Abstract
In this paper, the springback of the aluminium alloy AA5754 under hot stamping conditions was characterised under stretch and pure bending conditions. It was found that elevated temperature stamping was beneficial for springback reduction, particularly when using hot dies. Using cold dies, the flange springback angle decreased by 9.7 % when the blank temperature was increased from 20 to 450 °C, compared to the 44.1 % springback reduction when hot dies were used. Various other forming conditions were also tested, the results of which were used to verify finite element (FE) simulations of the processes in order to consolidate the knowledge of springback. By analysing the tangential stress distributions along the formed part in the FE models, it was found that the springback angle is a linear function of the average through-thickness stress gradient, regardless of the forming conditions used.
Highlights
In recent years, the automotive industry has been facing tough challenges associated with the need to improve fuel economy and reduce CO2 emissions, due to more stringent environmental regulations
It can be seen that the springback angles decreased with increasing initial blank temperature up to 450 °C, which is the temperature that would be used for HFQ forming of AA5754 [22]
For springback angle θA, the magnitude gently decreased by 15.7 % from 11.9 to 10.0° as the initial blank temperature (Tblank) was increased from 20 to 450 °C
Summary
The automotive industry has been facing tough challenges associated with the need to improve fuel economy and reduce CO2 emissions, due to more stringent environmental regulations These demands have sparked a surge in the usage of lightweight materials, such as aluminium alloys, to replace traditional steels. It is difficult to form complex shaped parts at cold forming conditions using high-strength aluminium alloys due to their poor formability and excessive springback, which limits their application These issues could be overcome by warm and hot stamping processes [2,3,4,5,6,7,8,9,10,11]. Warm forming technologies can enhance formability, there is a potential risk that the forming process may destroy the desirable microstructure of an alloy and reduce the post-formed strength
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