An Analytical and Numerical Investigation on Flange Wrinkling Behavior in Warm Forming Process of AA5754 Using Macro-Textured Tool Design

Abstract:

In this paper, an analytical buckling model is established to predict the flange wrinkling behavior of deep drawn cylindrical cups of aluminium alloy sheet in warm forming conditions using macro-textured blankholders for the first time. A continuum damage mechanism (CDM) based material model was utilized to reflect the visco-plastic feature of material at elevated temperatures. Forming speed and temperature effects were investigated, and texture ratio and draw ratio effects were also discussed. The developed analytical buckling model was validated by finite element simulations. The increase of forming temperature and forming speed is prone to cause wrinkling for AA5754, but the effects are not as significant as the texture geometry and draw ratio. The analytical model presented in this paper can be used as a design guide to determine tool texture geometry necessary to avoid wrinkling defects in the warm forming processes of aluminium alloy.

• Periodical: Key Engineering Materials (Volume 716)
• Pages: 586-594
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.716.586
• Online since: October 2016
• Authors: Kai Lun Zheng*, Lei Zhu, Denis J. Politis, Jian Guo Lin, Trevor A. Dean
• Keywords: Aluminium Alloy, Analytical Model, Flange Wrinkling, Macro-Textured Tool, Warm Forming

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