Aluminum alloys are increasingly used in automotive manufacturing to save weight. The drawability of Al 5182-O has been proven at room temperature (RT) and it is also shown that formability is further enhanced at elevated temperatures (ETs) in the range of 250–350 °C. A cost effective application of ET forming of Al alloys can be achieved using heated blank and cold dies (HB–CD). In this study, the material behavior of Al 5182-O is characterized using tensile test and viscous bulge test at RT. The nonisothermal finite element model (FEM) of deep drawing is developed using the commercial software pamstamp. Initially, deep drawing simulations and tests were carried out at RT using a 300 ton servo press, with a hydraulic cushion. The predictions with flow stress curves obtained from tensile and bulge tests were compared with experimental data. The effect of punch speed and temperature rise during forming at RT is investigated. The warm forming simulations were carried out by combining material data at ETs obtained from the literature. The coupled effects of sheet temperatures and punch speeds are investigated through the finite element analysis (FEA) to provide guidelines for ET stamping of Al 5182-O.

Electric discharge machining (EDM) is one of the viable techniques for machining of D2 steel, in which the material removal occurs by spark erosion. The poor selection of EDM parameters affect the machining quality and productivity. Considering this, the present work investigates the effect of current, charging and discharging time on the material removal rate (MRR) and the surface roughness (Ra) while machining of D2 steel using graphite electrode. The results were analysed using statistical methods to identify the effect of control parameters and to optimise the settings. The study shows that MRR and Ra was significantly influenced by current. At optimum settings, the MRR and the Ra obtained was 38.16 mg/min and 3.39 µm respectively. Morphological analysis of the machined surface show that the size of the globules formed decreased with increase in current.

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