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Research Papers

Research on Cold Orbital Forming of Complex Sheet Metal of Aluminum Alloy

[+] Author and Article Information
Xinghui Han

Hubei Key Laboratory of Advanced Technology
for Automotive Components,
Wuhan University of Technology,
Wuhan 430070, China

Qiu Jin

School of Materials Science and Engineering;Hubei Key Laboratory of Advanced Technology
for Automotive Components,
Wuhan University of Technology,
Wuhan 430070, China

Lin Hua

Hubei Key Laboratory of Advanced Technology for Automotive Components,
Wuhan University of Technology,
Wuhan 430070, China

1Corresponding author.

Manuscript received April 19, 2016; final manuscript received October 27, 2016; published online January 31, 2017. Assoc. Editor: Yannis Korkolis.

J. Manuf. Sci. Eng 139(6), 061013 (Jan 31, 2017) (9 pages) Paper No: MANU-16-1230; doi: 10.1115/1.4035124 History: Received April 19, 2016; Revised October 27, 2016

This study aims at exploring the potentialities of cold orbital forming in forming complex sheet metal. Aiming at a complex mobile phone shell component of aluminum alloy, two technical schemes for cold orbital forming are first presented. Then, the optimized one, i.e., the more complex inner surface of mobile phone shell is arranged to be formed by the rocking punch with a complex motion, is determined by analyzing the nonuniform plastic deformation laws and punch filling behaviors. On the basis of the optimized technical scheme, the blank geometry in cold orbital forming of mobile phone shell is also optimized based on the forming status of the most difficult forming zone. The consistent finite element (FE) simulated and experimental results indicate that under the optimized technical scheme, not only the bosses in the mobile phone shell are fully formed but also the obtained flow lines are reasonable, which proves that the technical scheme presented in this study is feasible and cold orbital forming exhibits huge potentialities in forming complex sheet metal.

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Figures

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Fig. 1

Experimental aluminum alloy mobile phone shell in cold orbital forming (The flash has been cut): (a) Inner surface and (b) outer surface

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Fig. 2

Solid model of cold orbital forming

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Fig. 3

Non-axisymmetric rocking punches in cold orbital forming of mobile phone shell under the two technical schemes: (a) The first technical scheme and (b) the second technical scheme

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Fig. 4

Three-dimensional FE models for cold orbital forming of mobile phone shell under the two technical schemes: (a) 3D FE model under the first technical scheme and (b) 3D FE model under the second technical scheme

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Fig. 5

Stress versus strain relation of annealed 6063 aluminum alloy

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Fig. 6

Geometry evolution of the cross section of mobile phone shell in cold orbital forming under the first technical scheme: (a) t = 0 s, (b) t = 0.422 s, (c) t = 0.685 s, (d) t = 0.802 s, (e) t = 0.894 s, (f) t = 1.05 s, (g) t = 1.30 s, and (h) t = 1.45 s

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Fig. 7

Geometry evolution of the horizontal plane of mobile phone shell in cold orbital forming under the first technical scheme: (a) t = 0 s, (b) t = 0.422 s, (c) t = 0.685 s, (d) t = 0.802 s, (e) t = 0.894 s, (f) t = 1.05 s, (g) t = 1.30 s, and (h) t = 1.45 s

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Fig. 8

Geometry evolution of the cross section of mobile phone shell in cold orbital forming under the second technical scheme: (a) t = 0 s, (b) t = 0.422 s, (c) t = 0.685 s, (d) t = 0.802 s, (e) t = 0.894 s, (f) t = 1.05 s, (g) t = 1.30 s, and (h) t = 1.45 s

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Fig. 9

Geometry evolution of the horizontal plane of mobile phone shell in cold orbital forming under the second technical scheme: (a) t = 0 s, (b) t = 0.422 s, (c) t = 0.685 s, (d) t = 0.802 s, (e) t = 0.894 s, (f) t = 1.05 s, (g) t = 1.30 s, and (h) t = 1.45 s

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Fig. 10

Final heights of three selected bosses in the inner surface of mobile phone shell under the two technical schemes

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Fig. 11

Schematic diagram of metal flow in the tangential direction in cold orbital forming of mobile phone shell

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Fig. 12

Forming status of the top left corners of mobile phone shell under the two technical schemes: (a) The first technical scheme and (b) the second technical scheme

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Fig. 13

Schematic diagram of the combined lower punch

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Fig. 14

Experimental punches in cold orbital forming of mobile phone shell: (a) Rocking punch, (b) combined lower punch, and (c) movable punch

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Fig. 15

FE simulated and experimental mobile phone shells when the thickness of the blank is 5 mm: (a) FE simulated mobile phone shells during the cold orbital forming process and (b) experimental mobile phone shells during the cold orbital forming process

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Fig. 16

FE simulated and experimental mobile phone shells when the thickness of the blank is 4.8 mm: (a) FE simulation and (b) experiment

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Fig. 17

FE simulated and experimental mobile phone shells when the thickness of the blank is 4.6 mm: (a) FE simulation and (b) experiment

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Fig. 18

Flow line photos of some bosses in the cold orbital formed mobile phone shell

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Fig. 19

Forming load comparison between cold orbital forming and traditional upsetting of mobile phone shell

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