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Research Papers

Improvement in Material Flow During Nonisothermal Warm Deep Drawing of Nonheat Treatable Aluminum Alloy Sheets

[+] Author and Article Information
Sudhy S. Panicker

Department of Mechanical Engineering,
Indian Institute of Technology-Kharagpur,
Kharagpur 721302, West Bengal, India
e-mail: sudhyspanicker@gmail.com

Sushanta Kumar Panda

Associate Professor
Department of Mechanical Engineering,
Indian Institute of Technology-Kharagpur,
Kharagpur 721302, West Bengal, India
e-mail: sushanta.panda@mech.iitkgp.ernet.in

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received August 17, 2016; final manuscript received August 25, 2016; published online October 6, 2016. Editor: Y. Lawrence Yao.

J. Manuf. Sci. Eng 139(3), 031013 (Oct 06, 2016) (8 pages) Paper No: MANU-16-1441; doi: 10.1115/1.4034594 History: Received August 17, 2016; Revised August 25, 2016

Automotive industries are very much interested in implementing warm forming technology for fabrication of light weight auto-body panels using aluminum alloys without localized thinning or splitting. A nonheat treatable and low formable AA5754-H22 aluminum alloy sheet was selected in the present work, and a laboratory scale warm deep drawing test set-up and process sequences were designed to improve material flow through independent heating of punch and dies. Significant enhancement in cup depth was observed when the temperature of punch and dies were set to 30 °C and 200 °C, respectively. Thermo-mechanical finite-element (FE) model of the nonisothermal deep drawing test was developed successfully to study the improvement in material flow incorporating Barlat-89 yield theory using temperature dependent anisotropy coefficients and Cowper–Symonds hardening model. It was found that a nonisothermal temperature gradient of approximately 93 °C was established within the blank from the center to flange at the start of deformation, and subsequent evolution of temperature gradient helped in improving material flow into the die cavity. The effect of temperature gradient on forming behavior in terms of cup height, ear profile, and thinning development across flange, cup wall, and blank center were predicted and validated with experimental results.

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Figures

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Fig. 1

Schematic of (a) experimental setup and (b) process sequence for typical warm deep drawing process

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Fig. 2

Comparison of the prediction of (a) yield strength, (b) Lankford's anisotropy parameters using Barlat-89 yield criterion, and (c) variation of Barlat-89 anisotropy coefficients with temperature

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Fig. 3

FE model of nonisothermal deep drawing

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Fig. 4

Cowper–Symonds curve fitting with experimental true stress–strain curve at two different strain rates and temperatures

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Fig. 5

Cup height validation: (a) isothermal and (b) nonisothermal deep drawing

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Fig. 6

Validation of thinning and comparison of evolution of thinning development

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Fig. 7

Major and minor strain distribution comparison at the final step of deformation

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Fig. 8

Earing profile development at different steps of deformation: (a) cup depth = 28.3 mm, (b) cup depth = 38.2 mm, and (c) cup depth = 41.42 mm

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Fig. 9

Temperature distribution at different deformation depths in nonisothermal deep drawing

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Fig. 10

True major strain at similar cup depths in cases of (a) isothermal and (b) nonisothermal deep drawing, and (c) comparison of strain evolution in both conditions

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