Studies on the Hot Forming and Cold-Die Quenching of AA6082 Tailor Welded Blanks

2016 ◽  
Vol 716 ◽  
pp. 941-947
Author(s):  
Jun Liu ◽  
Ai Ling Wang ◽  
Hao Xiang Gao ◽  
Omer El Fakir ◽  
Xi Luan ◽  
...  
Keyword(s):  
Strain Rate ◽  
Strain Path ◽  
Element Model ◽  
Hot Forming ◽  
Forming Limit ◽  
Forming Process ◽  
Tailor Welded Blanks ◽  
Die Quenching ◽  
Experiment And Simulation ◽  
Temperature Strain

An advanced forming process involving hot forming and cold-die quenching, also known as HFQ®, has been employed to form AA6082 tailor welded blanks (TWBs). The HFQ® process combines both forming and heat treatment in a single operation, whereby upon heating the TWB, it is stamped and held between cold tools to quench the component to room temperature. The material therefore undergoes temperature, strain rate or strain path changes during the operation. In this paper, a finite element model (FEM) was developed to investigate the formability and deformation characteristics of the TWBs under HFQ® conditions. Experimental results, i.e. strain distribution, were used to compare and validate the simulation results. A good agreement between the experiment and simulation has been achieved. The developed temperature, strain rate and strain path dependent forming limit prediction model has been implemented into FE simulation to capture the complicated failure features of the HFQ® formed TWBs. It is found from both experiment and simulation that the forming speed has important effects on the occurrence of failure position, where the failure mode for the 1.5-2 mm TWBs may change from localised circumferential necking to parallel weld necking.HFQ® is a registered trademark of Impression Technologies Ltd.

Study of the Strain Rate Effect on Cold-Reduced Carbon Steel and Aluminium Alloy with Numerical Simulations

2006 ◽  
Vol 532-533 ◽  
pp. 973-976
Author(s):  
Lin Wang ◽  
Tai Chiu Lee ◽  
Luen Chow Chan
Keyword(s):  
Carbon Steel ◽  
Strain Rate ◽  
Strain Path ◽  
Plastic Material ◽  
Strain Rate Effect ◽  
Rate Effect ◽  
Forming Process ◽  
Risk Area ◽  
Sensitive Material ◽  
Simulation Results

In this paper, the effect of strain rate has been considered in the simulation of forming process with a simple form combined into the material law. Quite a few researchers have proposed various hardening laws and strain rate functions to describe the material tensile curve. In this study, the strain rate model Cowper-Symonds is used with anisotropic elasto-plastic material law in the simulation process. The strain path evolution of certain elements, when the strain rate is considered and not, is compared. Two sheet materials, Cold-reduced Carbon Steel (SPCC) JIS G3141 and Aluminum alloy 6112 are used in this study. Two yield criteria, Hill 48 and Hill 90, are applied respectively to improve the accuracy of simulation result. They show different performance when strain rate effect is considered. Strain path of the elements in the fracture risk area of SPCC (JIS G3141) varies much when the strain rate material law is used. There is only little difference of the strain distribution of Al 6112 when the strain rate effect is included and excluded in the material law. The simulation results of material SPCC under two conditions indicate that the strain rate should be considered if the material is the rate-sensitive material, which provides more accurate simulation results.

scholarly journals Acquisition and Evaluation of Theoretical Forming Limit Diagram of Al 6061-T6 in Electrohydraulic Forming Process

Metals ◽  
2019 ◽  
Vol 9 (4) ◽  
pp. 401 ◽  
Author(s):  
Min-A Woo ◽  
Woo-Jin Song ◽  
Beom-Soo Kang ◽  
Jeong Kim
Keyword(s):  
Strain Rate ◽  
Split Hopkinson Pressure Bar ◽  
Forming Limit Diagram ◽  
Forming Limit ◽  
Forming Process ◽  
Electrohydraulic Forming ◽  
Al 6061 ◽  
Shpb Test ◽  
Strain Rate Hardening ◽  
Free Bulging

The current study examines the forming limit diagram (FLD) of Al 6061-T6 during the electrohydraulic forming process based on the Marciniak–Kuczynski theory (M-K theory). To describe the work-hardening properties of the material, Hollomon’s equation—that includes strain and strain rate hardening parameters—was used. A quasi-static tensile test was performed to obtain the strain-hardening factor and the split-Hopkinson pressure bar (SHPB) test was carried out to acquire the strain rate hardening parameter. To evaluate the reliability of the stress–strain curves obtained from the SHPB test, a numerical model was performed using the LS–DYNA program. Hosford’s yield function was also employed to predict the theoretical FLD. The obtained FLD showed that the material could have improved formability at a high strain rate index condition compared with the quasi-static condition, which means that the high-speed forming process can enhance the formability of sheet metals. Finally, the FLD was compared with the experimental results from electrohydraulic forming (EHF) free-bulging test, which showed that the theoretical FLD was in good agreement with the actual forming limit in the EHF process.

Establishment and Application of Forming Limit Diagram of Multi-Gauge Laser Tailor-Welded Blanks

2010 ◽  
Vol 97-101 ◽  
pp. 420-425
Author(s):  
Wei Chen ◽  
S. Cheng ◽  
Y. Ding ◽  
Y.Q. Guo ◽  
L. Xue
Keyword(s):  
High Strength Steel ◽  
Research Method ◽  
Forming Limit Diagram ◽  
High Strength ◽  
Failure Criteria ◽  
Limit Strain ◽  
Measuring System ◽  
Forming Limit ◽  
Forming Process ◽  
Tailor Welded Blanks

The method for establishing the forming limit diagram (FLD) of multi-gauge high strength steel laser tailor-welded blanks (LTWB) is introduced based on analyzing the failure mechanism of multi-gauge LTWB. The Nakazima test is performed to generate the limit strain of multi-gauge high strength steel LTWB. By means of the ARGUS strain measuring system, the limit strain is measured and the FLD of LTWB is plotted subsequently. The FLD established by the Nakazima test is introduced into the FEA forming process as the failure criteria. Compared with the predicted result of the FLD of thinner metal, better correlation between the simulation and experimental results is indicated by adopting the FLD of LTWB as the necking criteria, which also reveals the validity and practicability of the FLD research method for multi-gauge high strength steel LTWB.

Forming Limit Prediction of BCC Materials under Non-Proportional Strain-Path by Using Crystal Plasticity

2012 ◽  
Vol 201-202 ◽  
pp. 1110-1116
Author(s):  
Mei Yang ◽  
Xiao Yan Zhang ◽  
Hao Wang
Keyword(s):  
Sheet Metal ◽  
Crystal Plasticity ◽  
Strain Path ◽  
Forming Limit Diagram ◽  
Forming Limit ◽  
Slip Systems ◽  
Plasticity Model ◽  
Forming Process ◽  
Crystal Plasticity Model ◽  
Microstructure Effect

In this paper, the forming limit of a body-centered cubic (BCC) sheet metal under non-proportional strain-path is investigated by using the Marciniak and Kuczynski approach integrated with a rate-dependent crystal plasticity model. The prediction model has been proved to be effective in predicting Forming Limit Diagram (FLD) of anisotropic sheet metal with FCC type of slip systems[1]. The same model has been used to study the FLD under non-proportional strain-path of BCC slip systems numerically and experimentally. The agreement between the experiments and simulations is good. With crystal plasticity model well describing the crystal microstructure effect, our model can be used to predict the FLD of BCC sheet metal under complicated strain path in plastic forming process with good accuracy.

Forming Limit and Fracture Mode of Microscale Laser Dynamic Forming

2010 ◽  
Vol 132 (6) ◽  
Author(s):  
Ji Li ◽  
Huang Gao ◽  
Gary J. Cheng
Keyword(s):  
Strain Rate ◽  
Focused Ion Beam ◽  
Ion Beam ◽  
Measurement Techniques ◽  
Forming Limit Diagram ◽  
Aluminum Foil ◽  
Element Model ◽  
Forming Limit ◽  
Thin Foils ◽  
Optical Profilometer

The microscale laser dynamic forming (LDF) process is a high strain rate microfabrication technique, which uses a pulse laser to generate high pressure by vaporizing and ionizing an ablative coating, and thus produces complex 3D microstructures in thin foils. One of the most important features of this technique is ultrahigh strain rate (typically 106–7 s−1), which is theoretically favorable for increasing formability. However, due to the lack of measurement techniques in microscale and submicroscale, the formability of workpieces in LDF is hardly studied. In this article, experiments were carried out on aluminum foils to study the forming limits and fracture of thin films in LDF. The deformation depth was measured by an optical profilometer and the formed feature was observed using a focused ion beam and a scanning electron microscope. Meanwhile, a finite element model based on a modified Johnson–Cook constitutive model and a Johnson–Cook failure model was developed to simulate the mechanical and fracture behaviors of materials in LDF. Experimental results were used to verify the model. The verified model was used to predict the forming limit diagram of aluminum foil in LDF. The forming limit diagrams show a significant increase in formability compared with other metal forming processes.

Effect of Plastic Anisotropy on Forming Limit Prediction

2005 ◽  
Vol 495-497 ◽  
pp. 1573-1578 ◽  
Author(s):  
S. He ◽  
Albert Van Bael ◽  
Paul van Houtte
Keyword(s):  
Strain Path ◽  
Plastic Anisotropy ◽  
Yield Locus ◽  
Material Behavior ◽  
Forming Limit ◽  
Sheet Metals ◽  
Forming Process ◽  
Forming Limit Diagrams ◽  
Strain Path Changes ◽  
Complex Strain

A model based on Marciniak-Kuczynski (M-K) theory [1] for the prediction of forming limit diagrams (FLDs) for anisotropic sheet metals is presented. The plastic anisotropy is taken into account by the shape of the yield locus generated on the basis of measured crystallographic texture. As a result, not only the material behavior during the monotonic loading can be well described and predicted, but also the complex strain-path changes during the forming process can be taken into account. Examples of predicted FLDs for two aluminum alloys are given. Comparisons with experimental results are presented.

The Study on Numerical Simulation of Tailor Welded Blanks on Square Cup Stamping

2011 ◽  
Vol 189-193 ◽  
pp. 3932-3935
Author(s):  
Xiao Gang Qiu
Keyword(s):  
Numerical Simulation ◽  
Plastic Deformation ◽  
Strain Distribution ◽  
Weld Seam ◽  
Element Model ◽  
Forming Process ◽  
Tailor Welded Blanks ◽  
Tailor Welded Blank ◽  
Different Thickness ◽  
The Finite Element Model

The stamping process of the tailor welded blank(TWB) was simulated by the software of DYNAFORM. The finite element model of a boxy part was founded, and the forming of different thickness and properties of the material was studied. Meanwhile, the influence of weld seam on forming result was analyzed. The results show that the weld seam model which founded by real properties can describe the plastic deformation and strain distribution more exactly in the forming process.

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