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Research Papers

Thermal Response Modeling of Sheet Metals in Uniaxial Tension During Electrically-Assisted Forming

[+] Author and Article Information
Laine Mears

Department of Automotive Engineering,
Clemson University,
Greenville, SC 29607

Contributed by the Manufacturing Engineering Division of ASME for publication in the Journal of Manufacturing Science and Engineering. Manuscript received May 1, 2012; final manuscript received December 28, 2012; published online March 22, 2013. Assoc. Editor: Brad L. Kinsey.

J. Manuf. Sci. Eng 135(2), 021011 (Mar 22, 2013) (11 pages) Paper No: MANU-12-1133; doi: 10.1115/1.4023366 History: Received May 01, 2012; Revised December 28, 2012

For the current practice of improving fuel efficiency and reducing emissions in the automotive sector, it is becoming more common to use low density/high strength materials instead of costly engine/drivetrain technologies. With these materials there are normally many manufacturing difficulties that arise during their incorporation to the vehicle. As a result, new processes which improve the manufacturability of these materials are necessary. This work examines the manufacturing technique of electrically-assisted forming (EAF) where an electrical current is applied to the workpiece during deformation to modify the material's formability. In this work, the thermal response of sheet metal for stationary (i.e., no deformation) and deformation tests using this process are explored and modeled. The results of the model show good agreement for the stationary tests while for the deformation tests, the model predicts that all of the applied electrical current does not generate Joule heating. Thus, this work suggests from the observed response that a portion of the applied current may be directly aiding in deformation (i.e., the electroplastic effect). Additionally, the stress/strain response of Mg AZ31 under tensile forming using EAF is presented and compared to prior experimental work for this material.

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References

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Figures

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Fig. 1

Stationary thermal model schematic

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Fig. 2

Stationary model solution schematic

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Fig. 3

Linearized experimental strain data for parameter set 4 at failure (left) and corresponding input length strain surface (right)

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Fig. 4

Experimental testing setup

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Fig. 5

Stationary test thermal sequence over one period for parameter set 4

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Fig. 6

Stationary maximum temperature response of experimental and model results for parameter set 4

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Fig. 7

Stationary axial length temperature profile of experimental and model results for parameter set 4

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Fig. 8

Stationary maximum temperature response of exp. and model results for remaining parameter sets

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Fig. 9

Experimental response of stationary and deformation results for parameter set 4

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Fig. 10

Maximum temperature comparison of deformation models to exp. results for parameter set 4

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Fig. 11

Axial comparison of deformation model to experimental results for parameter set 4

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Fig. 12

Thermal response surface for deformation models and exp. data as a function of time

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Fig. 13

Original and modified (40% decrease) linearized experimental strain data for parameter set 4 at failure

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Fig. 14

Strain input sensitivity for diffuse deformation model versus experimental results at first application of current

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Fig. 15

Strain input sensitivity for diffuse deformation model versus experimental results at 300 s

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Fig. 16

Strain input sensitivity for diffuse deformation model versus experimental results at 420 s

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Fig. 17

Flow stress responses for room temperature and eaf parameter set 4 forming

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Fig. 18

Flow stress reductions during electrical current application for varying parameter sets

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