Research on Quick Superplastic Forming Technology of Industrial Aluminum Alloys for Rail Traffic

2018 ◽  
Vol 385 ◽  
pp. 468-473 ◽  
Author(s):  
Guo Feng Wang ◽  
Hui Hui Jia ◽  
Yi Bin Gu ◽  
Qing Liu
Keyword(s):  
Aluminum Alloy ◽  
High Speed ◽  
Thickness Distribution ◽  
New Technology ◽  
Side Wall ◽  
Superplastic Forming ◽  
Forming Process ◽  
Forming Technology ◽  
Hot Drawing ◽  
Industrial Aluminum

Quick superplastic forming is a new technology, which combines hot drawing preforming and superplastic forming. It makes full use of the high speed of hot drawing and good formability of superplasticity. For aluminum alloy complex components, the difficulties of stamping and low speed of superplasticity be perfect solved. In this work, the best forming process of side wall outer panel of metro vehicle was determined by forming experiment using quick superplastic forming technology. The high-speed rail edge skin with a very small fillet shape (R≤4 mm) and the large-size subway door frame part (h≈80 mm) formed by straight wall deep drawing were manufactured, using industrial aluminum alloy sheet with thickness of 4 mm. Meanwhile, the formed parts show the advantages of high dimensional accuracy and uniform wall thickness distribution, and the mechanical properties of formed parts can completely meet the requirements as well, which demonstrates the desirable efficiency, low cost and feasibility of this new technology.

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.

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.

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.

scholarly journals Finite Element Simulation of High-Speed Blow Forming of an Automotive Component

Metals ◽  
2018 ◽  
Vol 8 (11) ◽  
pp. 901 ◽  
Author(s):  
Omid Majidi ◽  
Mohammad Jahazi ◽  
Nicolas Bombardier
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Complex Geometry ◽  
New Technology ◽  
Size Variation ◽  
Superplastic Forming ◽  
Thickness Variation ◽  
Strain Rates ◽  
Element Size ◽  
The Impact

High-speed blow forming (HSBF) is a new technology for producing components with complex geometries made of high strength aluminum alloy sheets. HSBF is considered a hybrid-superplastic forming method, which combines crash forming and gas blow forming. Due to its novelty, optimization of the deformation process parameters is essential. In this study, using the finite element (FE) code ABAQUS, thinning of an aluminum component produced by HSBF under different strain rates was investigated. The impact of element size, variation of friction coefficient, and material constitutive model on thinning predictions were determined and quantified. The performance of the FE simulations was validated through forming of industrial size parts with a complex geometry for the three investigated strain rates. The results indicated that the predictions are sensitive to the element size and the coefficient of friction. Remarkably, compared to a conventional power law model, the variable m-value viscoplastic (VmV) model could precisely predict the thickness variation of the industrial size component.

Experimental Investigation and Finite Element Analysis on Electromagnetic Compression Forming Processed Aluminum Alloy Tubes

2011 ◽  
Vol 110-116 ◽  
pp. 1706-1710
Author(s):  
Selvam Rajiv ◽  
Karibeeran Shanmuga Sundaram ◽  
Pablo Pasquale
Keyword(s):  
Experimental Investigation ◽  
Finite Element ◽  
Aluminum Alloy ◽  
High Speed ◽  
High Energy ◽  
Work Piece ◽  
Outer Diameter ◽  
Forming Process ◽  
Element Analysis ◽  
Electromagnetic Compression

Electromagnetic forming (EMF) is a high energy rate forming (HERF) process. It is a high speed forming process using a pulsed magnetic field to form work pieces made of metals such as copper or aluminum alloys with high electrical conductivity. The work piece to be deformed will be located within the effective area of the tool coil so that the resulting type of stress during the forming process is determined by the type of coil used and its arrangement as related to the component. Tubular or structural components can be narrowed by means of compression coils or widened by means of expansion coils, where as sheet metal can be deformed by flat coils. In this work, the experimental investigation and simulation of electromagnetic compression forming of aluminum alloy tubes is studied. The aim of the paper was to verify the results from Finite element methods with experimental data. Experiments were conducted on Tubes of outer diameter 40 mm and wall thickness of 2 mm with a nominal tensile strength of 214 MPa. The tube was compressed using a 4 turn helical actuator discharge that can be energied up to 20 kJ. A field shaper made of aluminum was used. A Maximum reduction of 15.85% in diameters were measured. The same problem was simulated in ANSYS using static coupled electromagnetic analysis. The results of the Simulation showed good correlation with experimental results.

The Numerical Simulation of Transverse Tensile of High Temperature on Ti-6Al-4V Laser Butt Weld Joint

2013 ◽  
Vol 455 ◽  
pp. 163-166
Author(s):  
Yi Ping Chen ◽  
Zhao Fan ◽  
Dong Hai Cheng ◽  
Dean Hu
Keyword(s):  
Laser Welding ◽  
Weld Joint ◽  
Strain Curve ◽  
Superplastic Forming ◽  
Stress And Strain ◽  
Forming Process ◽  
Butt Weld ◽  
Tc4 Titanium Alloy ◽  
Transverse Tensile ◽  
Forming Technology

Forming process of TC4 titanium alloy laser weld joint during superplastic deformation is simulated. The stress and strain curve, which is obtained in the simulation, is compared with that obtained by hot tensile experiments. The simulation results provides a basis for subsequent laser welding / superplastic forming technology, and proposes outlook to the analyze problems for laser welding / superplastic forming (LBW / SPF) technology.

scholarly journals Hot Gas Forming of Aluminum Alloy Tubes Using Flame Heating

2020 ◽  
Vol 4 (2) ◽  
pp. 56 ◽  
Author(s):  
Ali Talebi-Anaraki ◽  
Mehdi Chougan ◽  
Mohsen Loh-Mousavi ◽  
Tomoyoshi Maeno
Keyword(s):  
Aluminum Alloy ◽  
Wall Thickness ◽  
Thickness Distribution ◽  
Forming Process ◽  
Hot Gas ◽  
Axial Feeding ◽  
Flame Heating ◽  
Lathe Machine ◽  
Aluminum Alloy Tube ◽  
Hot Gas Forming

Hot metal gas forming (HMGF) is a desirable way for the automotive industry to produce complex metallic parts with poor formability, such as aluminum alloys. A simple hot gas forming method was developed to form aluminum alloy tubes using flame heating. An aluminum alloy tube was heated by a flame torch while the tube was rotated and compressed using a lathe machine and simultaneously pressurized with a constant air pressure. The effects of the internal pressure and axial feeding on expansion and wall thickness distribution were examined. The results showed that the proposed gas forming method was effective for forming aluminum alloy tubes. It was also indicated that axial feeding is a vital parameter to prevent reductions in wall thickness by supplying the material flow during the forming process.

Development of Hot Press Machine for Superplastic Forming Technology

2011 ◽  
Vol 228-229 ◽  
pp. 563-567 ◽  
Author(s):  
Ho Sung Lee ◽  
Jong Hoon Yoon ◽  
Joon Tae Yoo ◽  
Yeng Moo Yi
Keyword(s):  
Control Process ◽  
Superplastic Forming ◽  
Gas Pressure ◽  
Process Variables ◽  
Hot Press ◽  
Forming Force ◽  
Forming Process ◽  
Forming Technology ◽  
Bonding Technology ◽  
And Diffusion

In most superplastic forming process, one or more sheets of superplastic grade materials are heated and forced onto or into single surface tools by gas pressure. Since the assembly includes only clamping dies, temperature chamber and regulated gas pressure to provide forming force, the assembly is easy to use for aircraft components. However, it is not easy to control process variables at high temperature. This paper presents an economic machinery method to develop hot press machine for manufacturing complex contoured components using superplastic forming and diffusion bonding technology.

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%.

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