Determination Of Formability Research Articles

Design and development of a micro-LDH apparatus to determine formability of sheet metal under hot stamping conditions using Gleeble

In the last few years, demand for hot stamped components has increased in the automotive industry. Determination of formability under hot stamping is challenging due to elevated temperature, fast cooling, and high punch velocity. Although there was various strive for formability determination, but there were limitations with experiments like non-uniform heating of specimen, non-uniform strain, and temperature distribution. Therefore, in this work, an experimental apparatus was developed to determine formability at room temperature, high temperature, hot stamping conditions, and any complex process cycle involving heating and cooling. New specimen was designed to produce different strain paths, uniform, and homogenous temperature distribution with the help of FEM software using thermomechanical and thermoelectrical simulation. A micro hemispherical dome-based experimental apparatus was designed using Solidworks. The designed apparatus was used in conjunction with the thermo-mechanical simulator (Gleeble-3800). Thermomechanical analysis was done in PAM STAMP software to optimize specimen size and shape to get uniform strain distribution and different strain paths. A thermoelectric FEM model was developed using Abaqus 6.14 to optimize the temperature distribution in the specimen. The developed model enables choosing the appropriate polarity of the electrical cable connection to achieve uniform temperature distribution in the specimen. Strain path and temperature profiles for experiment and simulation were compared. Further, a forming limit curve was developed using the designed apparatus to verify the feasibility of the apparatus. For feasibility test of apparatus, hot stamping process was selected. This new design apparatus can be used for a range of temperatures up to 1000 °C, hot stamping conditions, and for different materials (aluminum, magnesium alloys, different grade of steel, etc.). It concludes that the connection of different polarities of electrical cable was critical for homogenous and uniform temperature distribution in specimens.

Determination and predication of formability on 22MnB5 steel under hot stamping conditions using Gleeble

ABSTRACT Hot stamping process is a thermo-mechanical process in which blank is heated to austenitization temperature and then subsequent forming and quenching are done simultaneously. Due to complex process cycle in hot stamping conditions, like high temperature and cooling etc., determination of formability is difficult. Therefore, in this work a series of experiment was performed on thermomechanical simulator (Gleeble-3800) at different temperatures (750oC, 800 oC, 850 oC) and strain rates (0.01/s, 0.1/s, 1/s) to obtain flow behavior and formability of 22MnB5 Steel. Due to limitation of the uniaxial deformation in Gleeble-3800, modified tensile specimen was used to obtain plain strain conditions. Thickness gradient-based necking criterion was validated for high temperature forming at different strain rates. This criterion was further used to determine the formability of 22MnB5 steel. Thickness distribution and thickness gradient for modified specimen and simple tensile specimen is observed under various conditions. It was found that with increase in temperature and strain rate formability of 22MnB5 steel increased as well as uniform deformation occurs. Thickness gradient necking criteria indicates that at point of necking thickness gradient ratio falls below the critical value of 0.92. .

Determination of formability considering wrinkling defect in first-pass conventional spinning with linear roller path

Flange wrinkling is one of the common defects that occur in conventional spinning process, severely restricting the improvement of forming quality and formability. How to universally determine the formability dependent on flange wrinkling is a critical issue in conventional spinning process. For this end, such a determining method for the formability in the process is proposed to rationally design the forming parameters to prevent flange wrinkling. The method is as follows: firstly, the maximum circumferential stress during the process is calculated at the outer edge of the flange, where the circumferential stress is considered as the combining result of the shrinkage of flange diameter and the bending of flange; then, the formability is determined by comparing the maximum circumferential stress to critical circumferential stress for wrinkling defect. Based on the method, a formability analytical model considering wrinkling defect in the first-pass conventional spinning process with a linear roller path is established. The formability model is validated by experiments and FE simulations at different spinning conditions. Sequentially, the influences of forming parameters and their interaction on the formability considering wrinkling defect are systematically analyzed. Furthermore, the forming diagrams considering wrinkling defect for the first-pass conventional spinning are established. It is found that the feed ratio has the most significant effect on the formability, followed by the blank thickness, the hardening exponent, the feed ratio-hardening exponent interaction and the feed ratio-sheet blank thickness interaction. The smaller feed ratio and hardening exponent, thicker sheet blank and greater relative sheet blank radius are helpful to increase the formability. The research results could provide a theoretical basis and guidance for the selection of forming parameters in the actual production of the first-pass conventional spinning.

Investigation on the effect of curvature on forming limit prediction for aluminium sheet alloys

The investigation of bendability of sheet metal alloys is of great importance for the evaluation of process robustness in production of hemmed sheet metal assemblies. Furthermore, material cracks due to bending can also occur at deep drawing operations. This contribution focuses on the experimental determination of material’s formability at deep drawing, the characterisation of bendability especially for hemming operations and the determination of formability under combined deep drawing and bending loads, respectively.