Abstract
The sheet metal forming operations generally involve the production of parts characterized by a non-uniform thickness distribution. However, in some cases, a product characterized by a distribution of thicknesses that is as uniform as possible may be desirable. This result can be obtained by using multiphase processes or by subtraction or addition of material from the blank. In this work, which deals with the method for adding material, an innovative methodology has been proposed as an alternative to the welding process. Specifically, the methodology is based on the bonding of a patch (before the deformation process), on the base plate with a constant thickness, in the area that most suffers from the thinning caused by the forming process. In this way, it was possible to influence the deformation of the patchwork blank and its thicknesses distribution. Through finite element analysis, it was possible to study the formability of a patchwork blank by varying the thickness and size of the patch, in order to produce an axially symmetric component by stretching through a hemispherical punch. Preliminary experimental tests demonstrated the reliability of the bonding and the potential of this method to uniform the final thickness of the sheet.
Highlights
T o meet the growing needs of the automotive industry in terms of safety and comfort, the weight of cars has continuously increased over time
Sheet metal forming processes are used for the production of automotive parts [2]
The sheet is made of aluminum alloy due to the high strength-to-weight ratio and the high corrosion resistance presented by these materials [3,4]
Summary
T o meet the growing needs of the automotive industry in terms of safety and comfort, the weight of cars has continuously increased over time. This is due both to the increase in the overall dimensions of the car and to the introduction of various electrical and electronic components [1]. A different distribution of the thicknesses of the product obtained by forming may be necessary. This result can be achieved using multiphase processes by subtraction or addition of material from the initial semi-finished product.
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