Drawability of AZ31 magnesium alloy sheet produced by equal channel angular rolling at room temperature

The objective of this study is to investigate the possibility of improved drawability of AZ31 magnesium alloy sheet produced by equal channel angular rolling process at room temperature. Although with similar optical microstructure, the limiting drawing ratio of AZ31 magnesium alloy sheet is improved from 1.2 to 1.6 for the specimens before and after equal channel angular rolling, which is due to the changing crystal orientation that induces shear deformation through this process. The enhanced drawability in AZ31 magnesium alloy sheet provides the possibility for drawing at ambient temperature by controlling the crystal orientation in AZ31 magnesium alloy sheet.     

AZ31镁合金非等温拉深性能的研究

针对AZ31镁合金等温拉深性能差的问题,提出了AZ31镁合金的非等温拉深工艺.通过平底杯形冲头拉深试验研究了不同冲头温度和板料温度对AZ31镁合金非等温拉深性能的影响,确定了使AZ31镁合金具有最佳拉深性能的板料和冲头温度范围.实验结果表明,除了板料和冲头温度之外,拉深速度和润滑条件对AZ31镁合金的非等温拉深性能也有重要影响.     

Experimental and finite element analysis of fracture criterion in general yielding fracture mechanics

Efforts made over the last three decades to understand the fracture behaviour of structural materials in elastic and elasto-plastic fracture mechanics are numerous, whereas investigations related to fracture behaviour of materials in thin sheets or general yielding fracture regimes are limited in number. Engineering simulative tests are being used to characterize formability and drawability of sheet metals. However, these tests do not assure consistency in quality of sheet metal products. The prevention of failure in stressed structural components currently requires fracture mechanics based design parameters like critical load, critical crack-tip opening displacement or fracture toughness. The present attempt would aim to fulfill this gap and generate more information thereby increased understanding on fracture behaviour of sheet metals. In the present investigation, using a recently developed technique for determining fracture criteria in sheet metals, results are generated on critical CTOD and fracture toughness. Finite element analysis was performed to support the results on various fracture parameters. The differences are within 1 to 4%. At the end it is concluded that magnitude of critical CTOD and/or critical load can be used as a fracture criterion for thin sheets.     

Deep drawing formability of AZ31 magnesium alloy based on magnetorheological elastomer support

In this paper, the flexible support mould is designed by using magnetorheological elastomer (MRE) to assist in the deep-drawing of magnesium alloys. Based on the magnesium alloy mechanical tensile test and magnetorheological elastomer regular force experiments, the deep-drawing process of AZ31 magnesium alloy supported by support mould was numerically simulated by finite-element analysis software ABAQUS. By varying the current input to the excitation coil to change the magnetic induction intensity and thus adjust the magnetic normal force of the magnetorheological elastomer, then using magnetic normal force to complete the auxiliary sheet metal deep-drawing. The results show that, compared with the unsupported mould, the supported mould can effectively reduce the maximum thinning rate of magnesium alloy on the original basis, thus effectively increasing the ultimate depth of magnesium alloy deep-drawing. It can replace the original buffer device, effectively solution the problem of pulling and cracking at the bottom of magnesium alloy caused by the original excessive damping force, and improve the yield rate of workpiece.     

Experimental evaluation and prediction of deep drawability of adhesive bonded steel sheets

The main aim of the present work is to experimentally evaluate the deep drawing behaviour of adhesive bonded sheets at different adhesive properties and predict the same using finite element simulations. The deep drawing quality steel and SS316L stainless steel are used as base materials for experiments and simulations. The deep drawing behaviour is also predicted using available analytical equations and proposed semi‐empirical equations. Such predictions are validated with experimental results. It is observed that due to increased plasticity of adhesive layer, the hardener rich formulation of adhesive improves the deep drawability of adhesive bonded blanks. The presence of carbon black in the adhesive has improved the drawability of bonded sheets up to a certain limit, say 2% by weight in the present work. The deep drawing behaviour predicted either by approach 1 (by giving experimentally evaluated adhesive properties as input) and by approach 2 (adhesive properties evaluated from rule of mixtures) are almost same, which indicates that both the methods can be used for forming behaviour prediction. The deep drawability predictions are moderately accurate with respect to experimental observation. The accuracy of analytical models for maximum load predictions is encouraging while comparing it with experimental results and numerical predictions. The proposed semi‐empirical equations show promising results to obtain initial estimate about the load‐progression behaviour of bonded sheets.     

台阶盒形件起皱和开裂改善

目的 改善台阶盒形件拉深成形时凸缘区起皱和圆角区开裂的缺陷。方法 理论分析了起皱和开裂产生的原因,利用有限元模拟分析了压边力大小、凹模运行方式和板料形状对台阶盒形件拉深成形的影响,采用实验验证了有限元模拟结果的准确性。结果 长方形板料拉深成形时,4个角部相比直边部位流动阻力更大,直边部位材料过度向模具型腔内流动,造成凸缘区周向压应力过大,进而引起起皱,当零件拉深深度较大时,圆角部位材料变形剧烈且材料流动不均匀,极易产生开裂;采用20 kN的压边力、梯形的凹模向下运行方式和类椭圆形板料的工艺参数可以控制材料流动,使板料变形均匀并改善凸缘区起皱和圆角区开裂缺陷。结论 有限元模拟可为冲裁工艺参数的选取提供理论指导。     

6061铝合金飞机溢油口拉深成形研究

目的 掌握深腔薄壁溢油口拉深成形工艺,解决拉深成形过程中起皱和破裂问题,研究各参数对拉深成形的影响规律,最终成形出合格产品。方法 以6061铝合金飞机溢油口为主要研究对象,采用Dynaform有限元数值模拟软件建立有限元模型,分析成对拉深成形对材料流动的影响并与单一拉深成形进行对比,通过改变毛坯外形尺寸、凹凸模间隙和压边力等参数进行拉深成形模拟试验研究,最终通过拉深成形试验验证成形方法及各参数设置的合理性。结果 成对拉深成形能限制单一拉深成形圆弧开口位置材料收缩,改善开口处起皱和变形缺料的现象。随着凹凸模间隙的增大,最大减薄率逐渐降低而后升高,最佳成形凹凸模间隙为1.05t;随着压边力的增大,最大减薄率逐渐升高,最大增厚率逐渐降低,最佳成形压边力为50 kN;凹模圆角半径小于7 mm 时,板料最大减薄率逐渐减小,半径为4 mm时,最大减薄率下降最快,半径在7~8 mm范围内,板料最大减薄率趋于平稳,最佳成形凹模圆角半径为7 mm。结论 模拟得到了毛坯外形尺寸、凹凸模间隙和压边力等参数对拉深成形的影响规律,最终制造出了满足设计要求的产品,验证了各参数设置的合理性。     

Formabilities of steel/aluminium alloy laminated composite sheets

The tensile properties and press formabilities of laminates experimentally produced from mild steel and various aluminium alloy sheets are examined. The tensile properties of the laminates are approximately predictable by the mixture rule of the properties of the individual sheets. The forming limits in deep drawing, as well as stretch forming due to various types of fractures of the laminated composite sheets, cannot be predicted without considering the stress and strain histories of the individual sheets during forming. Furthermore, it is found that the drawability, as well as the stretch formability, is improved by setting the mild steel sheet on the punch side for the case of aluminium alloy sheet with comparatively high ductility, and by sandwiching the aluminium alloy sheet with the mild steel sheets for the case of low ductility.     

An experimental investigation into the warm deep-drawing process on laminated sheets under various grain sizes

It has been proved by many researchers that increasing the temperature in warm deep-drawing process of single layer sheets decreases the forming load, however, this phenomenon is not necessarily the case in warm deep-drawing process of laminate sheet. The objective of the present paper is to carry out a comprehensive investigation on warm deep-drawing process on laminated sheets experimentally. Based on the results of this study, it can be observed that by raising the temperature, variation of forming load more depends on blank holder force (BHF). In this study, thinning and wrinkling in Al 1050/St 304 and Al 5052/St 304 samples for each layer in warm deep-drawing process are evaluated individually. In addition, the effects of various grain sizes, blank temperatures and sequence layer on forming load are investigated. In order to carry out a comprehensive survey of warm deep-drawing; three blank temperatures namely, 25 °C, 100 °C and 160 °C are examined. Furthermore, to achieve various grain sizes, the aluminum sheets are annealed at 350 °C, 400 °C and 450 °C for 1 h. Finally, several tests are conducted to obtain the influences of grain size on some material characteristics such as stress, elongation and friction coefficient.     

Deep drawing behavior of twinning-induced plasticity-cored three-layer steel sheet

Herein, we report the results of our experimental and computational investigation of the deep drawing behavior of twinning-induced plasticity (TWIP)-cored three-layer steel sheet. Various directional tensile tests for monolayer sheets of the TWIP and low-carbon (LC) steels were performed for evaluation of flow curves and anisotropic coefficients, which are used as input data of the finite element analyses for deep drawing of the monolayer and three-layer sheets. The experimental deep drawing behaviors of the layered sheets of three thickness ratios, and of the monolayer sheets, are computationally analyzed in terms of earring and variations of local thickness along the positions in the drawn cups. It was found that the three-layer sheets are more planar-isotropic in the sense of earring than the monolayer sheets, even more than the TWIP steel sheet. The thickness uniformity along the initial radial direction in the layered sheets is in between the heterogeneous TWIP steel and the relatively homogeneous LC steel. The present results shed light on the future direction of development of steel sheets with planar-isotropic and homogeneous deep-drawing characteristics.     

A hybrid method for detecting the onset of local necking by monitoring the bulge forming load

Strain-based Forming Limit Diagrams (FLD), which are typically obtained under linear or quasi-linear loading conditions, describe the limiting strains in terms of the major and minor in-plane strains before the onset of necking or the final failure (FFD). These strains can be detected by analysing the strain field in the vicinity of necking or cracking defects. It has generally been agreed that the loading versus time signal is not suitable for detecting necking processes. A novel hybrid method of detecting the onset of necking based on the experimental and simulated bulging load is presented in this paper. This method consists mainly in comparing the experimental forming load, i.e., a load showing plastic instability, with the numerical predictions obtained by performing finite element simulation. The simulation of the bulging process does not include any damage or failure criteria. A homogeneous forming load can therefore be simulated without requiring any information about the localization. This method was applied to detecting the onset of local necking in circular and elliptic quasistatic bulge tests on sheet material, with a diameter of 200 mm. Two materials were tested, a 0.8 mm thick DP450 Dual Phase steel sheet and a 1 mm thick AA6016-T4 aluminium sheet. The onset of necking observed with our method was compared with the results obtained by performing Hogström’s analysis based on the measured strain field over time and similar necking strains were obtained. Beside, the Bressian Williams Hill (BWH) shear criterion was identified for each test from experimental results. A slight scattering of the shear stress values was observed.     

Effect of annealing on formability of aluminium grade 19000

Forming limit diagrams are used by the stampers to solve sheet metal forming problems. In practice, sheet metals have been subjected to various combinations of strain. Necking during sheet metal forming, sets the limit to which the sheet metal can be formed. Forming limit diagram is an effective tool to evaluate the formability of sheet metal in various strain conditions. The information upon the formability of the sheet metal is important for both sheet metal manufacturers and users. In this work, a study has been made on the formability of aluminium 19000 grades annealed at three different temperatures namely 160 °C, 200 °C and 300 °C for sheet thickness of 2.00 mm. The tensile properties and formability parameters were experimentally evaluated and they are related to forming limit diagram. Strain distribution profiles obtained from the forming experiment have been analyzed. The fractured surface of the formed samples were viewed using scanning electron microscope (SEM) and the SEM images were correlated with fracture behaviour and formability of sheet metal. The sheet which is annealed at 300 °C has been found to possess good drawability and stretchability compared to other two annealed sheets.     

预应力高性能混杂纤维增强布加固HPC梁的DNLC单元研究

对于不同混杂配比的预应力高性能混杂纤维增强(HFRP)布,建立高性能HFRP布加固高性能混凝土(HPC)梁的双重非线性分层组合(DNLC)单元模型。根据实体退化单元理论,采用初应力等参层单元对高性能HFRP布的体外预应力效应进行模拟,同时正确地考虑HPC梁的材料非线性效应以及结构的几何非线性,验证DNLC单元分析模型的正确性,并对HPC梁的开裂荷载、普通钢筋应力、高性能HFRP布应力重分布等进行研究。结合试验资料分析表明,预应力碳/玻璃纤维混杂(CFRP/GFRP)布加固HPC梁的理论结果与试验数据吻合程度良好,采用等参层单元有效地模拟高性能HFRP布的预应力作用,及所推导的DNLC单元正确性。预应力GFRP纤维布加固的开裂荷载等均较低,预应力CFRP纤维布加固的开裂荷载等有所提高,但剩余强度过大。HPC梁开裂荷载前预应力高性能HFRP布应力发展缓慢,屈服荷载后,其发展迅速直至结构失效。     

Deformation microstructures and the shear strain rate of type 304 stainless steel sheet in cylindrical deep drawing of warm working

A deep-drawing test was conducted under a single temperature or two temperatures on both sides of type 304 stainless steel sheet, 0.8 mm thick. The different results produced by these processes are described. A lower rate of shear straining is generated at 100 °C in the two-temperature process than in the single-temperature process, and a much larger rate is produced with room-temperature working. Their microstructures at the failure point and the flange portion nearing the die throat were studied by optical microscopy and TEM. An intermixed structure of lath and blocky α′-martensites appeared at the failure point in cold working. By warm working at a single temperature, homogeneous shear in a single direction and coarser slip bands were generated. Heterogeneous shear straining on both sides of the specimen occurred in the two-temperature process, and the microstructure of the failure point was observed as twin-twin intersections. The microstructures generated in the flange portion corresponding to the individual process, appeared to be blocky martensite nucleation and growth at the shear band intersections, twin-twin band or twin-slip band intersections, respectively. The strengths of these microstructures at different positions are compared with each other and the drawability is explained.     

飞机铝合金深锥型面零件多道次充液拉深技术

目的随着新一代飞机在隐身和战斗性能方面的提高,飞机钣金零件的复杂程度和制造精度要求也越来越高。对于深型腔复杂型面零件,充液拉深是一种有效的精密制造方法。方法针对难成形、复杂型面的某型飞机铝合金深锥零件,利用理论分析、有限元模拟和工艺试验相结合的方法,设计了多道次充液拉深技术方案,并建立有限元分析模型。基于等裕量函数法和零件锥面特征,分配并优化了不同道次的材料变形量。结果对多道次充液拉深成形过程中出现的起皱和破裂的失效形式进行了研究,分析了预成形高度,液室压力和压边力等关键工艺参数对零件成形质量的影响,获得了优化的预成形高度和液室压力加载轨迹。结论结果表明,提出的多道次充液成形技术能够实现复杂型面,大拉深比的铝合金零件的整体精确成形,采用优化的工艺参数能够成形出壁厚均匀,表面质量好,锥面精度高的零件。     

Blank design optimization on deep drawing of square shells

A numerical scheme for improving the drawability in the deep drawing of square shells by blank design optimization is presented. The numerical scheme is formulated as an optimization problem whose objective is to maximize the drawability, subject to the constraint that fracture failure and draw-in failure do not occur. Appropriate blank design parameters are used as the design variables of the formulation. To enable the numerical scheme to work models predicting the onset of fracture failure and draw-in failure are required. Numerical models simulating the onset of these failures under the given process conditions are thus discussed. Optimal designs for three cases are then presented. Finally, by considering both the drawability and the non-uniformity of the final flange profile it is shown that the circular profile can be considered to be the optimal blank shape for square cup drawing.     

高强轻骨料混凝土深受弯构件剪切损伤演化与服役性能研究

偶然的超越荷载、长期的环境侵蚀及温度变形等易导致深受弯构件斜截面的服役能力降低,出现开裂,影响正常使用。完成15根高强轻骨料混凝土深受弯构件受剪性能全过程试验,系统研究了剪切荷载作用下的损伤演化规律,分析了剪跨比、加载板宽度和截面高度对构件受剪服役能力的影响,基于裂缝发展趋势建立裂缝宽度与荷载水平的宏观对应关系,探讨了相关规范中正常使用阶段斜裂缝宽度限值对该类构件的适用性。研究表明:随剪跨比和加载板宽度增大,试件最大斜裂缝宽度呈增长趋势,且配置足够数量的水平和竖向腹筋能够有效抑制深受弯构件的斜向开裂,试件名义斜向开裂强度和最大斜裂缝宽度均受尺寸效应影响较小;受剪全过程中试件的宏观剪切裂缝宽度与相应承担荷载水平呈现显著对应关系,且基于普通混凝土深受弯构件试验数据建立的服役性能评价指标可用于高强轻骨料混凝土深受弯构件服役性能预测;按我国规范中最小腹筋配筋率设计的高强轻骨料混凝土深受弯构件难以满足斜裂缝宽度限值要求,建议适当增大腹筋最小配筋率。     

In-plane anisotropy in tensile deformation and its influence on the drawability of Nimonic c–263 alloy sheets

An effort has been made to comprehensively evaluate and rationalize the in-plane anisotropy in tensile properties and the effect of aging on the nature of deformation (strain hardening behaviour) and formability characteristics, especially the limit drawing ratio and forming limit diagram. Despite weak crystallographic texture and excellent ductility and high work hardening exponents, the alloy sheets of C-263 exhibit significant extent of in-plane anisotropy in its tensile properties and yield loci. The absolute magnitudes of yield stress and the exact nature of anisotropy that can be predicted from the tensile part of the yield locus need to be employed with caution. This is because when the magnitudes of the yield stresses, obtained from yield locus are more than 5 times higher as compared to the yield and ultimate tensile strength values and the nature and degree of in-plane anisotropy under tensile loading matches with that of only the compressive yield stresses of yield locus. The alloy sheet, due to weak crystallographic texture and relatively high strengths, is found to be far more suitable for structural applications, rather than for deep drawing applications, which was reflected in low limit drawing ratio values (1.34 for CR+ST and 1.23 for peak aged conditions). Further, the study conducted reveals that the safer forming limits in strain space is higher for CR+ST condition; while, the safer forming limits in stress space are higher for peak aged (CR+ST+1073 K/8 h) condition. Finally, detailed studies are outlined to arrive at suitable microstructural and textural characteristics that provide significantly enhanced drawability in the Nimonic C-263 alloy sheets.     

Today's sheet metal materials and their forming properties

The production and processing of sheet metals of high‐strength steels, titanium, aluminum or magnesium alloys is investigated intensively at universities and in the industry. The main emphasis is put for example on the aluminum space frame concept as well as on the succeeding projects of the ULSAB‐study in the field of the steel sheet metals. Within this article the qualification of the above mentioned materials for the application as deep‐drawing materials will be discussed. The aim of the development for new deep‐drawing sheet metals is to decrease the elastic part of the forming, which means to lower the yield point. A high elastic portion would cause a high resilience after the forming of the sheet metals and therefore an increased requirement of force and form error during the forming process. Furthermore the optimized sheet metal material should have a great uniform elongation, so that it can be plastically deformed in a wide range. The beginning of the deformation should be possible at low forming forces but due to the deformation an increase of the hardening should be caused, so that the finished component has high strength. But it is not possible to realize both aims, high strength and great uniform elongation, at the same time.     

Probabilistic design of aluminum sheet drawing for reduced risk of wrinkling and fracture

Often, sheet drawing processes are designed to provide the geometry of the final part, and then the process parameters such as blank dimensions, blank holder forces (BHFs), press strokes and interface friction are designed and controlled to provide the greatest drawability (largest depth of draw without violating the wrinkling and thinning constraints). The exclusion of inherent process variations in this design can often lead to process designs that are unreliable and uncontrollable. In this paper, a general multi-criteria design approach is presented to quantify the uncertainties and to incorporate them into the response surface method (RSM) based model so as to conduct probabilistic optimization. A surrogate RSM model of the process mechanics is generated using FEM-based high-fidelity models and design of experiments (DOEs), and a simple linear weighted approach is used to formulate the objective function or the quality index (QI). To demonstrate this approach, deep drawing of an aluminum Hishida part is analyzed. With the predetermined blank shape, tooling design and fixed drawing depth, a probabilistic design (PD) is successfully carried out to find the optimal combination of BHF and friction coefficient under variation of material properties. The results show that with the probabilistic approach, the QI improved by 42% over the traditional deterministic design (DD). It also shows that by further reducing the variation of friction coefficient to 2%, the QI will improve further to 98.97%.