High-Temperature Forming of a Vehicle Closure Component in Fine-Grained Aluminum Alloy AA5083: Finite Element Simulations and Experiments

2010 ◽  
Vol 433 ◽  
pp. 197-209 ◽  
Author(s):  
Louis G. Hector ◽  
Paul E. Krajewski ◽  
Eric M. Taleff ◽  
Jon T. Carter
Keyword(s):  
Finite Element ◽  
High Temperature ◽  
Sheet Thickness ◽  
Alloy Sheet ◽  
Forming Process ◽  
Material Models ◽  
Fine Grained ◽  
Plastic Forming ◽  
Quick Plastic Forming ◽  
Forming Defects

Fine-grained AA5083 aluminum-magnesium alloy sheet can be formed into complex closure components with the Quick Plastic Forming process at high temperature (450oC). Material models that account for both the deformation mechanisms active during forming and the effect of stress state on material response are required to accurately predict final sheet thickness profiles, the locations of potential forming defects and forming cycle time. This study compares Finite Element (FE) predictions for forming of an automobile decklid inner panel in fine-grained AA5083 using two different material models. These are: the no-threshold, two-mechanism (NTTM) model and the Zhao. The effect of sheet/die friction is evaluated with five different sheet/die friction coefficients. Comparisons of predicted sheet thickness profiles with those obtained from a formed AA5083 panel shows that the NTTM model provides the most accurate predictions.

Hot Tensile Behavior of Superplastic and Commercial AA5083 Sheets at High Temperature and Strain Rate

2013 ◽  
Vol 554-557 ◽  
pp. 63-70 ◽  
Author(s):  
Stefania Bruschi ◽  
Andrea Ghiotti ◽  
Francesco Michieletto
Keyword(s):  
High Temperature ◽  
Strain Rate ◽  
Automotive Industry ◽  
Hot Stamping ◽  
Superplastic Forming ◽  
Tensile Behavior ◽  
Tensile Behaviour ◽  
Fine Grained ◽  
Plastic Forming ◽  
Quick Plastic Forming

Since the last two decades, the automotive industry has dedicated an increasing attention to the manufacturing of sheet components made of high-resistant aluminium alloys; the superplastic AA5083 grade is currently utilized in both the conventional superplastic forming and the recently patented quick plastic forming, which assures higher productivity compared to that of superplastic forming, while the commercial AA5083 grade is rarely employed. The objective of the paper is to compare the hot tensile behaviour of commercial and fine-grained AA5083 sheets when processed at high temperature and strain rate, which are typical of hot stamping processes. The results are presented and commented in terms of flow stress, anisotropy, strain at failure, microstructural and hardness features as a function of temperature and strain rate. On the basis of the obtained results, the set of optimal forming conditions for the two grades is identified.

scholarly journals Study on Hot Press Forming Process of Large Curvilinear Generatrix Workpiece of Ti55 High-Temperature Titanium Alloy

Metals ◽  
2018 ◽  
Vol 8 (10) ◽  
pp. 827 ◽  
Author(s):  
Fengyong Wu ◽  
Wenchen Xu ◽  
Zhongze Yang ◽  
Bin Guo ◽  
Debin Shan
Keyword(s):  
Titanium Alloy ◽  
High Temperature ◽  
Fem Simulation ◽  
Alloy Sheet ◽  
Rolled Sheet ◽  
Strain Rates ◽  
Hot Press ◽  
Forming Process ◽  
Press Forming ◽  
Hot Press Forming

In order to manufacture complex curvilinear generatrix workpieces of high-temperature titanium alloy, the hot tensile behavior of Ti55 alloy sheet was tested and the hot press forming process was investigated using Finite Element Method (FEM) simulation and experiment. The hot tensile experiments of Ti55 rolled sheet were conducted at the temperatures of 800–900 °C with the strain rates of 0.001–0.1 s−1. According to the results of hot tensile tests and microstructure evolution, the proper hot press forming parameters were determined as the temperature of 850 °C and the strain rates of 0.001–0.01 s−1. The wrinkling mechanism in the transition region was analyzed and the initial blank sheet geometry was optimized by FE simulation of hot press forming. The two-step hot press forming process was better to produce the complex sheet workpiece of Ti55 alloy than the one-step hot forming scheme, which could restrain the wrinkling trend and ensure the microstructure and mechanical properties of the hot formed workpieces.

Research on the Finite Element Simulation of the Laser Shock Forming of TC4 Titanium Alloy

2016 ◽  
Vol 693 ◽  
pp. 1121-1128 ◽  
Author(s):  
Guo He Li ◽  
David Mbukwa ◽  
Wei Zhao
Keyword(s):  
Finite Element ◽  
Sheet Metal ◽  
Laser Energy ◽  
Sheet Thickness ◽  
High Amplitude ◽  
Laser Spot ◽  
Laser Shock ◽  
Forming Process ◽  
Element Analysis ◽  
Laser Shock Forming

laser shock forming, which combines the metal forming and material modification, is a non-mode, flexible forming new technology using laser-induced force effect of high amplitude shock waves to obtain the plastic deformation of sheet metal. in this paper, the simulation of laser shock forming process of tc4 sheet metal was carried out through the commercial finite element analysis software abaqus. the influence of the sheet thickness, laser energy, constraints aperture and laser spot spacing on the sheet metal deformation are investigated. the results show that: with the increase of sheet thickness, the deformation range of sheet decreases, and the amplitude of deformation decreases firstly and then increases. the deformation increases linearly with the increase of laser energy. the larger boundary constraint aperture leads to the larger deformation of sheet metal. there are no obvious influence on the forming accuracy when an opposite laser spot spacing is adopted. therefore, under the condition of meeting the accuracy requirement, for improving the efficiency, adopting a certain laser spot spacing to finish the forming should be considered.

Numerical Simulation of Non-Circular Hole Joint Precision Forming

2009 ◽  
Vol 16-19 ◽  
pp. 462-465
Author(s):  
Yong Fei Gu ◽  
Jun Ting Luo
Keyword(s):  
Numerical Simulation ◽  
Finite Element Method ◽  
Finite Element ◽  
Circular Hole ◽  
Developed Countries ◽  
Forming Process ◽  
Backward Extrusion ◽  
Forming Technology ◽  
Plastic Forming ◽  
And Performance

The precision forming technology developed rapidly during passing two decades, however technologies of precision plastic forming the parts with deeper hole are far behind developed countries. The warm backward extrusion-ironing forming technology was presented for precision forming of non-circular hole joint in this paper. The forming process and parameter variable trend were simulated by finite element method, which the software MSC.Marc was applied. The forming die was designed and the forming experiment was finished. The products were deserved with good quality and performance. The feasibility of the forming technology is proved by experimental results and numerical simulation.

The Implementation of Spray Forming for High Temperature Casing Applications

2001 ◽  
Author(s):  
Alan Partridge ◽  
Michael B. Henderson ◽  
David G. Cole ◽  
Paul Andrews
Keyword(s):  
High Temperature ◽  
Hot Isostatic Pressing ◽  
Spray Forming ◽  
Ring Rolling ◽  
Lead Times ◽  
Forming Process ◽  
Fine Grained ◽  
Near Net Shape ◽  
Property Assessment ◽  
Processing Steps

Many current gas turbine casings are manufactured using conventional wrought processing routes. Although well established this approach often requires numerous and complex processing steps. This can result in relatively long component lead times and high part costs. In an attempt to reduce lead times and cost the production of parts using the spray-forming process is under consideration. In the spray forming process the material is deposited from the molten state to produce a near net shape ring. The deposited ring is then subject to hot isostatic pressing (HIP) and/or ring rolling to consolidate the material and expand the ring to the required size. The material thus produced is usually relatively fine grained and can have a different balance of properties compared to conventionally processed alloys. However, the major advantage is that cost reductions can be achieved through the elimination of many process steps. In the current work a high temperature nickel alloy, RS5, has been produced as a spray formed ring. The influence of HIP and ring rolling have been investigated and a detailed microstructure-mechanical property assessment of the material has been carried out. The results of this work will be reported and the implications of the work on cost and manufacturing issues will be discussed.

Scale Effects in the High Temperature Gas Pressure Forming of Electrodeposited Fine-Grained Copper Thin Sheet

2007 ◽  
Vol 551-552 ◽  
pp. 347-353
Author(s):  
K. Lei ◽  
Kai Feng Zhang ◽  
M.J. Tong
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
High Temperature ◽  
Scale Effects ◽  
Gas Pressure ◽  
Small Scale ◽  
Fine Grained ◽  
Experimental Values ◽  
High Temperature Gas ◽  
Element Method

Scale effects in the high temperature gas pressure forming of electrodeposited fine-grained copper thin sheets were investigated by a series of tests at various forming temperatures and die apertures. The average as-deposited copper grain size was 5 μm. The geometrical parameters of the bugling die system and the thickness of copper sheet varied in proportion. Different radius hemisphere parts from 0.5mm to 5mm were obtained at a strain rate of 5.0×10−4 s−1, which was controlled by pressure forces curves determined in terms of a finite element method (FEM) based on constitutive equation proposed by Backoften in 1964. The experimental relative bulging height (RBH) values were measured, and compared with that predicted by the same finite element method (FEM). It was found that the experimental values of large scale parts approach to simulated values, whereas the experimental values of small scale parts were quite different from simulated values. In order to explain these phenomena, a grain-rotation-weakened mechanism was proposed.

A New Technique for the Investigation of Tribological Behavior of Sliding Pairs Used in Hot Forming Processes

2008 ◽  
Author(s):  
Vjekoslav Franetovic
Keyword(s):  
Tribological Behavior ◽  
Hot Forming ◽  
New Technique ◽  
Aluminum Sheet ◽  
Forming Process ◽  
The Real ◽  
Plastic Forming ◽  
Quick Plastic Forming ◽  
A New Technique ◽  
Interacting Surfaces

Hot forming of aluminum sheet is highly influenced by the tribological behavior of the interacting surfaces of sliding pairs. Here we describe a new technique to investigate tribo-pair candidates for Quick Plastic Forming (QPF) and warm forming processes. This technique represents a bench type simulation of the real forming process where the sheet and tool interact by sliding against each other in a single motion (slide/stroke).

Investigation on Variation of Bow Defect in Roll Forming Process

2017 ◽  
Vol 729 ◽  
pp. 80-85
Author(s):  
Dong Won Jung
Keyword(s):  
Steel Strip ◽  
Sheet Thickness ◽  
Roll Forming ◽  
Spring Back ◽  
Forming Process ◽  
Complex Deformation ◽  
Plastic Forming ◽  
Set Up ◽  
Roll Forming Process ◽  
Abaqus Software

Roll forming is a kind of plastic forming process in which a steel strip is bent by several sets of rolls gradually into the desired shape. The products are cold roll forming steels with various sections. Roll forming is one of the most widely used processes in the world for forming metal. Roll forming is a complex deformation process, which involves large displacement, finite strain and the problems of contact and friction between strip and rolls. This process exhibits obvious geometry, physical and boundary nonliterary. The complex processes contain many aspects such as geometry, kinematics and dynamics, etc. The forming process involves not only transverse bending, but also other additional deformations. In this paper, a group of simulations have been established with ABAQUS software to studying about the spring back and bow defect in the roll forming process. At last, experiments have been accomplished to verify the simulation results. The simulations based on the ABAQUS software calculate the spring back angles and bow displacements. The bow displacement of the roll forming process is considered relate to many factors include inner distance between stands, gaps of the rolls, channel width, the material of the sheet, sheet thickness and so on.To verify the bow displacement in roll forming process, 9 groups of simulations were set up use Taguchi method to figure out the influence on bow displacement of every factor. The longitudinal strain also has been learned in the present study.

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