Forming limit coefficient and bursting criterion of hydro-bulging automobile axle housings

2007 ◽  
Vol 43 (05) ◽  
pp. 210
Author(s):  
Liandong WANG
Keyword(s):  
Forming Limit ◽  
Limit Coefficient

scholarly journals A numerical approach for the modelling of forming limits in hot incremental forming of AZ31 magnesium alloy

2021 ◽  
Author(s):  
Davide Campanella ◽  
Gianluca Buffa ◽  
Ernesto Lo Valvo ◽  
Livan Fratini
Keyword(s):  
Room Temperature ◽  
Incremental Forming ◽  
Material Model ◽  
Numerical Approach ◽  
Forming Limit ◽  
Material Strength ◽  
Wall Angle ◽  
Analytical Expression ◽  
The Poor ◽  
Specific Material

AbstractMagnesium alloys, because of their good specific material strength, can be considered attractive by different industry fields, as the aerospace and the automotive one. However, their use is limited by the poor formability at room temperature. In this research, a numerical approach is proposed in order to determine an analytical expression of material formability in hot incremental forming processes. The numerical model was developed using the commercial software ABAQUS/Explicit. The Johnson-Cook material model was used, and the model was validated through experimental measurements carried out using the ARAMIS system. Different geometries were considered with temperature varying in a range of 25–400 °C and wall angle in a range of 35–60°. An analytical expression of the fracture forming limit, as a function of temperature, was established and finally tested with a different geometry in order to assess the validity.

scholarly journals Formability study and metallurgical properties analysis of FSWed AA 6061 blank by the SPIF process

2021 ◽  
Vol 3 (3) ◽  
Author(s):  
Payam Tayebi ◽  
Ali Fazli ◽  
Parviz Asadi ◽  
Mahdi Soltanpour
Keyword(s):  
Base Metal ◽  
Strain Distribution ◽  
Thickness Distribution ◽  
Experimental Studies ◽  
Welding Process ◽  
Forming Limit ◽  
Forming Process ◽  
Friction Stir ◽  
Numerical Process ◽  
Tailor Welded Blank

AbstractIn this study, in order to obtain the maximum possible formability in tailor-welded blank AA6061 sheets connected by the friction stir welding (FSW) procedure, the incremental sheet forming process has been utilized. The results are presented both numerically and experimentally. To obtain the forming limit angle, the base and FSWed sheets were formed in different angles with conical geometry, and ultimately, the forming limit angle for the base metal and FSWed sheet is estimated to be 60° and 57.5°, respectively. To explore the effects of welding and forming procedures on AA6061 sheets, experimental studies such as mechanical properties, microstructure and fracture analysis are carried out on the samples. Also, the thickness distribution of the samples is studied to investigate the effect of the welding process on the thickness distribution. Then, the numerical process was simulated by the ABAQUS commercial software to study the causes of the FSWed samples failure through analyzing the thickness distribution parameter, and major and minor strains and the strain distribution. Causes of failure in FSWed samples include increased minor strain, strain distribution and thickness distribution in welded areas, especially in the proximity of the base metal area.

scholarly journals Ultrasound Effect on the Microstructure and Hardness of AlMg3 Alloy under Upsetting

Materials ◽  
2021 ◽  
Vol 14 (4) ◽  
pp. 1010
Author(s):  
Przemysław Snopiński ◽  
Tibor Donič ◽  
Tomasz Tański ◽  
Krzysztof Matus ◽  
Branislav Hadzima ◽  
...  
Keyword(s):  
Flow Stress ◽  
Ultrasonic Vibration ◽  
Light And Electron Microscopy ◽  
Load Flow ◽  
Forming Limit ◽  
Ultrasonic Vibrations ◽  
Softening Effect ◽  
Simultaneous Application ◽  
Ultrasonic Assisted ◽  
Acoustic Softening

To date, numerous investigations have shown the beneficial effect of ultrasonic vibration-assisted forming technology due to its influence on the forming load, flow stress, friction condition reduction and the increase of the metal forming limit. Although the immediate occurring force and mean stress reduction are known phenomena, the underlying effects of ultrasonic-based material softening remain an object of current research. Therefore, in this article, we investigate the effect of upsetting with and without the ultrasonic vibrations (USV) on the evolution of the microstructure, stress relaxation and hardness of the AlMg3 aluminum alloy. To understand the process physics, after the UAC (ultrasonic assisted compression), the microstructures of the samples were analyzed by light and electron microscopy, including the orientation imaging via electron backscatter diffraction. According to the test result, it is found that ultrasonic vibration can reduce flow stress during the ultrasonic-assisted compression (UAC) process for the investigated aluminum–magnesium alloy due to the acoustic softening effect. By comparing the microstructures of samples compressed with and without simultaneous application of ultrasonic vibrations, the enhanced shear banding and grain rotation were found to be responsible for grain refinement enhancement. The coupled action of the ultrasonic vibrations and plastic deformation decreased the grains of AlMg3 alloy from ~270 μm to ~1.52 μm, which has resulted in a hardness enhancement of UAC processed sample to about 117 HV.

Optimization of Tube Hydroforming Process Using Probabilistic Constraints on Failure Modes

2011 ◽  
Vol 62 ◽  
pp. 21-35 ◽  
Author(s):  
Anis Ben Abdessalem ◽  
A. El Hami
Keyword(s):  
Failure Modes ◽  
High Reliability ◽  
Thickness Distribution ◽  
Tube Hydroforming ◽  
Forming Limit Diagram ◽  
Plastic Instability ◽  
Probabilistic Constraints ◽  
Forming Limit ◽  
Reliability Based Design ◽  
Hydroforming Process

In metal forming processes, different parameters (Material constants, geometric dimensions, loads …) exhibits unavoidable scatter that lead the process unreliable and unstable. In this paper, we interest particularly in tube hydroforming process (THP). This process consists to apply an inner pressure combined to an axial displacement to manufacture the part. During the manufacturing phase, inappropriate choice of the loading paths can lead to failure. Deterministic approaches are unable to optimize the process with taking into account to the uncertainty. In this work, we introduce the Reliability-Based Design Optimization (RBDO) to optimize the process under probabilistic considerations to ensure a high reliability level and stability during the manufacturing phase and avoid the occurrence of such plastic instability. Taking account of the uncertainty offer to the process a high stability associated with a low probability of failure. The definition of the objective function and the probabilistic constraints takes advantages from the Forming Limit Diagram (FLD) and the Forming Limit Stress Diagram (FLSD) used as a failure criterion to detect the occurrence of wrinkling, severe thinning, and necking. A THP is then introduced as an example to illustrate the proposed approach. The results show the robustness and efficiency of RBDO to improve thickness distribution and minimize the risk of potential failure modes.

scholarly journals Forming Limit Stress Diagram Prediction of Pure Titanium Sheet Based on GTN Model

Materials ◽  
2019 ◽  
Vol 12 (11) ◽  
pp. 1783 ◽  
Author(s):  
Tao Huang ◽  
Mei Zhan ◽  
Kun Wang ◽  
Fuxiao Chen ◽  
Junqing Guo ◽  
...  
Keyword(s):  
Volume Fraction ◽  
Pure Titanium ◽  
Void Volume Fraction ◽  
Void Volume ◽  
Forming Limit ◽  
Stress And Strain ◽  
Gtn Model ◽  
Stress Diagram ◽  
Limit Stress ◽  
Hemispherical Punch

In this paper, the initial values of damage parameters in the Gurson–Tvergaard–Needleman (GTN) model are determined by a microscopic test combined with empirical formulas, and the final accurate values are determined by finite element reverse calibration. The original void volume fraction (f0), the volume fraction of potential nucleated voids (fN), the critical void volume fraction (fc), the void volume fraction at the final failure (fF) of material are assigned as 0.006, 0.001, 0.03, 0.06 according to the simulation results, respectively. The hemispherical punch stretching test of commercially pure titanium (TA1) sheet is simulated by a plastic constitutive formula derived from the GTN model. The stress and strain are obtained at the last loading step before crack. The forming limit diagram (FLD) and the forming limit stress diagram (FLSD) of the TA1 sheet under plastic forming conditions are plotted, which are in good agreement with the FLD obtained by the hemispherical punch stretching test and the FLSD obtained by the conversion between stress and strain during the sheet forming process. The results show that the GTN model determined by the finite element reverse calibration method can be used to predict the forming limit of the TA1 sheet metal.

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