A Novel Experimental Design to Obtain Forming Limit Diagram of Aluminium Alloys for Solution Heat Treatment, Forming and In-Die Quenching Process

Abstract:

Solution heat treatment, forming and in-die quenching (HFQ) is a patented process to form complex shape metal components at a high efficiency and a low cost. Conventional experiment approaches to determine forming limit curves (FLCs) at different strain paths are not applicable for the HFQ forming process. A novel biaxial tensile test rig is designed to overcome the difficulties and determine the FLCs at high temperatures based on the commercial Gleeble machine. This test device employs the circle plate and connecting rod mechanism in order to achieve different strain states, such as uniaxial tension, plane strain and biaxial tension. Resistance heating and air cooling are adopted to obtain an isothermal environment and to control cooling rates in Gleeble respectively. The designs of the cruciform specimen for this test are also introduced in this paper.

• Periodical: Key Engineering Materials (Volumes 622-623)
• Pages: 241-248
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.622-623.241
• Online since: September 2014
• Authors: Zhu Tao Shao*, Qian Bai, Jian Guo Lin
• Keywords: Constant Strain Rate, Controllable Cooling Rate, Forming Limit Diagram (FLD), HFQ Forming, Novel Experimental Design

References

[1] W.S. Miller, L. Zhuang, J. Bottema, A.J. Wittebrood, P. De Smet, A. Haszler, A. Vieregge, Recent development in aluminium alloys for the automotive industry, Materials Science and Engineering, 280 (2000) 37-49.

DOI: 10.1016/s0921-5093(99)00653-x

[2] K.R. Brown, M.S. Venie, R.A. Woods, The increasing use of aluminum in automotive applications, JOM, 47 (1995) 20-23.

DOI: 10.1007/bf03221224

[3] D. Banabic, F. Barlat, O. Cazacu, T. Kuwabara, Advances in anisotropy and formability, International Journal of Material Forming, 3 (2010) 165-189.

DOI: 10.1007/s12289-010-0992-9

[4] M.S. Mohamed, A.D. Foster, J. Lin, D.S. Balint, T.A. Dean, Investigation of deformation and failure features in hot stamping of AA6082: Experimentation and modelling, International Journal of Machine Tools and Manufacture, 53 (2012) 27-38.

DOI: 10.1016/j.ijmachtools.2011.07.005

[5] L. Wang, M. Strangwood, D. Balint, J. Lin, T.A. Dean, Formability and failure mechanisms of AA2024 under hot forming conditions, Materials Science and Engineering: A, 528 (2011) 2648-2656.

DOI: 10.1016/j.msea.2010.11.084

[6] E. Hsu, J.E. Carsley, R. Verma, Development of Forming Limit Diagrams of Aluminum and Magnesium Sheet Alloys at Elevated Temperatures, Journal of Materials Engineering and Performance, 17 (2008) 288-296.

DOI: 10.1007/s11665-007-9196-y

[7] S.P. Keeler, W.A. Backofen, Plastic instability and fracture in sheets stretched over rigid punches., ASM Transactions Quarterly, 56 (1963) 25-48.

[8] G.M. Goodwin, Application of Strain Analysis to Sheet-Metal-Forming Problems in the Press Shop, MET ITAL, 60 (1968) 767-774.

[9] T.Y. Olsen, Machines for ductility testing, Proceeding of the American Society of Materials, 20 (1920) 398-403.

[10] S.S. Hecker, A Simple Forming-Limit Curve Technique and Results on Aluminum Alloys, in: Procedings of the IDDRG Congress, Amsterdam, 1972, p.35.

[11] K. Nakazima, T. Kikuma, K. Hasuka, Study on the formability of steel sheets, in: Yawata Technical Report 264, 1968, p.8517–8530.

[12] Z. Marciniak, K. Kuczynski, Limit strains in the processes of stretch-forming sheet metal, International Journal of Mechanical Sciences, 9 (1967) 609-620.

DOI: 10.1016/0020-7403(67)90066-5

[13] K.S. Raghavan, A simple technique to generate in-plane forming limit curves and selected applications, Metallurgical and Materials Transactions A, 26 (1995) 2075-(2084).

DOI: 10.1007/bf02670679

[14] R.A. Ayres, M.L. Wenner, Strain and strain-rate hardening effects in punch stretching of 5182-0 aluminum at elevated temperatures, Metallurgical Transactions A, 10 (1979) 41-46.

DOI: 10.1007/bf02686404

[15] Z. Shi, Y. Wang, J. Lin, T. Dean, D. Balint, M. Stanton, D. Watson, An Investigation, Using Standard Experimental Techniques, to Determine FLCs at Elevated Temperature for Aluminium Alloys, in: Proceedings of the 3rd International Conference on New Forming Technology, (2012).

[16] R. Bagheriasl, Formability of Aluminum Alloy Sheet at Elevated Temperature, in, University of Waterloo, (2012).

[17] T. Naka, G. Torikai, R. Hino, F. Yoshida, The effects of temperature and forming speed on the forming limit diagram for type 5083 aluminium-magnesium alloy sheet, Journal of Materials Processing Technology, 113 (2001) 648-653.

DOI: 10.1016/s0924-0136(01)00650-1

[18] D. Li, A.K. Ghosh, Biaxial warm forming behavior of aluminum sheet alloys, Journal of Materials Processing Technology, 145 (2004) 281-293.

DOI: 10.1016/j.jmatprotec.2003.07.003

[19] H.S. Kim, M. Koc, J. Ni, A. Ghosh, Finite Element Modeling and Analysis of Warm Forming of Aluminum Alloys—Validation Through Comparisons With Experiments and Determination of a Failure Criterion, Journal of Manufacturing Science and Engineering, 128 (2006).

DOI: 10.1115/1.2194065

[20] G. Palumbo, D. Sorgente, L. Tricarico, The design of a formability test in warm conditions for an AZ31 magnesium alloy avoiding friction and strain rate effects, International Journal of Machine Tools and Manufacture, 48 (2008) 1535-1545.

DOI: 10.1016/j.ijmachtools.2008.06.010

[21] L. Leotoing, D. Guines, I. Zidane, E. Ragneau, Cruciform shape benefits for experimental and numerical evaluation of sheet metal formability, Journal of Materials Processing Technology, 213 (2013) 856-863.

DOI: 10.1016/j.jmatprotec.2012.12.013

[22] A. Hannon, P. Tiernan, A review of planar biaxial tensile test systems for sheet metal, Journal of Materials Processing Technology, 198 (2008) 1-13.

DOI: 10.1016/j.jmatprotec.2007.10.015

[23] G. Ferron, A. Makinde, Design and development of a biaxial strength testing device, Journal of Testing Evaluation, 16 (1988) 253-256.

DOI: 10.1520/jte10375j

[24] P. Terriault, K. Settouane, V. Brailovski, Biaxial Testing at Different Temperatures of Cruciform Ti-Ni Samples, in: SMST 2003: Proceedings of the International Conference on Shape Memory and Superelastic Technologies, (2003).