Abstract
Using a finite element calculation code, this work analyses the influence of friction during a stamping test conducted on the AA6060 aluminium-based alloy. The study focuses on phenomena happening when the sheet necking appears. This condition, based on the Hill’s localized necking theory and the Swift’s diffuse necking theory, is dependent on the material hardening index. This work shows that the punch stroke at the necking condition point is maximum when the main strain measured on the sheet surface are unbalanced and close to a balanced biaxial tension condition.
Highlights
I n the last decades, the use of aluminium alloys has considerably grown in the automobile and aerospace industries due to its high strength-to-weight ratio and corrosion resistance [1, 2]
The use of software based on the finite element method (FEM) allows significant savings in time and cost, including the limitation of the onerous "trial-and-error" operations
The effect of the temperature on formability is important too; the mechanical behaviour of different aluminium alloys at “warm” process temperature was studied by Li and Ghosh [5], an increase in the flow stress with the decreasing deformation temperature was found by Lu et al [6], while an increased formability in warm temperature condition was found by Wang et al for AA7075 [7]
Summary
I n the last decades, the use of aluminium alloys has considerably grown in the automobile and aerospace industries due to its high strength-to-weight ratio and corrosion resistance [1, 2]. The friction effects on sheet formability are very important [20]; Yan et al presented a scale factor to adjust the Wanheim/Bay friction model [21], Ma et al studied the effect of temperature on the tribological behaviour in tube forming [22], Wang et al investigated the substitution of zinc phosphate precoat with another lubricant coating [23], Hol et al introduced a physical based model for friction simulation in fullscale modelling, taking into consideration the surface topography variation [24], Wang et al examined the dry forming process carried out by means of a coated tool [25], Hol et al presented an advanced friction model, based on Coulomb law, suitable for large-scale forming modelling [26], Zhang et al studied the effect of reciprocal speed and surface roughness on the Coulomb friction coefficient through FEM simulations [27] and Wang et al performed a study on the challenges and trends of friction analysis in sheet metal forming [28]
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