Search results for: Formability.

Authors: K. Rattanachan

Abstract:

In sheet metal forming process, raw material mechanical properties are important parameters. This paper is to compare the wall’s incline angle or formability of SS 400 steel and SUS 304 stainless steel in single point incremental forming. The two materials are ferrous base alloyed, which have the different unit cell, mechanical property and chemical composition. They were forming into cone shape specimens having 100 mm diameter with different wall’s incline angle: 90o, 75o and 60o. The investigation was continued until the specimens formed surface facture. The experimental result showed that the smaller the wall incline angle higher the formability with the both materials. The formability limit of the ferrous base alloy was approx. 60o wall’s incline angle. By nature, SS 400 has higher formability than SUS 304. This result can be used as the initial data in designing the single point incremental forming parts.

Keywords: NC incremental forming, Single point incremental forming, Wall incline angle, Formability.

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Authors: Basavaraj Vadavadagi, Satishkumar Shekhawat

Abstract:

Interstitial free steels possess better formability and have many applications in automotive industries. Forming limit diagrams (FLDs) indicate the formability of materials which can be determined by experimental and finite element (FE) simulations. FLDs were determined experimentally by LDH test, utilizing optical strain measurement system for measuring the strains in different width specimens and by FE simulations in Interstitial Free (IF) and Interstitial Free High Strength (IFHS) steels. In this study, the experimental and FE simulated FLDs are compared and also the stress based FLDs were investigated.

Keywords: Forming limit diagram, Limiting Dome Height, optical strain measurement, interstitial

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Authors: Eshwara K. Prasad, Raman R. Goud, Swadesh Kumar Singh, N. Sateesh

Abstract:

In the present work, forming limit diagrams and strain distribution profile diagrams for extra deep drawing steel at room and elevated temperatures have been determined experimentally by conducting stretch forming experiments by using designed and fabricated warm stretchforming tooling setup. With the help of forming Limit Diagrams (FLDs) and strain, distribution profile diagrams the formability of Extra Deep Drawing steel has been analyzed and co-related with mechanical properties like strain hardening COEFFICIENT (n) and normal anisotropy (r−). Mechanical properties of EDD steel from room temperature to 4500C were determined and discussed the impact of temperature on the properties like work hardening exponent (n) anisotropy (r-) and strength coefficient of the material. In addition, the fractured surfaces after stretching have undergone the some metallurgical investigations and attempt has been made to co-relate with the formability of EDD steel sheets. They are co-related and good agreement with FLDs at various temperatures.

Keywords: FLD, microhardness, strain distribution profile, stretch forming.

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Authors: Talal S. Abdullah, Shahin Mehraban, Geraint Lodwig, Nicholas P. Lavery

Abstract:

The defining property of Interstitial Free (IF) steels is formability, comprehensively measured using the Lankford coefficient (r-value) on uniaxial tensile test data. The contributing factors supporting this feature are grain size, orientation, and elemental additions. The processes that effectively modulate these factors are the casting procedure, hot rolling, and heat treatment. An existing methodology is well-practised in the steel industry; however, large-scale production and experimentation consume significant proportions of time, money, and material. Introducing small-scale rapid alloy prototyping (RAP) as an alternative process would considerably reduce the drawbacks relative to standard practices. The aim is to finetune the existing fundamental procedures implemented in the industrial plant to adapt to the RAP route. IF material is remelted in the 80-gram coil induction melting (CIM) glovebox. To birth small grains, maximum deformation must be induced onto the cast material during the hot rolling process. The rolled strip must then satisfy the polycrystalline behaviour of the bulk material by displaying a resemblance in microstructure, hardness, and formability to that of the literature and actual plant steel. A successful outcome of this work is that small-scale RAP can achieve target compositions with similar microstructures and statistically consistent mechanical properties which complements and accelerates the development of novel steel grades.

Keywords: Interstitial free, miniaturized tensile specimen, plastic anisotropy, rapid alloy prototyping.

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Authors: Nhat Khoa Tran, Yee Cheong Lam, Chee Yoon Yue, Ming Jen Tan

Abstract:

Metallic micro parts are playing an important role in micro-fabrication industry. Recently, we have demonstrated a new deformation mechanism for micro-formability of polycrystalline materials. Different depressed micro-features smaller than the grain size have been successfully fabricated on 6061 aluminum alloy (AA6061) substrates with good fidelity. To further verify this proposed deformation mechanism that grain size is not a limiting factor, we demonstrate here that in addition of depressed features, protruded micro-features on a polycrystalline substrate can similarly be fabricated.

Keywords: Deformation mechanism, grain size, microfabrication, polycrystalline materials.

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Authors: D. H. Park, Y. H. Tak, H. H. Kwon, G. J. Kwon, H. G. Kim

Abstract:

The purpose of this study is to develop a forging process of automotive parts that satisfies the deformation characteristics. The analyses of temperature variation and deformation behavior of the material are important to obtain the optimal forging products. The hot compression test was carried out to know formability at high temperature. In order to define the optimum forging conditions including material temperature, strain and forging load, the commercial finite element analysis code was used to simulate the forging procedure of engine mounting parts. Experimental results were compared with the simulation results by finite element analysis. Test results were in good agreement with the simulations.

Keywords: Cold forging, hot forging, engine mounting, automotive parts, optimization.

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Authors: Morteza Khaleghi Meybodi, Hossein Bisadi

Abstract:

Explosive forming is one of the unconventional techniques in which, most commonly, the water is used as the pressure transmission medium. One of the newest methods in explosive forming is gas detonation forming which uses a normal shock wave derived of gas detonation, to form sheet metals. For this purpose a detonation is developed from the reaction of H2+O2 mixture in a long cylindrical detonation tube. The detonation wave goes through the detonation tube and acts as a blast load on the steel blank and forms it. Experimental results are compared with a finite element model; and the comparison of the experimental and numerical results obtained from strain, thickness variation and deformed geometry is carried out. Numerical and experimental results showed approximately 75 – 90 % similarity in formability of desired shape. Also optimum percent of gas mixture obtained when we mix 68% H2 with 32% O2.

Keywords: Explosive forming, High strain rate, Gas detonation, Finite element analysis.

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Authors: S. Onoda, S. Yoshihara, B. J. MacDonald, Y. Okude

Abstract:

Aluminum alloy sheets have several advantages such as the lightweight, high-specific strength and recycling efficiency. Therefore, aluminum alloy sheets in sheet forming have been used in various areas as automotive components and so forth. During the process of sheet forming, wrinkling which is caused by compression stress might occur and the formability of sheets was affected by occurrence of wrinkling. A few studies of uniaxial compressive test by using square tubes, pipes and sheets were carried out to clarify the each wrinkling behavior. However, on uniaxial compressive test, deformation behavior of the sheets hasn-t be cleared. Then, it is necessary to clarify the relationship between the buckling behavior and the forming conditions. In this study, the effect of dimension of the sheet in the buckling behavior on compression test of aluminum alloy sheet was cleared by experiment and FEA. As the results, the buckling deformation was classified by three modes in terms of the distribution of equivalent plastic strain.

Keywords: Sheet forming, Compression test, Aluminum alloy sheet, Buckling behavior

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Authors: Emrah Ersoy, Yusuf Özçatalbas

Abstract:

The aim of this study is to investigate formability of Al based closed cell metallic foams at high temperature. The foam specimens with rectangular section were produced from AlMg1Si0.6TiH20.8 alloy preform material. Bending and free bending tests based on gravity effect were applied to foam specimens at high temperatures. During the tests, the time-angular deformation relationships with various temperatures were determined. Deformation types formed in cell walls were investigated by means of Scanning Electron Microscopy (SEM) and optical microscopy. Bending deformation about 90° was achieved without any defect at high temperatures. The importance of a critical temperature and deformation rate was emphasized in maintaining the deformation. Significant slip lines on surface of cell walls at tensile zones of bending specimen were observed. At high strain rates, the microcrack formation in boundaries of elongated grains was determined.

Keywords: Al alloy, Closed cell, hot deformation, metallic foam.

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Authors: Hossein Mamusi, Abolfazl Masoumi, Ramezanali Mahdavinezhad

Abstract:

Tailor-welded Blanks (TWBs) are tailor made for different complex component designs by welding multiple metal sheets with different thicknesses, shapes, coatings or strengths prior to forming. In this study the Hemispherical Die Stretching (HDS) test (out-of-plane stretching) of TWBs were simulated via ABAQUS/Explicit to obtain the Forming Limit Diagrams (FLDs) of Stainless steel (AISI 304) laser welded blanks with different thicknesses. Two criteria were used to detect the start of necking to determine the FLD for TWBs and parent sheet metals. These two criteria are the second derivatives of the major and thickness strains that are given from the strain history of simulation. In the other word, in these criteria necking starts when the second derivative of thickness or major strain reaches its maximum. With having the time of onset necking, one can measure the major and minor strains at the critical area and determine the forming limit curve.

Keywords: TWB, Forming Limit Diagram, Necking criteria, ABAQUS/Explicit

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Authors: Lucie Novakova, Petr Homola, Vaclav Kafka

Abstract:

Asymmetric incremental sheet forming (AISF) could significantly reduce costs incurred by the fabrication of complex industrial components with a minimal environmental impact. The AISF experiments were carried out on commercially pure titanium (Ti-Gr2), Timetal (15-3-3-3) alloy, and Ti-6Al-4V (Ti-Gr5) alloy. A special testing geometry was used to characterize the titanium alloys properties from the point of view of the forming zone and titanium structure effect. The structure and properties of the materials were assessed by means of metallographic analyses and microhardness measurements.The highest differences in the parameters assessed as a function of the sampling zone were observed in the case of alpha-phase Ti-Gr2at the expense of the most substantial sheet thinning occurrence. A springback causes a smaller stored deformation in Timetal (β alloy) resulting in less pronounced microstructure refinement and microhardness increase. Ti-6Al-4V alloy exhibited early failure due to its poor formability at ambient temperature.

 

Keywords: Incremental forming, metallography, hardness, titanium alloys.

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Authors: Lakshman Singh, Rajeshwar Singh, Naveen Kumar Singh, Davinder Singh, Pargat Singh

Abstract:

Tungsten Inert Gas (TIG) welding is a high quality welding process used to weld the thin metals and their alloy. 5083 Aluminium alloys play an important role in engineering and metallurgy field because of excellent corrosion properties, ease of fabrication and high specific strength coupled with best combination of toughness and formability.

TIG welding technique is one of the precise and fastest processes used in aerospace, ship and marine industries. TIG welding process is used to analyze the data and evaluate the influence of input parameters on tensile strength of 5083 Al-alloy specimens with dimensions of 100mm long x 15mm wide x 5mm thick. Welding current (I), gas flow rate (G) and welding speed (S) are the input parameters which effect tensile strength of 5083 Al-alloy welded joints. As welding speed increased, tensile strength increases first till optimum value and after that both decreases by increasing welding speed further. Results of the study show that maximum tensile strength of 129 MPa of weld joint are obtained at welding current of 240 Amps, gas flow rate of 7 Lt/min and welding speed of 98 mm/min. These values are the optimum values of input parameters which help to produce efficient weld joint that have good mechanical properties as a tensile strength.

Keywords: 5083 Aluminium alloy, Gas flow rate, TIG welding, Welding current, Welding speed and Tensile strength.

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Authors: A. Soualem

Abstract:

The design of multi stage deep drawing processes requires the evaluation of many process parameters such as the intermediate die geometry, the blank shape, the sheet thickness, the blank holder force, friction, lubrication etc..These process parameters have to be determined for the optimum forming conditions before the process design. In general sheet metal forming may involve stretching drawing or various combinations of these basic modes of deformation. It is important to determine the influence of the process variables in the design of sheet metal working process. Especially, the punch and die corner for deep drawing will affect the formability. At the same time the prediction of sheet metals springback after deep drawing is an important issue to solve for the control of manufacturing processes. Nowadays, the importance of this problem increases because of the use of steel sheeting with high stress and also aluminum alloys.

The aim of this paper is to give a better understanding of the springback and its effect in various sheet metals forming process such as expansion and restreint deep drawing in the cup drawing process, by varying radius die, lubricant for two commercially available materials e.g. galvanized steel and Aluminum sheet. To achieve these goals experiments were carried out and compared with other results. The original of our purpose consist on tests which are ensured by adapting a U-type stretching-bending device on a tensile testing machine, where we studied and quantified the variation of the springback.

Keywords: Deep drawing, Expansion, Restreint deep drawing, Springback.

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Authors: M. C. Cardoso, L. P. Moreira

Abstract:

In this work, the plastic behaviour of cold-rolled zinc coated dual-phase steel sheets DP600 and DP800 grades is firstly investigated with the help of uniaxial, hydraulic bulge and Forming Limit Curve (FLC) tests. The uniaxial tensile tests were performed in three angular orientations with respect to the rolling direction to evaluate the strain-hardening and plastic anisotropy. True stressstrain curves at large strains were determined from hydraulic bulge testing and fitted to a work-hardening equation. The limit strains are defined at both localized necking and fracture conditions according to Nakajima’s hemispherical punch procedure. Also, an elasto-plastic localization model is proposed in order to predict strain and stress based forming limit curves. The investigated dual-phase sheets showed a good formability in the biaxial stretching and drawing FLC regions. For both DP600 and DP800 sheets, the corresponding numerical predictions overestimated and underestimated the experimental limit strains in the biaxial stretching and drawing FLC regions, respectively. This can be attributed to the restricted failure necking condition adopted in the numerical model, which is not suitable to describe the tensile and shear fracture mechanisms in advanced high strength steels under equibiaxial and biaxial stretching conditions.

Keywords: Advanced high strength steels, forming limit curve, numerical modeling, sheet metal forming.

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Authors: A. Fallahi, R. Khamedi

Abstract:

Dual phase steels (DPS)s have a microstructure consisting of a hard second phase called Martensite in the soft Ferrite matrix. In recent years, there has been interest in dual-phase steels, because the application of these materials has made significant usage; particularly in the automotive sector Composite microstructure of (DPS)s exhibit interesting characteristic mechanical properties such as continuous yielding, low yield stress to tensile strength ratios(YS/UTS), and relatively high formability; which offer advantages compared with conventional high strength low alloy steels(HSLAS). The research dealt with the characterization of damage in (DPS)s. In this study by review the mechanisms of failure due to volume fraction of martensite second phase; a new method is introduced to identifying the mechanisms of failure in the various phases of these types of steels. In this method the acoustic emission (AE) technique was used to detect damage progression. These failure mechanisms consist of Ferrite-Martensite interface decohesion and/or martensite phase fracture. For this aim, dual phase steels with different volume fraction of martensite second phase has provided by various heat treatment methods on a low carbon steel (0.1% C), and then AE monitoring is used during tensile test of these DPSs. From AE measurements and an energy ratio curve elaborated from the value of AE energy (it was obtained as the ratio between the strain energy to the acoustic energy), that allows detecting important events, corresponding to the sudden drops. These AE signals events associated with various failure mechanisms are classified for ferrite and (DPS)s with various amount of Vm and different martensite morphology. It is found that AE energy increase with increasing Vm. This increasing of AE energy is because of more contribution of martensite fracture in the failure of samples with higher Vm. Final results show a good relationship between the AE signals and the mechanisms of failure.

Keywords: Dual phase steel (DPS)s, Failure mechanisms, Acoustic Emission, Fracture strain energy to the acoustic energy.

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Authors: Shanawaz Patil, Mohamed Haneef, K. S. Narayanaswamy

Abstract:

In the recent years, aluminum metal matrix composites were most widely used, which are finding wide applications in various field such as automobile, aerospace defense etc., due to their outstanding mechanical properties like low density, light weight, exceptional high levels of strength, stiffness, wear resistance, high temperature resistance, low coefficient of thermal expansion and good formability. In the present work, an effort is made to study the effect of heat treatment on mechanical properties of aluminum 7075 alloy reinforced with constant weight percentage of naturally occurring mineral beryl and varying weight percentage of graphene. The hybrid composites are developed with 0.5 wt. %, 1wt.%, 1.5 wt.% and 2 wt.% of graphene and 6 wt.% of beryl  by stir casting liquid metallurgy route. The cast specimens of unreinforced aluminum alloy and hybrid composite samples were prepared for heat treatment process and subjected to solutionizing treatment (T6) at a temperature of 490±5 ^oC for 8 hours in a muffle furnace followed by quenching in boiling water. The microstructure analysis of as cast and heat treated hybrid composite specimens are examined by scanning electron microscope (SEM). The tensile test and hardness test of unreinforced aluminum alloy and hybrid composites are examined. The wear behavior is examined by pin-on disc apparatus. The results of as cast specimens and heat treated specimens were compared. The heat treated Al7075-Beryl-Graphene hybrid composite had better properties and significantly improved the ultimate tensile strength, hardness and reduced wear loss when compared to aluminum alloy and  as cast hybrid composites.

Keywords: Beryl, graphene, heat treatment, mechanical properties.

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Authors: S. S. Sharma, P. R. Prabhu, K. Jagannath, Achutha Kini U., Gowri Shankar M. C.

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In present global scenario, aluminum alloys are coining the attention of many innovators as competing structural materials for automotive and space applications. Comparing to other challenging alloys, especially, 7xxx series aluminum alloys have been studied seriously because of benefits such as moderate strength; better deforming characteristics and affordable cost. It is expected that substitution of aluminum alloys for steels will result in great improvements in energy economy, durability and recyclability. However, it is necessary to improve the strength and the formability levels at low temperatures in aluminum alloys for still better applications. Aluminum–Zinc–Magnesium with or without other wetting agent denoted as 7XXX series alloys are medium strength heat treatable alloys. In addition to Zn, Mg as major alloying additions, Cu, Mn and Si are the other solute elements which contribute for the improvement in mechanical properties by suitable heat treatment process. Subjecting to suitable treatments like age hardening or cold deformation assisted heat treatments; known as low temperature thermomechanical treatments (LTMT) the challenging properties might be incorporated. T6 is the age hardening or precipitation hardening process with artificial aging cycle whereas T8 comprises of LTMT treatment aged artificially with X% cold deformation. When the cold deformation is provided after solution treatment, there is increase in hardness related properties such as wear resistance, yield and ultimate strength, toughness with the expense of ductility. During precipitation hardening both hardness and strength of the samples are increasing. The hardness value may further improve when room temperature deformation is positively supported with age hardening known as thermomechanical treatment. It is intended to perform heat treatment and evaluate hardness, tensile strength, wear resistance and distribution pattern of reinforcement in the matrix. 2 to 2.5 and 3 to 3.5 times increase in hardness is reported in age hardening and LTMT treatments respectively as compared to as-cast composite. There was better distribution of reinforcements in the matrix, nearly two fold increase in strength levels and up to 5 times increase in wear resistance are also observed in the present study.

Keywords: Reinforcement, precipitation, thermomechanical, dislocation, strain hardening.

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