °C within 22 min. During the forming process, hot drawing first formed the part partially from the starting metal sheet within a few seconds, and then followed by a designed gas forming process to achieve the desired conical shape by high gas pressure at a targeted strain rate. The maximum thinning of 59 % was found to occur at the first contact area between the material and the punch. The thickness distribution and superplastic deformation behavior during the hybrid superplastic forming were investigated. In addition, the microstructure evolutions of AZ31 at different forming stages were examined by electron backscatter diffraction. Superplastic forming capability of the non-superplastic grade magnesium alloy was achieved. Furthermore, the part formed by this superplastic-like forming was done faster and attained a more even material distribution than conventional superplastic forming.

Influencing Factors of AZ31B Sheet Deep Drawing

2011 ◽  
Vol 189-193 ◽  
pp. 88-91
Author(s):  
Jun Gao ◽  
Zhen Ming Yue ◽  
Shu Xia Lin
Keyword(s):  
Numerical Simulation ◽  
Deep Drawing ◽  
Experimental Approach ◽  
Elevated Temperatures ◽  
Heating Temperature ◽  
Thickness Distribution ◽  
Simulation Software ◽  
Forming Limit ◽  
Forming Process ◽  
Specific Strength

Magnesium alloys have been attracting much more attentions due to its low density, high specific strength and its lightweight during the past 30 years. In this paper, the deep drawing performance of AZ31B magnisium alloy sheets at elevated temperature was studied by the experimental approach. The results indicated that the formability of the AZ31B sheets at elevated temperatures could be improved significantly. The best external forming parameters can be obtained such as heating temperature of sheet, die-punch clearance, punch fillet radius, etc. Simulating the forming process by using the numerical simulation software, we investigated the stress-strain distribution, thickness distribution and forming limit, etc. The thickness distribution by the numerical simulation agrees well with the experimental results.

The Influence of the Roller Forming Path on the Neck-Spinning Process of Tube at Elevated Temperature

2011 ◽  
Author(s):  
Chi-Chen Huang ◽  
Jung-Chung Hung ◽  
Cheng-Chan Lo ◽  
Chia-Rung Lin ◽  
Chinghua Hung
Keyword(s):  
Finite Element ◽  
Elevated Temperature ◽  
Elevated Temperatures ◽  
Thickness Distribution ◽  
Optimization Technique ◽  
Element Model ◽  
Strain Rates ◽  
Forming Process ◽  
Tube Spinning ◽  
Spinning Process

The tube spinning process is a metal forming process used in the manufacture of axisymmetric products, and has been widely used in various applications. In this paper, the neck-spinning process was applied to form the neck part of the tube end at an elevated temperature. The spun tube was used as a high pressure CO2 vessel, which is a component of motorcycle airbag jackets. An uneven surface will occur on the tube surface if the thickness distribution of the tube is not uniform after the neck-spinning process. This is because different thicknesses result from different contractions during the cooling stage. For this reason, the aim of this research was to numerically investigate the roller forming path to improve the thickness distribution of the tube during the neck-spinning process. The finite element method was used to simulate the neck-spinning process of the tube at an elevated temperature. For the construction of the material model, special uni-axial tensile tests were conducted at elevated temperatures and various strain rates, because the material is sensitive to strain rates at high temperatures. This paper compares the experimental and simulation results of the thickness distribution and the outer contour of the spun tube. The validated finite element model was used to investigate the influence of the roller forming path on the thickness distribution of the tube. The thickness distribution of the tube formed by a curved path was found to be more uniform than for the tube formed by a straight path. Finally, the optimization technique was used to find the optimal forming path, and the optimal result was verified experimentally.

Investigation on Wrinkling Deformation in Multi-Pass Incremental Sheet Forming Process

2016 ◽  
Vol 725 ◽  
pp. 578-585 ◽  
Author(s):  
Zhao Bing Liu ◽  
Paul Anthony Meehan
Keyword(s):  
Thickness Distribution ◽  
Three Dimensional ◽  
Experimental Tests ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Final Part ◽  
Optimized Design ◽  
Forming Process ◽  
Element Analysis ◽  
Form Complex

Incremental Sheet Forming (ISF) is a promising rapid prototyping technology used to form complex three-dimensional shapes. For forming a part with severely sloped regions, design of multi-stage deformation passes (intermediate shapes or preforms) before the final part, is widely adopted as a desirable and practical way to control the material flow in order to obtain a more uniform thickness distribution and avoid forming failure. However, a problem sometimes encountered in multi-pass forming is wrinkling deformation between two adjacent deformation passes. This may lead to forming process instability and even fracture. The overall quality of the final part may also deteriorate even if the part is formed successfully. In this paper, the wrinkling phenomenon in multi-pass incremental sheet forming is investigated by means of finite element analysis (FEA) and experimental tests to analyse the wrinkling formation mechanism. This research gives an insight into the optimized design of deformation passes in order to eliminate the unwanted wrinkling deformation in multi-pass incremental forming process.

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