Forming of AA5182-O and AA5754-O at elevated temperatures using coupled thermo-mechanical finite element models

Abedrabbo, Nader; Pourboghrat, Farhang; Carsley, John E.

doi:10.1016/j.ijplas.2006.10.005

Cited by 198 publications

(85 citation statements)

References 44 publications

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“…To study the formability of cryorolled sheets in warm working temperature range (0.3T m -0.5T m , where Tm is absolute melting temperature) [18], LDH tests were carried out at three different temperature: 200°C, 250°C and 300°C (below recrystallization temperature of AA5083 alloy) on double action hydraulic press of 80T capacity with the help of heated tooling arrangement as shown in Fig. 3.…”

Section: Formability At Elevated Temperaturesmentioning

confidence: 99%

Formability of Cryorolled Aluminum Alloy Sheets in Warm Forming

Satish¹,

Feyissa²,

Kumar³

2018

IJMMM

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Abstract-Aluminium alloys are widely used in automobile industry due to their high strength to weight ratio, excellent corrosion resistance and easy machinability making them an alternative material to low carbon steel. But, one of the limitations of aluminum alloy sheets is their inferior strength and formability at room temperature when compared to low carbon deep drawing grade steels. Cryorolling is a severe plastic deformation process used to obtain ultra-fine grain structure in aluminium alloys along with high strength. However, it results in poor ductility and formability. Formability can be enhanced by warm forming, in which sheets metals are formed into desired shape at elevated temperatures but below the recrystallization temperature combining the advantages of both cold working and hot working. In this work, a hybrid processing route has been developed to enhance strength as well as formability of AA5083 alloy by cryorolling followed by warm forming. AA5083 aluminium alloy sheets of 5mm thickness were solutionized at 530°C followed by water quenching. These sheets were cryorolled to 1 mm thickness with 80% thickness reduction. Formability in biaxial stretch forming (in terms of limiting dome height) of these sheets was characterized at room temperature and elevated temperatures (200°C, 250°C and 300°C). Formability of the cryorolled sheets has been enhanced by forming in the warm working temperature range. The limit strains and limiting dome height have been found to be higher than in the case of conventional processing route (cold rolled, annealed and formed at room temperature) making this process capable of producing sheet metal parts of aluminium alloys with high strength and better formability.Index Terms-Aluminium alloy, Cryorolling, Formability, Warm forming I. INTRODUCTIONDue to high emissions, recyclability and increased fuel prices problems, automobile industries are trying to produce light weight vehicles. In this scenario, use of aluminium alloys become alternative to steels in automobile industries because of its low strength to weigh ratio, 99% recyclability, higher fuel efficiency and environmental advantages [1] . Adopting aluminium alloys in automobile is still questionable due to relatively higher cost, poor formability, poor final strength, stiffens and dent resistance. Therefore, aluminium alloys with combination of very high strength and satisfactory ductility, leading to a high potential for light-weight automobiles. The introduction of severe plastic deformation to aluminium sheet significantly changes the microstructure with leads to high strength but poor formability [2]. To achieve ultrafine grains (UFG) structured materials, severe plastic deformation (SPD) processes like equal channel angular pressing [3], repetitive corrugation and straightening [4], accumulative roll bonding [5] and high-pressure torsion [6] were used and requires, large plastic deformations, special tooling and adopting these processes in industries is difficult. An alternative method for producing UFG st...

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Section: Formability At Elevated Temperaturesmentioning

confidence: 99%

Formability of Cryorolled Aluminum Alloy Sheets in Warm Forming

Satish¹,

Feyissa²,

Kumar³

2018

IJMMM

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“…Most of these researches used general purpose FEM packages. Some authors preferred using ABAQUS [8], [9], while others (mainly overseas authors) performed a lot of simulation work using LS-DYNA [10]. As it was mentioned earlier, these systems can be programmed relatively easily; in these systems various realistic constitutive equations and damage modelling can be used.…”

Section: General Purpose Commercial Packages Vs Dedicated Sheet Metalmentioning

confidence: 99%

Some recent developments in sheet metal forming for production of lightweight automotive parts

Tisza

Lukács

Kovács

et al. 2017

J. Phys.: Conf. Ser.

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Abstract. Low cost manufacturing in the automotive industry is one of the main targets due to the ever increasing global competition among car manufacturers all over the World. Sheet metal forming is one of the most important key technologies in the automotive industry; therefore the elaboration of new, innovative low cost manufacturing processes is one of the main objectives in sheet metal forming as well. In 2015 with the initiative of the Imperial

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“…Each area segment of the sheet is under influence of the heat load for a time step equal to the laser-sheet interaction time which is determined by the scanning velocity (see Figure 2a). Temperature dependent thermal properties of this alloy are selected from the reference [7]. In this model heat losses due to radiation and natural convection are considered while the heat conduction to the backing plate and clamping plates is neglected.…”

Section: Numerical Description Of the Thermal Modelmentioning

confidence: 99%

“…An optimum laser power and scanning speed have been obtained for a 10 mm laser spot size in a way that a circular heated region of 10 mm diameter on a sheet perpendicular to the laser beam exceeds 270°C (see Figure 2b). This temperature is considered as an optimum warm forming temperature of AA5182 alloys [7].Results of the infrared thermography measurement of the sheet are presented in Figure 2 c.During LASPIF tests, for the cases indicated in Figure 1 c and d the circular laser beam or the part of it has been irradiated to the inclined surface (i.e. cone wall) this results in the reduction of heat flux compared to the case where the laser beam is radiated on a surface perpendicular to the laser beam.…”

Section: Numerical Description Of the Thermal Modelmentioning

confidence: 99%

Influence of laser assisted single point incremental forming on the accuracy of shallow sloped parts

Mohammadi

Vanhove

Bael

et al. 2013

AIP Conference Proceedings

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Abstract.Inwards bulging of the bottom is a typical geometric inaccuracy in shallow sloped Single Point Incrementally Formed (SPIF) parts. In this work, the effect of applying a localized heated spot moving synchronously with the forming tool on the geometrical accuracy of shallow sloped parts has been studied. To investigate the bulging of the bottom the results of an experimentally validated three-dimensional elasto-plastic finite element modelhave been utilized. These results have been used to identify the contact zone between the tool and the sheet, during Laser Assisted SinglePoint Incremental Forming (LASPIF) process. Moreover, a three-dimensional transient heat transfer model was formulated to identify optimum process parameters for the heating process. FE modeling results have been validated by temperature field measurements obtained from IR camera observations and a good agreement between the experimental data and the model has been observed. Based on the selected process parameters different relative positioning strategies between the tool position and the dynamically heated spot have been selected. Geometrical accuracies and the process forces have been measured and the best forming strategy has been identified accordingly.

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Forming of AA5182-O and AA5754-O at elevated temperatures using coupled thermo-mechanical finite element models

Cited by 198 publications

References 44 publications

Formability of Cryorolled Aluminum Alloy Sheets in Warm Forming

Formability of Cryorolled Aluminum Alloy Sheets in Warm Forming

Some recent developments in sheet metal forming for production of lightweight automotive parts

Influence of laser assisted single point incremental forming on the accuracy of shallow sloped parts

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