Investigation of EN AW 5754 Aluminum Alloy’s Formability at Elevated Temperatures

2017 ◽  
Vol 885 ◽  
pp. 98-103 ◽  
Author(s):  
Dávid Budai ◽  
Miklós Tisza ◽  
Péter Zoltán Kovács
Keyword(s):  
Elevated Temperatures ◽  
High Strength Steels ◽  
High Strength ◽  
Carbon Composite ◽  
Alloy Sheet ◽  
High Mass ◽  
Mass Reduction ◽  
Forming Process ◽  
Forming Temperature ◽  
Operating Distance

Nowadays, mass reduction is the most often used term in the automotive industry. Car manufacturers are continuously working on getting ever lighter models than the previous ones, because of the global competition and the rigorous emission rules. A light car has many advantages: lower consumption, better handling, longer operating distance, etc. The emission rules forced the car brands to start new researches to find new solutions for mass reduction. The formula is relatively simple, using lighter or less materials or both and the car will be lighter. In the recent solutions there are three different ways: application of high strength steels, aluminum alloys, and carbon-composite elements. Our investigations are focusing mainly on aluminum, because of its high mass reduction potential. The biggest problem with the aluminum is its low formability. The formability of aluminum is lower than the steel, and it causes problems for the manufacturers. To increase the formability of the aluminum is a hot topic in the research and development area. Forming at elevated temperatures is one of the best solutions to increase the formability of aluminum. The relation between the formability and the forming temperature is not linear, furthermore beyond the optimum forming temperature the formability decreases. We need dozens of investigations to describe the perfect relation, but sometimes a good approximation is enough to form sheet products safely. In our work we investigated the EN AW 5754 aluminum alloy sheet at room temperature, 130°C, 200°C and 260°C. From these tests we could obtain FLC curves of the alloy at different temperatures. Using these curves, the process engineers could find the optimum parameters of their forming process.

Comparison of Material Behavior and Economic Effects of Cold and High Temperature Forming Technologies Applied to High-Strength Steels

2005 ◽  
Vol 6-8 ◽  
pp. 101-108 ◽  
Author(s):  
Reimund Neugebauer ◽  
Angela Göschel ◽  
Andreas Sterzing ◽  
Petr Kurka ◽  
Michael Seifert
Keyword(s):  
Elevated Temperatures ◽  
High Strength Steels ◽  
Dimensional Accuracy ◽  
High Strength ◽  
Economic Effects ◽  
Material Behavior ◽  
Spring Back ◽  
Forming Process ◽  
Cold Forming ◽  
Forming Tools

The focus of forming high-strength steel at elevated temperature is to improve its forming properties like elongation and to reduce the power requirements during the forming process in opposite to cold forming. Because of the undefined and large spring-back effects parts made by cold forming are not able to achieve the demanded dimensional accuracy, which is necessary for laser welding operations in car body assembly. The reduction of the spring-back behavior is another advantage of the temperature controlled forming technology. On the other side the forming at elevated temperatures requires increased costs for forming tools and tempering equipment. For a fundamental evaluation of this technology, expenditures for the complete process chain have to be considered.

Consideration of Elastic Tool Deformation in Numerical Simulation of Hydroforming with Granular Material Used as a Medium

2011 ◽  
Vol 473 ◽  
pp. 707-714 ◽  
Author(s):  
Martin Grüner ◽  
Marion Merklein
Keyword(s):  
Numerical Simulation ◽  
Granular Material ◽  
Elevated Temperatures ◽  
High Strength Steels ◽  
High Strength ◽  
Appropriate Technology ◽  
The Body ◽  
Warm Forming ◽  
Forming Process ◽  
Blank Holder

The use of high and ultra high strength steels in modern bodies in white raises steadily since the 1980’s. This trend is caused by the consumers’ wish of low fuel consuming cars with an increased passenger’s safety. The processing of these steels brings new challenges e.g. high flow stresses and a low formability at room temperature or high tool loads. These challenges can be resolved by warm forming at temperatures up to 600 °C reducing the flow stresses and increasing formability. For the production of complex parts that can not be produced by deep drawing hydroforming is an appropriate technology which can also help to reduce the number of parts and thus the weight of the body in white. Nowadays typical fluids used for hydroforming are only temperature stable up to about 330 °C so that it is not possible to combine the benefits of warm forming and hydroforming. Media like gases and fluids tend to leakage during the process which can only be avoided by a sealing or high blank holder forces. A new approach is the use of ceramic beads as medium for hydroforming at elevated temperatures. Building up a heatable tool for hydroforming with granular material used as medium makes it necessary to consider thermal conductivity so that there is a need of thick insulation plates. These insulation plates show high elastic deformations affecting the blank holder forces during the forming process. Measurements of the compressibility of these plates and implementation in numerical simulation allow a significant increase of the prediction accuracy of the model. A comparison of real part geometry and numerical results from models with and without consideration of elastic deformation will be given.

An Analytical and Numerical Investigation on Flange Wrinkling Behavior in Warm Forming Process of AA5754 Using Macro-Textured Tool Design

2016 ◽  
Vol 716 ◽  
pp. 586-594 ◽  
Author(s):  
Kai Lun Zheng ◽  
Lei Zhu ◽  
Denis J. Politis ◽  
Jian Guo Lin ◽  
Trevor A. Dean
Keyword(s):  
Aluminium Alloy ◽  
Draw Ratio ◽  
Elevated Temperatures ◽  
Material Model ◽  
Damage Mechanism ◽  
Alloy Sheet ◽  
Warm Forming ◽  
Forming Process ◽  
Flange Wrinkling ◽  
Forming Temperature

In this paper, an analytical buckling model is established to predict the flange wrinkling behavior of deep drawn cylindrical cups of aluminium alloy sheet in warm forming conditions using macro-textured blankholders for the first time. A continuum damage mechanism (CDM) based material model was utilized to reflect the visco-plastic feature of material at elevated temperatures. Forming speed and temperature effects were investigated, and texture ratio and draw ratio effects were also discussed. The developed analytical buckling model was validated by finite element simulations. The increase of forming temperature and forming speed is prone to cause wrinkling for AA5754, but the effects are not as significant as the texture geometry and draw ratio. The analytical model presented in this paper can be used as a design guide to determine tool texture geometry necessary to avoid wrinkling defects in the warm forming processes of aluminium alloy.

scholarly journals Punch Stretch Test for TRIP690 and DP780 Steel at Elevated Temperatures

2016 ◽  
Vol 854 ◽  
pp. 118-123
Author(s):  
Robert Krupa
Keyword(s):  
Elevated Temperatures ◽  
New Technology ◽  
Temper Embrittlement ◽  
High Strength Steels ◽  
High Strength ◽  
Phase Changes ◽  
Warm Forming ◽  
Forming Process ◽  
Contact Heat ◽  
Sheet Formability

The forming at elevated temperatures for Advanced High Strength Steels (AHSS) opens up a new technology. The phase changes during warm deformation are the key to understanding the warm forming process. The desired microstructure and mechanical properties before and after warm forming have to be known in order to find optimal conditions for achieving good sheet formability and preferred material properties in service. In this work, the TRIP690 and DP780 steels are investigated under punch stretch test conditions in order to evaluate the temperature influence on neck formation and fracture occurrence at ambient and elevated temperatures 200oC, 400oC. Contact heat treatment was used for heating up the circular specimens. It was found that formability of the investigated steels was drastically reduced at a temperature of 400oC and brittle fracture occurred because of temper embrittlement. It is recommended to avoid steel tempering at this critical temperature.

scholarly journals Determining the material model at elevated temperatures with different strain rates and simulating the warm forming process for Mg alloy AZ31B sheet

2015 ◽  
Vol 18 (2) ◽  
pp. 149-158
Author(s):  
Thien Tich Truong ◽  
Long Thanh Nguyen ◽  
Binh Nguyen Thanh Vu ◽  
Hien Thai Nguyen
Keyword(s):  
Magnesium Alloy ◽  
Constitutive Equations ◽  
Elevated Temperatures ◽  
Material Model ◽  
Alloy Sheet ◽  
Strain Rates ◽  
Functional Requirements ◽  
Temperature Dependent ◽  
Forming Process ◽  
Az31b Alloy

Magnesium alloy is one of lightweight alloys has been studied more extensively today. Because weight reduction while maintaining functional requirements is one of the major goals in industries in order to save materials, energy and costs, etc. Its density is about 2/3 of aluminum and 1/4 of steel.The material used in this study is commercial AZ31B magnesium alloy sheet which includes 3% Al and 1% Zn. However, due to HCP (Hexagonal Close Packed) crystal structure, magnesium alloy has limited ductility and poor formability at room temperature. But its ductility and formability will be improved clearly at elevated temperature. From the data of tensile testing, the constitutive equations of AZ31B was approximated using the Ramgberg-Osgood model with temperature dependent parameters to fit in the experiment results in tensile test. Yield locus are also drawn in plane stress σ1- σ2 with different yield criteria such as Hill48, Drucker Prager, Logan Hosford, Y. W. Yoon 2013 and particular Barlat 2000 criteria with temperature dependent parameters. Applying these constitutive equations were determined at various temperatures and different strain rates, the finite element simulation stamping process for AZ31B alloy sheet by software PAM- STAMP 2G 2012, to verify the model materials and the constitutive equations.

Springback Analysis in Bilayer Material Bending

2017 ◽  
Author(s):  
Chetan P. Nikhare
Keyword(s):  
Fuel Consumption ◽  
Elastic Recovery ◽  
Dissimilar Materials ◽  
High Strength Steels ◽  
Thick Layer ◽  
High Strength ◽  
Geometric Error ◽  
Forming Process ◽  
Tailor Welded Blanks ◽  
Geometric Defect

Exponential increase in the use of auto vehicles, and thus the fuel consumption, which relates to the air pollution, vehicle industry are in a strict environmental regulation from government. Due to which the innovation related to light-weighting is not only an option anymore but became a mandatory necessity to decrease the fuel consumption. To achieve this target, industry has been looking in fabricating components from high strength to ultra-high strength steels. With the usage of these material the lightweight was achieved by reducing a gage thickness. However due to their high strength property often challenges occurred are higher machine tonnage requirement, sudden fracture, geometric defect, etc. The geometric defect comes from elastic recovery of a material, which is also known as a springback. Springback is commonly known as a manufacturing defect due to the geometric error in the part, which would not be able to fit in the assembly without secondary operation or compensation in the forming process. Due to these many challenges, other research route involved is composite material, where light materials can be used with high strength material to reduce the overall vehicle weight. This generally includes, tailor welded blanks, multi-layer material, mechanical joining of dissimilar material, etc. Due to the substantial use of dissimilar materials, these parts are also called as hybrid components. It was noted that the part weight decreases with the use of hybrid components without compromising the integrity and safety. In this paper, a springback analysis was performed considering bilayer metal. For this two dissimilar materials aluminum and composite was considered as bonded material. This material was then bent in a channel forming set-up. The bilayer springback was compared in different condition like aluminum layer on punch side and then on die side. These results were then compared with the baseline springback of only aluminum thin and thick layer. It was found that the layer, which sees the punch side, matters due to the differences in elastic properties for both material and thus it directly influences the springback.

Modeling and FE Simulation of Quenchable High Strength Steels Sheet Metal Hot Forming Process

2010 ◽  
Vol 20 (6) ◽  
pp. 894-902 ◽  
Author(s):  
Hongsheng Liu ◽  
Jun Bao ◽  
Zhongwen Xing ◽  
Dejin Zhang ◽  
Baoyu Song ◽  
...  
Keyword(s):  
Sheet Metal ◽  
Fe Simulation ◽  
High Strength Steels ◽  
High Strength ◽  
Hot Forming ◽  
Forming Process

scholarly journals RESIDUAL STRENGTH OF STRUCTURAL STEELS: SN400, SM520 AND SM570

2016 ◽  
Author(s):  
In-Rak Choi ◽  
Kyung-Soo Chung
Keyword(s):  
Mechanical Properties ◽  
Elevated Temperatures ◽  
High Strength Steels ◽  
High Strength ◽  
Building Construction ◽  
Steel Plates ◽  
Seismic Resistance ◽  
Building Structures ◽  
Reliable Performance ◽  
Strength And Stiffness

<p>This paper presents post-fire mechanical properties of mild to high-strength steels commonly used in building structures in Korea. Steel is one of the main materials for building construction due to fast construction, light weight, and high seismic resistance. However, steel usually loses its strength and stiffness at elevated temperatures, especially over 600°C. But steel can regain some of its original mechanical properties after cooling down from the fire. Therefore, it is important to accurately evaluate the reliable performance of steel to reuse or repair the structures. For this reason, an experimental study was performed to examine the post-fire mechanical properties of steel plates SN400, SM520 and SM570 after cooling down from elevated temperatures up to 900°C. The post-fire stress-strain curves, elastic modulus, yield and ultimate strengths and residual factors were obtained and discussed.</p>

Experimental Study on Galling Behavior of Advanced High Strength Steel in Sheet Metal Forming

2012 ◽  
Vol 502 ◽  
pp. 36-40
Author(s):  
Ying Ke Hou ◽  
Shu Hui Li ◽  
Yi Xi Zhao ◽  
Zhong Qi Yu
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Sheet Material ◽  
High Strength Steels ◽  
High Strength ◽  
Forming Process ◽  
Advanced High Strength Steels ◽  
Sheet Materials ◽  
Materials Used

Galling is a known failure mechanism in many sheet metal forming processes. It limits the lifetime of tools and the quality of the products is affected. In this study, U-channel stamping experiments are performed to investigate the galling behavior of the advanced high strength steels in sheet metal forming . The sheet materials used in the tests are DP590 and DP780. In addition to the DP steels, the mild steel B170P1 is tested as a reference material in this study. Experimental results indicate that galling problem becomes severe in the forming process and the galling tendency can be divided into three different stages. The results also show that sheet material and tool hardness have crucial effects on galling performance in the forming of advanced high strength steels. In this study, DP780 results in the most heaviest galling among the three types of sheet materials. Galling performance are improved with increased hardness of the forming tool.

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