Development of Forming Temperature Curves for Warm Deep Drawing Process Under Non-isothermal Conditions

Abstract

Temperature is the main effective process parameter in the warm deep drawing (WDD) process to improve the formability of light-weight engineering materials, and this feature requires the accurate measurement and assessment of temperature for process stability. In this study, an evaluation of the WDD process was conducted according to the forming temperature curves (FTCs) characterized from work piece temperatures instead of tool temperatures, as usual. To achieve this goal, a special index material was developed to accurately obtain FTCs from the work piece material under closed and heated tool conditions. The differences of temperature on work piece material are required to define temperatures by curves. The characteristic behavior of these curves was investigated under non-isothermal WDD of AA 5754-O. In the experimentation stage, the process parameters, namely FTC, blank holder force and punch velocity, which assure successful deep drawability, were determined according to the failure-free cups by analyzing wrinkling and tearing conditions and minimum cup height parameters as output parameters. As the next step, optimum conditions were investigated by evaluating the cup volume and springback parameters. As a general conclusion, approximately 330 • C in the flange-die radius region and 100 • C in the cup wall-punch bottom region are the ideal optimum temperatures for the warm deep drawing process.

Elevated temperature forming limit strain diagrams of automotive alloys Al6014-T4 and DP600: A case study

“…Laurent et al 22 reported that formability improves above die temperatures of 150°C for Al5754. Some of the recently published works also deal with the warm forming research on aluminum alloys [23][24][25][26][27][28] and steels [29][30][31][32][33] with a focus on specific applications. It seems from the literatures that the technology of warm forming is limited to laboratory research only.…”

Investigation of Al 5754 Alloy in Warm Processing Conditions in Terms of Deep Drawability and Sheet Thickness Variation by Finite Element Method

“…Derin çekme imal usulünde kalıp yardımıyla düzlemsel geometrili iki boyutlu saclardan belirli şekle ve derinliğe sahip üç boyutlu ürünler elde edilir [1]. Derin çekme işlemi tek kademede gerçekleştirilebileceği gibi birden fazla kademede de gerçekleştirilebilir [2]. Endüstri uygulamalarında karmaşık veya basit şekle sahip birçok ürün kolaylıkla üretilebildiğinden derin çekme yöntemi önem arz etmektedir [3].…”

Investigation of tribological performance of hydrothermal carbon by pin-on-disc test and warm deep drawing process

“…While readily available and costeffective paraffin and polyamide-based oil are sufficient for cold-forming processes [12,13], warm deep drawing processes (approximately ∼300 °C and higher) require lubricants that can maintain their tribological performance at high temperatures without burning [14][15][16]. Studies in the literature have utilized Teflon and copper-containing grease lubricants for warm deep drawing processes [9,[17][18][19][20][21][22][23]. These lubricants have drawbacks such as evaporation, generating unpleasant odors, and high costs [9].…”