New approach to gas pressure profile prediction for high temperature AA5083 sheet forming

Jarrar, Firas; Hector, Louis G.; Khraisheh, Marwan; Bower, Allan F.

doi:10.1016/j.jmatprotec.2010.01.002

Cited by 36 publications

(21 citation statements)

References 11 publications

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“…As a result, however, with such high friction, more thinning will occur at the die bottom corner (for example see point C), as it is the last part of the sheet to get in contact with the die. This behavior noticed here is consistent with that described by Jarrar et al (2010) and Albakri et al (2011). Thickness uniformity throughout the formed part can be quantified using the thinning factor, which is defined as the ratio of the minimum thickness to the average thickness of the formed sheet.…”

Section: Superplastic Formability Of Fins With Triangular Cross Sectisupporting

confidence: 89%

“…It was found by a number of researchers (Jarrar, Hector Jr., Khraisheh, & Bower, 2010), (Ghosh & Hamilton, 1980), (Harrison, Luckey, Friedman, & Xia, 2004), and (Albakri, Jarrar, & Khraisheh, 2011) that the friction conditions at the die-sheet interface strongly affect the metal flow and thus the thickness distribution during the forming process. Therefore, the SPF process of an AA5083 sheet into fins with triangular cross sections based on the dimensions from the pressure drop analysis was simulated under different friction conditions.…”

Section: Superplastic Formability Of Fins With Triangular Cross Sectimentioning

confidence: 99%

See 1 more Smart Citation

Design for Manufacturing of an Aluminum Superplastic AA5083 Alloy Plate-Fin Heat Exchanger

Juneidi¹,

Asha²,

Jarrar³

et al. 2016

JMSR

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Compact, lightweight, strong, and corrosion-resistant heat exchangers are required for many applications. In heat exchangers, plate-fin exchangers design with corrugated fins of triangular cross-sections provide high heat transfer surface area to volume ratio. This study focuses on the design for manufacturing of an aluminum AA5083 alloy plate-fin heat exchanger. The superplastic forming method is considered for the fabrication of the heat exchanger. A two-dimensional plane strain finite element model is used to study the effect of the triangular fins' aspect ratio on the thickness distribution and the required gas forming pressure cycles. The simulation results show that the thinning in deep channels can be improved by increasing the coefficient of friction but only up to a certain limit. In addition, increasing the coefficient of friction reduces the required applied pressure on the sheet and increases the forming time. The present effort represents a necessary step toward the design of sophisticated corrugated triangular fin surfaces considering both performance and manufacturability.

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Section: Superplastic Formability Of Fins With Triangular Cross Sectisupporting

confidence: 89%

Section: Superplastic Formability Of Fins With Triangular Cross Sectimentioning

confidence: 99%

Design for Manufacturing of an Aluminum Superplastic AA5083 Alloy Plate-Fin Heat Exchanger

Juneidi¹,

Asha²,

Jarrar³

et al. 2016

JMSR

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show abstract

“…In the studies of W. J. Kim [13] and F.S. Jarrar [28], the Coulomb friction model was used for all contact surfaces with the coefficient of 0.1 at 400-450°C and the experimental results were good agree with the simulation results. Considering a higher temperature in this study, the friction coefficient of 0.12 was adopted.…”

Section: Methodsmentioning

confidence: 80%

Loading path and microstructure study of Ti-3Al-2.5V tubular components within hot gas forming at 800 °C

Liu

Wang

et al. 2016

Int J Adv Manuf Technol

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Hot tube gas forming is a forming technology, whose ultimate goal is forming a uniform cross-section blank tube into a complex shape die cavity with varying crosssections without necking, wrinkling, or buckling by applying of axial feeding and internal pressure at elevated temperature. In this paper, the effects of feeding speed and internal pressure on the quality of formed tubular components were studied by theoretical analysis, FEM simulation, and experiment. The microstructure evolutions at four typical positions were analyzed by electron back-scattered diffraction (EBSD). The mechanical properties of tubular component were tested by the uniaxial tensions and hardness tests. A good tubular component can be formed under a two-stage loading path at 800°C, the feeding speed is 0.1 mm/s and the internal pressure is 5 MPa during the first feeding stage while the feeding speed is 0.2 mm/s and the internal pressure is 7 MPa during the second feeding stage. At the forming zone, the grains are significantly elongated along the hoop direction. Compared with the as-received tube, the tensile strength of parts reduces about 6 % along axial direction.Titanium alloys are found extensive applications including aerospace, marine, chemical, and medical industries due to their excellent properties such as good high temperature performance, high specific strength, good creep resistance, biocompatibility, and good corrosion resistance [1]. Ti-alloy complex tubular components are widely used in petrochemical equipment, vehicle exhaust system, sports equipment and piping system of ship, air-inlet system, and hydraulic control system of aerospace and aviation [2, 3]. However, for titanium alloy, it is hard to be formed at room temperature because of high springback and low plasticity. The problems can be counteracted by improving the forming temperature. In recent years, superplastic forming (SPF) were popularly used to form complex components at elevated temperature [1,4,5]. Nevertheless, the disadvantages of localized thinning, expensive microstructure refining processing, low productive efficiency, and high deforming temperature in superplastic forming limit applications of Ti-alloy SPF. Thus, it is urgent need to develop a forming technology with low energy consumption, high efficiency, and without microstructure refining processing.Quick plastic forming, developed by General Motors to form AA5083 aluminum automobile body panels, affords comparable capabilities yet at higher production rates due to lower forming temperature, higher strain rates, and without refining grains [5,6]. R. Neugebauer [7], A.W. Dykstr [8], W. Xin [9], and B. Dykstra [10] set up hot metal gas forming (HMGF), and mainly investigated and applied the process on forming of aluminum and magnesium alloy components. J. Liu [11,12], utilizing the mechanical pre-forming, investigated the AA5083 sheet gas forming using argon gas at 400°C. W.J. Kim [13] formed an Al-Mg-Cr aluminum suspension component successfully at 520°C under a constant gas pressure of 7 MPa d...

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“…This effect was clearly predicted by the simulation results. The behavior of thinning in the vicinity of the die entry radius has been reported by many researchers [24,[31][32][33]. It is attributed to the combined compression and bending effects caused by the small die entry radius, which usually takes place at the beginning of the forming process.…”

Section: Spf a Cup With A Cylindrical Bossmentioning

confidence: 88%

An Accurate Constitutive Model for AZ31B Magnesium Alloy during Superplastic Forming

Dai

Jarrar

Öztürk

et al. 2019

Metals

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Accurate constitutive material models are essential for the realistic simulation of metal forming processes. However, for superplastic forming, mostly the material models found in the literature are based on fitting of the simple power law equation. In this study, an AZ31B constitutive model that takes into account microstructural evolution is introduced. This model takes into account grain growth and cavity formation in addition to strain and strain rate hardening. The model parameters were calibrated using the results of high temperature bulge forming tests and microstructural analysis. The Taguchi optimization method was used in the fitting process. In order to verify the model, simulations of the superplastic forming of two different geometries were carried out, and the results were compared with those obtained experimentally. Results show that the proposed model can accurately predict the formed geometry and thickness distribution.

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New approach to gas pressure profile prediction for high temperature AA5083 sheet forming

Cited by 36 publications

References 11 publications

Design for Manufacturing of an Aluminum Superplastic AA5083 Alloy Plate-Fin Heat Exchanger

Design for Manufacturing of an Aluminum Superplastic AA5083 Alloy Plate-Fin Heat Exchanger

Loading path and microstructure study of Ti-3Al-2.5V tubular components within hot gas forming at 800 °C

An Accurate Constitutive Model for AZ31B Magnesium Alloy during Superplastic Forming

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