Abstract
Magnesium alloys have many distinguished advantages, therefore, they are more and more popularly used in lightweight design of automotive and aviation manufacturing industry. However, its poor plasticity at room temperature has prevented its further application, especially in magnesium alloy sheets forming process. To expand the application of magnesium alloy sheets, single point incremental forming process for rapid prototype manufacturing and small scale productions of sheet metal was investigated. Combining finite element numerical simulations with physical experiments, the relationships between the maximum thickness differences and different process parameters are explored and the optimal process parameters for forming a certain straight wall cylindrical part of AZ31 magnesium alloy were determined. Based on the analysis of the results, the formability of AZ31 magnesium alloy sheet using warm SPIF is improved with the increases of number of forming stage, forming temperature and tool diameter but reduced with the increase of feed rate and interlayer spacing. The suitable forming temperature for AZ31 magnesium alloy sheet is about 250℃. For forming the deeper straight wall cylindrical parts, at least four forming stages are needed.
Highlights
Magnesium alloys are very light in weight and has only 2/3 of the density of aluminum alloys
The commercial AZ31B magnesium alloy sheet produced through hot rolling and annealing is used for mechanical property testing and part forming, and its main chemical compositions is Mg−3Al−0.95Zn−0.28Mn
The relationships between maximum thickness difference and different process parameters including number of stages, forming temperature, tool diameter, feed rate, and interlayer spacing are expressed in formula (3)
Summary
Magnesium alloys are very light in weight and has only 2/3 of the density of aluminum alloys. They have the advantages of high specific strength, good shock absorption performance, good thermal conductivity, and good electromagnetic shielding performance. They are used more and more in lightweight design of products. Magnesium alloy sheets are prominent in automotive and aviation manufacturing industries (Dziubinska et al, 2015; Joost and Krajewski, 2017; Masood et al, 2019), but their wide applications are limited by their poor plasticity at room temperature.
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