Simulation Based Development of Quick Plastic Forming

2005 ◽  
Author(s):  
Frank Lee ◽  
Krishna Murali ◽  
Andrew Heath ◽  
Raju Gandikota
Keyword(s):  
Simulation Based ◽  
Plastic Forming ◽  
Quick Plastic Forming

Simulation-Based Tracking of UOE Pipe Yield Strength Considering Various Thickness-to-Diameter Ratios

2018 ◽  
Author(s):  
Jiwoon Yi ◽  
Soo-Chang Kang ◽  
Hyun-Moo Koh ◽  
Jinkyo F. Choo
Keyword(s):  
Yield Strength ◽  
Bauschinger Effect ◽  
Steel Plate ◽  
Tensile Yield Strength ◽  
Forming Process ◽  
Factors Influencing ◽  
Simulation Based ◽  
Plastic Forming ◽  
Final Yield ◽  
Flattening Process

The plastic forming processes involved in the production of UOE pipes alter significantly the yield strength of the original steel plate. Numerous studies indicated that the work hardening and Bauschinger effect are the main factors influencing the alteration of the yield strength. Moreover, apart from the forming process itself, the flattening executed on strips sampled from the formed pipe appears to have also nonnegligible effect on the final yield strength that is used as quality index of the formed pipe. Therefore, this study tracks the yield strength of UOE pipe made of API-X70 steel with various thickness-to-diameter ratios by FE-simulation of the forming and flattening processes so as to identify the factors influencing the yield strength of the UOE pipe. The results show that the flattening process constitutes a critical phase in which steel experiences large loss of its tensile yield strength.

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).

Sheet Orientation Effects on the Hot Formability Limits of Lightweight Alloys

2011 ◽  
Vol 133 (6) ◽  
Author(s):  
Fadi Abu-Farha ◽  
Louis G. Hector
Keyword(s):  
Rolling Direction ◽  
Superplastic Forming ◽  
Strain Ratio ◽  
Forming Limit ◽  
Specific Strain ◽  
Plastic Forming ◽  
Lightweight Alloys ◽  
Quick Plastic Forming ◽  
The Relationship ◽  
5083 Aluminum Alloy

The formability curves of AZ31B magnesium and 5083 aluminum alloy sheets were constructed using the pneumatic stretching test at two different sets of forming conditions. The test best resembles the conditions encountered in actual hydro/pneumatic forming operations, such as the superplastic forming (SPF) and quick plastic forming (QPF) techniques. Sheet samples were deformed at (400 °C and 1 × 10−3 s−1) and (450 °C and 5 × 10−3 s−1), by free pneumatic bulging into a set of progressive elliptical die inserts. The material in each of the formed domes was forced to undergo biaxial stretching at a specific strain ratio, which is simply controlled by the geometry (aspect ratio) of the selected die insert. Material deformation was quantified using circle grid analysis (CGA), and the recorded planar strains were used to construct the forming limit curves of the two alloys. The aforementioned was carried out with the sheet oriented either along or across the direction of major strains in order to establish the relationship between the material’s rolling direction and the corresponding limiting strains. Great disparities in limiting strains were found in the two orientations for both alloys; hence, a “composite FLD” is introduced as an improved means for characterizing material formability limits.

Reverse Bulging in Hydro/Pneumatic Sheet Metal Forming Operations: Is it Worth It?

2010 ◽  
Author(s):  
Fadi Abu-Farha
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Thickness Distribution ◽  
Complex Part ◽  
Plastic Forming ◽  
Quick Plastic Forming ◽  
Time Savings ◽  
Direct Feedback ◽  
Specific Part

The merits of warm and elevated temperature hydro/pneumatic sheet metal forming operations, most prominently superplastic and quick plastic forming, have been ever counteracted by two major drawbacks: slow forming rates and non-uniform thickness distribution with potentially severe thinning. Trying to resolve one of the two issues has generally led to escalating the other, so a compromise based on the nature of the part being formed is often targeted. To tackle the latter of the two issues, imposing a pre-thinning reverse bulging step has been shown to ease the problem with specific part geometries that involve large plastic strains and intricate details. The aerospace industry, however, is the prime sector that is able to afford the “seemingly” prolonged forming times associated with this approach. Yet with the lack of adequate details on the implications of utilising reverse bulging, this effort explores some of the hidden merits of the approach. A recently-developed simple monitoring technique for providing a direct feedback on the sheet’s advancement during pneumatic forming operations, coupled with an interrupted testing methodology, are utilised to have a closer look at the process. The results reveal significant time-savings that can be achieved with the proper use of reverse bulging, for both simple and complex part geometries.

Tribological Testing of Graphite and Boron Nitride Lubricant Formulations for High Temperature Aluminum Sheet Forming Processes

2007 ◽  
Author(s):  
M. David Hanna ◽  
Paul E. Krajewsk ◽  
James G. Schroth
Keyword(s):  
High Temperature ◽  
Boron Nitride ◽  
Superplastic Forming ◽  
Solid Lubricants ◽  
Sheet Forming ◽  
Aluminum Sheet ◽  
Plastic Forming ◽  
Quick Plastic Forming ◽  
Performance And Evaluation

The tribological behavior of AA5083 aluminum sheet sliding against tool steel impacts the quality of components manufactured with the elevated temperature metal forming processes such as Quick Plastic Forming (QPF), Superplastic Forming (SPF), or warm forming. This study focuses on the tribological performance and evaluation of alternative solid lubricants using a flat-on-flat tribo-tester to simulate sheet forming at high temperature applications. Improved lubricant formulations containing boron nitride with graphite additions were found to enhance lubricity while maintaining good adherence to the surface of the aluminum blank at a temperature of 450°C.

scholarly journals Dimensional accuracy in quick plastic forming of aluminum alloy using demolding mechanism

2021 ◽  
Vol 13 (6) ◽  
pp. 168781402110217
Author(s):  
Chin-Wei Liu ◽  
Shyong Lee ◽  
Dean Chou ◽  
Shu-Han Hsu ◽  
Chun Lin Chu
Keyword(s):  
Dimensional Accuracy ◽  
Cnc Machining ◽  
Process Efficiency ◽  
Process Time ◽  
Metal Shell ◽  
Shell Mold ◽  
Operation Temperature ◽  
Temperature Loss ◽  
Plastic Forming ◽  
Quick Plastic Forming

This study focuses on quick plastic forming (QPF), product dimensional tolerances, and removal methods. The traditional curled metal shell mold in QFP, has limitations such as long process time and unstable quality. Therefore, this investigation designed a demolding mechanism, in order to improve the process efficiency and dimensional accuracy of QPF, in the manufacture of metal casings. The research results show that the proposed mechanism can significantly decrease the process time, because it replaces most of the operations of specimens movement after forming completely. The shorter process time reduce the die temperature loss during operation, thus also improving the efficiency by eliminating the need to wait for the die to return to its operation temperature. In terms of dimensional tolerance, the tolerance grade of QPF process was determined using the standard deviation, and found to be between IT10 and IT14. This range covers the scope of CNC cutting and stamping processing, indicating that the process has commercial value in the production of metal casings, because the current mainstream manufacturing process of metal casings comprises casting, stamping and CNC machining.

Quick Plastic Forming Behavior of AZ91 Magnesium Alloy Sheet

2011 ◽  
Vol 314-316 ◽  
pp. 842-846
Author(s):  
Gang Wang ◽  
Zhi Peng Zhang ◽  
Cheng Bo Liu ◽  
Xia Sheng
Keyword(s):  
Grain Size ◽  
Magnesium Alloy ◽  
Alloy Sheet ◽  
Gas Pressure ◽  
Test Results ◽  
Free Gas ◽  
Magnesium Alloy Sheet ◽  
Plastic Forming ◽  
Quick Plastic Forming ◽  
Bulging Test

The quick plastic forming (QPF) behavior for fine-grained AZ91D magnesium alloy sheet with the thickness of 1.0 mm and the grain size of 6.0 µm was investigated. Free gas bulging tests were conducted under different gas pressure for 300 s in the range of 250-400°C to investigate how the temperature and pressure impact on the formability of QPF. Free gas bulging test results show that the bulge height of semisphere part exist the peak value of 33 mm under the gas pressure of 0.5 MPa at 400°C. QPF tests of cup part were performed based on the free gas bulging test results. A cup part with the height of 20 mm which both of surface quality and fillet radius were satisfactory was formed using a two-stage loading path at 400°C during 300 s. Furthermore the microstructural revolution law during the QPF was discussed. The larger the thinning rate of parts is, the smaller the grain size will be.

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.

Forming Limit Diagrams for AA5083 under SPF and QPF Conditions

2007 ◽  
Vol 551-552 ◽  
pp. 129-134 ◽  
Author(s):  
Mary Anne Kulas ◽  
Paul E. Krajewski ◽  
John R. Bradley ◽  
Eric M. Taleff
Keyword(s):  
Strain Rate ◽  
Plane Strain ◽  
Superplastic Forming ◽  
Forming Limit ◽  
Forming Limit Diagrams ◽  
Commercial Grade ◽  
Bulge Testing ◽  
Macroscopic Fracture ◽  
Plastic Forming ◽  
Quick Plastic Forming

Forming Limit Diagrams (FLD’s) for AA5083 aluminum sheet were established under both Superplastic Forming (SPF) and Quick Plastic Forming (QPF) conditions. SPF conditions consisted of a strain rate of 0.0001/s at 500°C, while QPF conditions consisted of a strain rate of 0.01/s at 450°C. The forming limit diagrams were generated using uniaxial tension, biaxial bulge, and plane strain bulge testing. Forming limits were defined using two criteria: (1) macroscopic fracture and (2) greater than 2% cavitation. Very little difference was observed between the plane strain limits in the SPF and QPF conditions indicating comparable formability between the two processes with a commercial grade AA5083 material.

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