Abstract
The application of forming processes using lightweight magnesium alloys is known to be difficult with regard to minor formability caused by a small number of active slip systems, especially at low temperatures. However, a new approach for deep drawing at elevated temperatures considers flexible motion profiles of a servo-screw press. The so-called cushion-ram-pulsation (CRP) is a newly developed method of position-controlled motion. As a result, the process limitations for deep drawing are significantly extended. This study investigates the deep drawing process of AZ31 cups by variable motion profiles of cushion and ram, focusing on enhanced drawability. Therefore the initial AZ31 sheet was fabricated by twin-roll casting. Furthermore, the adjustment of the forming temperature for an improved forming process and optimized component properties are described. In addition, the results were evaluated in comparison to conventional deep drawing, and the superior technological potential will be outlined.
Highlights
Due to the continuing trend towards lightweight design, magnesium as a construction material is predicted to become increasingly widespread [1]
2.1 Production of the blanks The initial sheets of magnesium alloy AZ31 were produced by a twin-roll casting process (TRC) [16]
The final holding time is not implemented in this present study of forming magnesium sheet
Summary
Due to the continuing trend towards lightweight design, magnesium as a construction material is predicted to become increasingly widespread [1]. Thanks to its crystal structure, the hexagonal solidifying magnesium has only a small number of independent slip systems at low temperatures: two instead of the required five [5,6]. The flow performance of AZ31 sheet metal depends very much on the strain rate. Higher strain rates lead to a lower logarithmic strain at fracture [2,7]. In the past magnesium has only been successfully deep-drawn at low forming speeds and high process temperatures as described in [3,8,9,10]
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