Research Papers: FORMING

Forming of Al 5182-O in a Servo Press at Room and Elevated Temperatures

[+] Author and Article Information
Long Ju

School of Mechanical Engineering,
University of Science and Technology Beijing,
30 Xueyuan Road,
Haidian, Beijing 100083, China
e-mail: ju.64@osu.edu

Shrinivas Patil

Aida-America Corporation,
7660 Center Point 70 Boulevard,
Dayton, OH 45424
e-mail: spatil@aida-america.com

Jim Dykeman

Honda R&D Americas, Inc.,
21001 State Route 739,
Raymond, OH 43067-9705
e-mail: JDykeman@oh.hra.com

Taylan Altan

Center for Precision Forming,
The Ohio State University,
339 Baker Systems,
1971 Neil Avenue,
Columbus, OH 43210
e-mail: altan.1@osu.edu

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received January 8, 2015; final manuscript received March 26, 2015; published online September 4, 2015. Assoc. Editor: Yannis Korkolis.

J. Manuf. Sci. Eng 137(5), 051009 (Sep 04, 2015) (7 pages) Paper No: MANU-15-1015; doi: 10.1115/1.4030334 History: Received January 08, 2015

Aluminum alloys are increasingly used in automotive manufacturing to save weight. The drawability of Al 5182-O has been proven at room temperature (RT) and it is also shown that formability is further enhanced at elevated temperatures (ETs) in the range of 250–350 °C. A cost effective application of ET forming of Al alloys can be achieved using heated blank and cold dies (HB–CD). In this study, the material behavior of Al 5182-O is characterized using tensile test and viscous bulge test at RT. The nonisothermal finite element model (FEM) of deep drawing is developed using the commercial software pamstamp. Initially, deep drawing simulations and tests were carried out at RT using a 300 ton servo press, with a hydraulic cushion. The predictions with flow stress curves obtained from tensile and bulge tests were compared with experimental data. The effect of punch speed and temperature rise during forming at RT is investigated. The warm forming simulations were carried out by combining material data at ETs obtained from the literature. The coupled effects of sheet temperatures and punch speeds are investigated through the finite element analysis (FEA) to provide guidelines for ET stamping of Al 5182-O.

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Fig. 1

Schematic of VPB test [18]: before forming and after forming

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Fig. 2

Flow stress curves of Al 5182-O obtained from tensile and VPB tests at RT

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Fig. 3

Flow stress curves from tensile tests at different strain rates for ETs: (a) 100 °C, (b) 200 °C, and (c) 300 °C [7]

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Fig. 4

Top and cross-sectional view of deep drawing tooling, dimensions are in mm (R1 = 1501.6, R2 = 1998.4, R3 = 51.6, R4 = 55.6, R5 = 61.6, R6 = 66.6, R7 = 20, and R8 = 10)

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Fig. 5

Ram speed profiles with crank motion (1 SPM, 10 SPM, and 18 SPM) and nearly constant (50 mm/s and 310 mm/s) punch speed during deformation (Aida 300 ton servo press)

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Fig. 6

Flange perimeters measured from formed cups with various lubricants at BHF 16 ton

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Fig. 7

(a) 3D FEM of deep drawing process and (b) blank dimensions (mm)

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Fig. 8

Variation of HTC with contact pressure [20]

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Fig. 9

Test results and predicted punch force at RT: (a) formed part and (b) comparison of punch forces between experiment and FEM

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Fig. 10

Comparison of thickness variations: (a) selected corner sections A–D and (b) thinning variations from experiment and FE simulations

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Fig. 11

Results of deep drawing tests with a dry film lubricant under different forming speeds at RT, stroke 60.8 mm: (a) 50 mm/s, crack at lower right corner and (b) 310 mm/s, defect free formed part

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Fig. 12

Experimental and predicted load–stroke curves at forming speeds 50 mm/s and 310 mm/s

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Fig. 13

Estimated temperature distribution in the drawn part at forming speed 310 mm/s, stroke = 60 mm

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Fig. 14

Predicted temperature distributions in the drawn part along the selected sections E–J (Fig. 13) at different forming speeds, stroke = 60 mm

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Fig. 15

The effect of initial sheet temperature on the thinning distribution in the part corner, forming speed 310 mm/s, punch stroke 75 mm (locations A, B, C, and D are shown in Fig. 10(a))

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Fig. 16

The effect of forming speed on the thickness distribution in the part corner, initial sheet temperature 200 °C, punch stroke 75 mm (simulation)

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Fig. 17

Temperature distribution in the part under forming speed: (a) 50 mm/s and (b) 310 mm/s, initial sheet temperature 200 °C, punch stroke 75 mm (simulation)



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