Abstract
This work presents a finite element model to analyze the distribution of the strains due to an axisymmetric stretching of a metal sheet. The sheet is characterized by a variable initial thickness. The resulting strain state is compared with that of a sheet with a constant initial thickness. The results of the present study allow asserting that the distribution of strains in the sheet can be controlled by setting opportunely the trend of the sheet initial thickness. In this way, it is possible to see that, starting from a sheet with variable initial thickness, a lighter final product is obtained, whose final thickness distribution is more uniform than that of the product obtained from a classic stretching process that requires a sheet with constant initial thickness. Encouraging results from an experimental activity carried out on an AA6060 aluminum alloy sheet, whose trend of initial thicknesses was prepared by removing material from a commercial sheet with a constant thickness, allow us to note the good agreement with what was theoretically highlighted.
Highlights
To reduce the weight of the parts used in the transport sector and, the fuel needed to move them, steel parts have been replaced by light alloys based on aluminum or magnesium
Conventional stretching processes at room temperature have two important drawbacks: light alloys are generally not formable and the thickness distribution produced is not uniform in the part subjected to deformation. 5xxx aluminum alloys have cold formability better than that of the 6xxx and 7xxx series alloys [1]
Light alloys have reduced formability compared to steel and generate greater problems in terms of elastic return
Summary
To reduce the weight of the parts used in the transport sector and, the fuel needed to move them, steel parts have been replaced by light alloys based on aluminum or magnesium. Conventional stretching processes at room temperature have two important drawbacks: light alloys are generally not formable and the thickness distribution produced is not uniform in the part subjected to deformation. To optimize the final thickness distribution, the weight of the formed part, and to improve the formability of the material, a cold working technique is used which uses an initial plate characterized by a variable thickness profile. The authors in [23] tested the use of numerical modeling based on the finite element method on a process for superplastic deformation of the sheet with excellent results and the forming limit diagram was analyzed in [24]. The proposed paper presents a numerical model based on the finite element method to simulate an axisymmetric stretching of a metal sheet. (1 where σ and ε represent the equivalent stress and the equivalent strain respectively, whi
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