Analysis of constrained groove pressing and constrained groove pressing-cross route process on AA5052 sheet for automotive body structure applications

Abstract

In this paper, a hybrid experimental-numerical approach was developed to analyze the constrained groove pressing and constrained groove pressing–cross route process on AA5052 sheets which are comprehensively used to produce body in white and closure panels and beams of the automotive. The microstructure and mechanical properties were evaluated using scanning electron microscopy, tensile tests, and microhardness measurements. Then, the developed procedure was used to predict the mechanical properties of the sheets fabricated by constrained groove pressing process. This enabled the evaluation of the effects of the groove angle, width, and height of the die on strength and hardness of the processed sheets. To complete the conceptual design of the grooved dies, the Taguchi method was used to optimize the die design. The obtained results show that the inhomogeneity factor in the sheets processed by constrained groove pressing–cross route is less than those processed by constrained groove pressing. The analysis indicates that the developed procedure would result in an acceptable prediction of the material behavior of the processed sheets. The procedure could save a great deal of time and is economical in the matter of design. Finally, the procedure in conjunction with Taguchi method would lead to an optimum die design to enrich the processed sheets.