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1
Yu, Hai Yan, Li Bao, You Zhi Deng, and Wei Cao. "Forming Response of Ultra High Strength Steel Sheet to Stamping Speed during Hot Forming." Advanced Materials Research 160-162 (November 2010): 123–29. http://dx.doi.org/10.4028/www.scientific.net/amr.160-162.123.
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Stamping speed is an important parameter in sheet metal forming especially in hot forming. In this study, hot forming of a U-shaped part made of ultra high strength boron steel (22MnB5) sheet is simulated with solid elements. The mechanical properties of 22MnB5 steel sheet and the key process parameters are introduced in detail. Emphasis is laid on the forming response of the boron steel sheet to stamping speeds of 3.25m/s, 0.325m/s and 0.0325m/s. The mechanism of stamping speed acting on hot formability and temperature field of the stamped part is analyzed. It is demonstrated that stamping speed affects both formability and the heat transferred from blank to tools and to environment during hot forming. And the coupling effect of material properties, the heat produced during plastic deformation and heat boundary condition decides the formability and temperature field. An appropriate stamping speed is more important for hot forming than that for common cold forming.
2
You, Kang Ho, and Heung-Kyu Kim. "A Study on the Effect of Process and Material Variables on the Hot Stamping Formability of Automotive Body Parts." Metals 11, no. 7 (June 26, 2021): 1029. http://dx.doi.org/10.3390/met11071029.
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Hot stamping is a method capable of manufacturing high-strength automotive body parts by inducing a martensitic phase transformation through forming and die quenching after heating a metal sheet into a high temperature austenite phase. However, it is not easy to solve various formability problems occurring in the hot stamping process due to the complexity of the process and material behavior during high temperature forming. In this study, fracture-related forming limits and martensite phase ratio were selected as criteria for evaluating hot stamping formability. First, a hot stamping test was performed on a T-type part that simplified the B-pillar, an automotive body part, and the fracture behavior according to the temperature and thickness of the sheet blank was investigated. Additionally, forming analysis was performed on the hot stamping process of mass-produced B-pillar parts by varying the temperature of the sheet blank, the thickness of the sheet blank, the die-blank friction coefficient, and the strain-rate sensitivity of material among various process and material variables. Based on the analysis results, the effect of each process and material variable on the hot stamping formability of B-pillar parts was quantitatively analyzed. By utilizing the results of this study, it will be possible to solve the formability problem that occurs in the mass-production hot stamping process for automotive body parts and improve the quality of parts in the future.
3
Hu, X., C. Creighton, P. Zhang, N. Müller, T. Reincke, R. Taube, and M. Weiss. "Formability of roll-formed carbon fibre reinforced metal hybrid components and its experimental validation." IOP Conference Series: Materials Science and Engineering 1238, no. 1 (May 1, 2022): 012026. http://dx.doi.org/10.1088/1757-899x/1238/1/012026.
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Abstract Carbon Fibre Reinforced Metal Hybrid (CFRMH) materials that combine a sheet metal substrate with a reinforcing carbon fibre patch represent a promising solution to reduce weight while increasing the structural and crash performance of future automotive vehicles. CFRMHs cannot be formed with conventional stamping processes and at high volumes. This currently reduces their widespread application. Roll forming is increasingly used in the automobile industry for the forming of lightweight and high-strength metal structural components. The major deformation mode in roll forming is simple bending and this reduces interlaminar shear and compressive stresses that lead to fibre failure and delamination issues when stamping CFRMH sheet materials. This work analyses the potential of applying the conventional roll forming process for the manufacture of a simple top hat section shape from CFRMH sheet. For this, first, the material is produced in a hot press and then formed to shape in a laboratory roll forming facility at room temperature. Different layup sequences are tested, and component quality is analysed after roll forming by visual inspection. The results suggest that roll forming presents a promising manufacturing method for the production of automotive components from CFRMH sheets. The roll formed open shells are joined to produce crash box structure and tested in 3-point bending. The results show that depending on the fibre orientation a significant increase in weight specific strength is achieved.
4
Liu, Han Wu, Zhao Hui Liu, Hui Xiao Li, and Shao Bo Ping. "Computer Simulation of Hot Stamping Process of DP Steel Car Bumper Chain Based on Dynaform." Applied Mechanics and Materials 178-181 (May 2012): 2877–80. http://dx.doi.org/10.4028/www.scientific.net/amm.178-181.2877.
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Owing to the advantages of weight loss and security, duplex steel plate has been the priority for the saloon car body instead of ordinary one among a majority of engine factories. While there are undesirable phenomena because of its high strength at normal temperature, such as its formability is worsened dramatically, and failure and fracture always occur in the stamping. So hot stamping process must be adopted to make the formability available. Based on the Bumper chain of Beijing Hyundai Reina and taken DP600 high strength steel as research object, this paper analyzes the distributions of stress, strain and thickness changes during the process of sheet metal forming by using eta/DYNAFORM software, simulates the spring-back quantity after hot stamping forming, and the numerical simulation of the temperature field distribution with time during stamping process was done. The result shows that duplex steel plate can meet the performance requirements of automotive chain forming, which offers theory basis for the production of such parts.
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Luan, Xi, Omer El Fakir, Hao Xiang Gao, Jun Liu, and Li Liang Wang. "Formability of AA6082-T6 at Warm and Hot Stamping Conditions." Key Engineering Materials 716 (October 2016): 107–13. http://dx.doi.org/10.4028/www.scientific.net/kem.716.107.
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Forming limit diagrams (FLDs) of AA6082 at warm/hot stamping conditions were determined by using a specially designed test rig. The tests were carried out at various temperatures from 300 to 450°C and forming speeds ranging from 75 to 400 mm/s. The strain was visualized and measured using ARGUS software provided by GOM. The results clearly show that the formability of AA6082-T6 sheet metal, in terms of the limit major strain, increased by 38.9 % when the forming temperature was increased from 300°C to 450°C at a speed of 250 mm/s, and increased by 42.4 % when the forming speed was decreased from 400 to 75 mm/s at a temperature of 400°C. It was verified that hot stamping is a promising technology for manufacturing complex-shaped components.
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Jung, Dong Won. "A New Engineering Technique in Roller Design to Prevent Thinning of Sheet in Roll Forming Process." Applied Mechanics and Materials 873 (November 2017): 42–47. http://dx.doi.org/10.4028/www.scientific.net/amm.873.42.
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These days sheet metal forming is a widely used in different industrial fields with large production volumes. Formability of metal sheets is limited by localized necking and plastic instability. In sheet metal forming processes like drawing and stamping the main challenge is thinning of the metal sheet in some regions. To reduce thinning of the sheet product, roll forming has been suggested instead of stamping process. Thinning strain can cause necking, tearing or wrinkling which are failure of the metal sheet. In this study a new engineering technique is proposed in order to prevent thinning of the steel galvanized hot coil commercial (SGHC) in roll forming process. An explicit finite element code, ABAQUS software, was used to simulate the roll forming process. The results show that the proposed technique has an important effect on thinning of the sheet and can reduce it significantly. Investigation on the second and third and fourth rollers show the effect of modified roller dimension as on reducing the thickness. These reductions in second, third and fourth rollers are from 4 percent to 0.5 percent, 2.8 to 1.4 percent and from 1.4 to 0.7 percent respectively. The reasons of the new techniques effect were also discussed.
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Ko, Dae-Cheol, Dae-Hoon Ko, Jae-Hong Kim, and Joon-Hong Park. "Development of a partition panel of an Al6061 sheet metal part for the improvement of formability and mechanical properties by hot forming quenching." Advances in Mechanical Engineering 9, no. 2 (February 2017): 168781401769121. http://dx.doi.org/10.1177/1687814017691213.
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In this study, the hot forming quenching process was investigated to improve the deficiencies that arise in materials subjected to conventional cold stamping, such as low formability and undesirable mechanical properties. The hot forming quenching process was mainly discussed in terms of formability and mechanical properties in this study and was first evaluated by preliminary tests. To examine formability, an evaluation was conducted using hot-tensile and hemispherical-dome stretching tests at temperatures of 350°C and 450°C, respectively. In addition, the mechanical properties of the formed part were predicted using quench factor analysis, which was based on the cooling temperature during the die quenching process. These preliminary test results were then used to predict the formability and hardness of the partition panel of an automotive part, where the analytical results indicated high performance of the hot forming quenching process, in contrast to conventional forming. Finally, the hot forming quenching experiment of the partition panel was carried out to validate the predicted results and the obtained formability and hardness values were compared with conventional forming at room temperature using T4 and T6 heat-treated sheets. The analytical and experimental results indicate that the hot forming quenching process is a very effective method for obtaining desirable formability and mechanical properties in the forming of aluminum sheets.
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Venema, Jenny, Javad Hazrati, David Matthews, and Ton van den Boogaard. "An Insight in Friction and Wear Mechanisms during Hot Stamping." Key Engineering Materials 767 (April 2018): 131–38. http://dx.doi.org/10.4028/www.scientific.net/kem.767.131.
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Hot stamping is often used in the automotive industry to combine formability and strength. However, during forming process at high temperatures, friction and tool wear are determining factors that can affect the efficiency of the whole process. The goal of this paper is to investigate the effects of temperature on the local coefficient of friction and tool wear and to provide an insight in the phenomena which take place at the tool-sheet metal interface during hot stamping processes. For this purpose, hot friction draw tests between uncoated tool steel and Al-Si coated press hardening steel were carried out at several temperatures between 500-700°C. Consecutive tests were performed to mimic industrial hot stamping process and to investigate the effect of tool wear on the friction phenomenon. Finally, tool-sheet metal tribological behavior and the interaction between the friction and tool wear mechanisms were analyzed using different imaging and chemical characterization techniques. The results show that several stages can be distinguished at the interface between tool and sheet metal coating during hot stamping: flattening due to initial normal contact, ploughing of tool asperities through coating, secondary ploughing in the coating by adhered material on the tooling, and abrasive wear in the tool by embedded particles in the sheet metal coating. Furthermore, tool wear shows some major differences in the temperature range of 500-700°C. At high temperature a larger abrasive area and more severe compaction galling occurs that can be explained by material properties of Al-Si coating at elevated temperatures. The results of this study can be used for more efficient process design and a more realistic modelling of the hot stamping process.
9
Mohamed, Mohamed, Sherif Elatriby, Zhusheng Shi, and Jian Guo Lin. "Prediction of Forming Limit Diagram for AA5754 Using Artificial Neural Network Modelling." Key Engineering Materials 716 (October 2016): 770–78. http://dx.doi.org/10.4028/www.scientific.net/kem.716.770.
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Warm stamping techniques have been employed to solve the formability problem in forming aluminium alloy panels. The formability of sheet metal is a crucial measure of its ability for forming complex-shaped panel components and is often evaluated by forming limit diagram (FLD). Although the forming limit is a simple tool to predict the formability of material, determining FLD experimentally at warm/hot forming condition is quite difficult. This paper presents the artificial neural network (ANN) modelling of the process based on experimental results (different temperature, 20°C-300°C and different forming rates, 5-300 mm.s-1) is introduced to predict FLDs. It is shown that the ANN can predict the FLDs at extreme conditions, which are out of the defined boundaries for training the ANN. According to comparisons, there is a good agreement between experimental and neural network results
10
Ota, Eiichi, Yasuhiro Yogo, Takamichi Iwata, Noritoshi Iwata, Kenjiro Ishida, and Kenichi Takeda. "Formability Improvement Technique for Heated Sheet Metal Forming by Partial Cooling." Key Engineering Materials 622-623 (September 2014): 279–83. http://dx.doi.org/10.4028/www.scientific.net/kem.622-623.279.
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A forming process for heated sheet metal, such as hot-stamping, has limited use in deformable shapes. Higher temperature areas which have not yet come into contact with dies are more easily deformed; therefore, local deformation occurs at these areas which leads to breakage. To improve the formability of heated sheet metal, a deformation control technique utilizing the temperature dependence of flow stress is proposed. This technique can suppress local deformation by partial cooling around potential cracking areas to harden them before forming. In order to apply this technique to a variety of product shapes, a procedure to determine a suitable initial temperature distribution for deep drawing and biaxial stretching was developed with a coupled thermal structural simulation. In this procedure, finite elements exceeding forming limit strain are highlighted, and an initial temperature distribution is defined with areas of decreased temperature around the elements to increase their resistance to deformation. Subsequently, the partial cooling technique was applied to a deep drawing test with a heated steel sheet. The results of the experiment showed that the proposed technique improved 71% in the forming limit depth compared with results obtained using a uniform initial temperature distribution.
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Borsetto, Francesca, Andrea Ghiotti, and Stefania Bruschi. "Investigation of the High Strength Steel Al-Si Coating during Hot Stamping Operations." Key Engineering Materials 410-411 (March 2009): 289–96. http://dx.doi.org/10.4028/www.scientific.net/kem.410-411.289.
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To improve the low formability that HSS sheets exhibit at room temperature, innovative forming technologies like the hot stamping process are currently applied. In order to avoid scaling and decarburization during the heating step, metal sheets coated with a specially developed Al-Si coating are utilized. In the present work the coating characteristics in terms of morphology, surface roughness and tribological behaviour are investigated as function of heating temperature, holding time and cooling rate that are typical of hot stamping processes.
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Qian, Fang. "Numerical Simulation of Hot Stamping Forming of AZ Series Magnesium Alloys and Optimization of Die Process." Journal of Chemistry 2022 (May 28, 2022): 1–7. http://dx.doi.org/10.1155/2022/6484242.
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In order to deal with the bottleneck of poor plasticity and low formability of magnesium alloys at room temperature, a numerical simulation and a die process optimization method based on hot stamping of AZ series magnesium alloys were proposed. Firstly, based on the PAM-STAMP finite element analysis platform, the thermomechanical coupling numerical simulation is carried out for the cross cup-shaped deep drawing, and the changes in the stress and temperature field during the forming process are analyzed. Aiming at the influence of various process parameters on the plastic formability of magnesium alloys, the effects of sheet metal shape, die fillet size, friction factor, and blank holder force on the forming quality were analyzed through experiments. The experimental results show that under the same conditions such as temperature and blank holder force, the numerical simulation method and the mold process optimized in this paper can be used to form parts that are 25% deeper than the traditional process, and the sheet material can be thinned to the maximum at this time. The amount is 0.152 mm, which verifies the correctness and superiority of the method and process in this paper.
13
Demes, Michael, Jan Beuscher, Markus Kühn, and Klaus Dröder. "Influencing Intermetallic Layers of Hot Stamped Steel for Adhesively Bonded Plastic Metal Hybrids." Key Engineering Materials 801 (May 2019): 258–63. http://dx.doi.org/10.4028/www.scientific.net/kem.801.258.
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Hot stamping of high strength steel parts is an established way to realize today ́s structural lightweight components in car bodies through sheet thickness reduction. The steel typically used for hot stamping is a boron-manganese 22MnB5 steel reaching up to 1,900 MPa in strength. New boron-manganese alloys achieving higher strength are expected to be developed, generating challenges for the manufacturing process by means of formability. Thus, a further reduction of steel thickness resulting in lighter components is not expected. Hybrid lightweight design approaches aim at weight reduction by reducing steel thickness and applying fiber-reinforced plastics (FRP) to regain structural stiffness and strength. The use of residual heat remaining from the hot stamping process allows to activate adhesives to bond FRP to hot stamped steel. The performances of adhesive bonds depend strongly on surface characteristics. To avoid scaling and decarburization during the heating process several coatings for hot stamped steels are used forming intermetallic layers through heat treatment. The most common coating in today’s automotive application is an Al-Si coating. Thus, the overall performance of the adhesive bonded hot stamped metal polymer hybrid is not only depending on adhesives performance but also strongly on the hot stamped steel’s coating performance. In this paper, the characteristics of hot stamped steel 22MnB5 Al-Si coating are investigated with regard to adhesion performance. Therefore, hot stamped specimens are manufactured under realistic industrial conditions investigating the influence of furnace temperature and dwell time on the overall coating and intermetallic layers of Al-Si coating. The specimens are investigated with respect to Al-Si coating thickness, lap shear strength of hybrid specimen and tensile strength of hot stamped steel demonstrating the dependency of the overall hybrid specimen performance from the coating performance.
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Ghiotti, Andrea, Stefania Bruschi, Francesco Sgarabotto, and Francesco Medea. "Novel Wear Testing Apparatus to Investigate the Reciprocating Sliding Wear in Sheet Metal Forming at Elevated Temperatures." Key Engineering Materials 622-623 (September 2014): 1158–65. http://dx.doi.org/10.4028/www.scientific.net/kem.622-623.1158.
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Hot stamping has gained increasing importance in the last years due to the introduction of High Strength Steels (HSS) to improve the strength-to-mass ratio of stamped components. Despite the advantages in terms of load decrease, springback reduction and increased formability, the elevated temperatures the tools are subjected to may determine severe thermal mechanical cycling, increased oxidation and wear, which influence the tools service life and the quality of the produced parts. In addition, the frictional behaviour is also changing with temperature, thus affecting the performance of the forming operation itself. In this paper a novel experimental apparatus suitable for reciprocating sliding wear tests at elevated temperatures is presented. It consists of a linear sliding guideway connected to an electrical actuator and equipped with a heating plate to heat metal sheets. A solid frame embeds a screw device used to apply normal load. Thermocouples placed both on the plate and on sheet sample are used to control temperature during the test. The machine is also equipped with two load cells to record the normal and the tamgential loads. The 22MnB5 high strength steel was chosen as reference material for the machine testing. The results showed the capability of the new equipment and the good stability of the mechanical and thermal condition during testing.
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Lane, Connor, Zhutao Shao, Kailun Zheng, and Jianguo Lin. "Effect of the thickness reduction of specimens on the limit strains in thermomechanical tensile tests for hot-stamping studies." Manufacturing Review 5 (2018): 11. http://dx.doi.org/10.1051/mfreview/2018009.
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Sheet metal formability under hot stamping conditions has been evaluated using a novel planar testing system developed previously, being used within a Gleeble machine. Nevertheless, the specimen design with the central recess was not standardised, and the thickness reduction was not applied to the dog-bone type of specimen for testing at the uniaxial straining state. In this paper, effect of thickness reduction of dog-bone specimens on limit strain measurement under hot stamping conditions is investigated, and two types of dog-bone specimens without and with central recess are presented. Thermomechanical uniaxial tensile tests were performed at various deformation temperatures and strain rates, ranging from 370–510 °C and 0.01–1/s, respectively, by using the developed biaxial testing system in the Gleeble. The distributions of temperature and axial strain along gauge region of the two types of specimen were measured and compared. The specimen with consistent thickness had a better uniformity of temperature and strain distributions, compared to that with thickenss reduction. Forming limits for both types of specimen were also determined using the section-based international standard method. It is found that the accuracy of the calculation of forming limits based on the use of specimen with thickness reduction was highly dependent on the selection of the stage of the deformation of the specimen.
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Kumar, Manoj, Georg Kirov, Florian Grabner, and Ermal Mukeli. "Sheet Forming Processes for AW-7xxx Alloys: Relevant Process Parameters." Materials Science Forum 879 (November 2016): 1036–42. http://dx.doi.org/10.4028/www.scientific.net/msf.879.1036.
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High strength AW-7xxx sheet alloys are promising candidates to manufacture crash relevant parts, but their limited formability at room temperature presents a major challenge. Formability is controlled through heating rate, heat treatment temperature and time, quenching rate, forming temperature and strain rate. In the literature retrogression forming, W-temper forming, warm forming and hot stamping processes have been proposed to improve the formability of AW-7xxx alloys. Of these the greatest improvement in formability comes from W-temper forming and hot stamping. Considering the similarity to the conventional forming processes of cold stamping for aluminium and hot stamping for steel, the W-temper forming and hot stamping of aluminium are promising for AW-7xxx alloys.
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Liang, Hai Jian, Xiao Wei Wu, Yong Wang, Quan Lin Jin, Zhao Li Ma, and Shuang Sheng Feng. "Research on Quick Superplastic Forming for Aluminium Alloy Sheet." Materials Science Forum 735 (December 2012): 301–6. http://dx.doi.org/10.4028/www.scientific.net/msf.735.301.
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This article describes the high rate superplastic forming. The high rate superplastic forming technology is a new complex process,which integrates hot stamping and superplastic forming .It has feature of rapidity of the hot stamping and character of excellent formability of the superplastic forming.We obtained the best proportion of the hot forming and the superplastic forming through simulation experiment, and formed a car’s abonnet by applying the proportion.Compared with the high rate superplastic forming,the forming quality is better than that of hot forming. and the forming time is less than that of superplastic forming. Result shows that ,the high rate superplastic forming technology can meet the requirements for mass production.
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Fracz, W., F. Stachowicz, T. Trzepieciński, and T. Pieją. "Forming Limit Diagram of the AMS 5599 Sheet Metal." Archives of Metallurgy and Materials 58, no. 4 (December 1, 2013): 1213–17. http://dx.doi.org/10.2478/amm-2013-0153.
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Abstract Formability of sheet metal is dependent on the mechanical properties. Some materials form better than others - moreover, a material that has the best formability for one stamping may behave very poorly in a stamping of another configuration. For these reasons, extensive test programs are often carried out in an attempt to correlate material formability with value of some mechanical properties. The formability of sheet metal has frequently been expressed by the value of strain hardening exponent and plastic anisotropy ratio. The stress-strain and hardening behaviour of a material is very important in determining its resistance to plastic instability. However experimental studies of formability of various materials have revealed basic differences in behaviour, such as the ”brass-type” and the ”steel-type”, exhibiting respectively, zero and positive dependence of forming limit on the strain ratio. In this study mechanical properties and the Forming Limit Diagram of the AMS 5599 sheet metal were determined using uniaxial tensile test and Marciniak’s flat bottomed punch test respectively. Different methods were used for the FLD calculation - results of these calculations were compared with experimental results
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Kumar, M., and N. G. Ross. "Investigations on the Hot Stamping of AW-7921-T4 Alloy Sheet." Advances in Materials Science and Engineering 2017 (2017): 1–10. http://dx.doi.org/10.1155/2017/7679219.
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AW-7xxx alloys have been nowadays considered for greater light weighting potential in automotive industry due to its higher strength compared to AW-5xxx and AW-6xxx alloys. However, due to their lower formability the forming processes are still in development. This paper investigates one such forming process called hot stamping. The investigation started by carrying out hot tensile testing of an AW-7xxx alloy, that is, AW-7921 at temperatures between 350°C and 475°C, to measure the strength and formability. Formability was found to improve with increasing temperature and was sensitive to the strain rate. Dynamic recovery is considered as usual reason for the formability improvement. However, examining the precipitation states of the as-received condition and after hot stamping using differential scanning calorimetry (DSC), the dissolution of precipitates was also believed to contribute to this increase in formability. Following solution heat treatment there was no precipitation during cooling across the cooling rates investigated (5–10°C/s). Samples taken from parts hot stamped at 10 and 20 mm s−1 had similar yield strengths. A 3-step paint baking heat treatment yielded a higher postpaint baking strength than a single step treatment.
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Wang, Lei Gang, Ting Zhou, and Yao Huang. "Zinc Coating Failure Analysis and Sheet Formability during Hot-Dip Galvanized Sheet Stamping." Key Engineering Materials 575-576 (September 2013): 510–14. http://dx.doi.org/10.4028/www.scientific.net/kem.575-576.510.
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By doing Erichsen experiments, samples of hot-dip galvanized sheet under different Erichsen depths (ED) were got. Surface and cross-section of these samples were analyzed by using SEM and EDS, which can show morphology and chemical composition respectively. Failure modes of galvanized sheet under different ED were researched. Then evolution process of zinc coating failure and effects of it on galvanized sheet formability were discussed. The results indicate that during hot-dip galvanized sheet stamping, zinc coating will pulverize, exfoliate and fracture for influence of friction and forming force, which leads to decrease of galvanized sheet formability.
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Bohn, M. L., S. G. Xu, K. J. Weinmann, C. C. Chen, and A. Chandra. "Improving Formability in Sheet Metal Stamping With Active Drawbead Technology." Journal of Engineering Materials and Technology 123, no. 4 (July 24, 2000): 504–10. http://dx.doi.org/10.1115/1.1395577.
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Aluminum is expected to gain popularity as material for the bodies of the next generation of lighter and more fuel-efficient vehicles. However, its lower formability compared with that of steel tends to create considerable problems. A controllable restraining force caused by adjusting the penetration of drawbeads can improve the formability. This paper describes the effects of temporal variations in drawbead penetration on the strain distribution in a symmetric stamped part. Comparison of the results of numerical simulations with the corresponding experimental results shows that the predictions of strain distribution on the panel are in very good agreement. Furthermore, forming limit diagram analysis indicates that the active drawbead concept is beneficial to the formability of AA 6111-T4.
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Wang, Lei Gang, Ting Zhou, and Yao Huang. "Experimental and Simulation Research on Stamping Formability of Hot-Dip Galvanized Sheet." Applied Mechanics and Materials 364 (August 2013): 542–46. http://dx.doi.org/10.4028/www.scientific.net/amm.364.542.
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When stamping galvanized sheet, the formability usually decreases for failure of zinc coating. In this paper, formability of galvanized sheet was firstly researched by Erichsen experiment. The results show that zinc coating has lost efficacy when the cup arrives the value of Erichsen depth (ED). Then finite element analysis was used, it puts the zinc coating and the substrate in connection by using automatic-surface-to-surface-tiebreak and sets up a series of forming limitation diagrams (FLD) of galvanized sheet and of zinc coating under different punch strokes. Then depth of the cup when zinc coating reaches critical state was got, which decreased about 5%-10% compared with bare sheet. At last, failure mechanism of zinc coating was discussed, the reason is that material of zinc coating is soft and the friction leads to pulverization and exfoliation of zinc coating. The simulation results are consistent with the Erichsen experiment ones. Conclusions of this paper can provide theoretical guidance for the stamping process design of galvanized sheet.
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Ariffin, M. K. A., Shamsuddin Sulaiman, and M. S. Mohd Ruslan. "Finite Element Analysis of Sheet Metal Formability Effect on Automotive Part." Applied Mechanics and Materials 660 (October 2014): 788–93. http://dx.doi.org/10.4028/www.scientific.net/amm.660.788.
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An increasing demand for lower price and better quality vehicle has increase complexity of tool development process. This includes concept evaluation, design phase, prototype phase and pre production phase. Experience show that R&D spends most of the time and cost for tool development process, which includes assembly tooling, product tooling for automobile sheet metal component or part requires the highest cost in tool development process as most metal stamping part requires more than one tool to produce finished stamping part. For these reason, sheet metal forming simulation and analysis at early stage of tool development process is very important to shorten the tool development cycle time and cost. In other word by applying sheet metal forming simulation and analysis at early stage it can reduce the die manufacturing cycle time and cost.
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Liu, Yao Guo. "Car Progressive Stamping Molding Process Simulation and Process Optimization." Advanced Materials Research 971-973 (June 2014): 414–17. http://dx.doi.org/10.4028/www.scientific.net/amr.971-973.414.
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Based on the beam outside the front car plate , for example, to use DYNAFORM software for finite element analysis method to start the process of drawing molding method, the research body stamping design and formability analysis. Numerical simulation techniques for forming sheet metal stamping simulation .
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Cai, Gan Wei, Xi Yong Xu, Zhan Guang Zheng, Zhuan Zhang, and Du Chao Wu. "Numerical Simulation and Process Optimization for Multi-Stage Forming of Wheel Centre Disc." Advanced Materials Research 189-193 (February 2011): 2770–74. http://dx.doi.org/10.4028/www.scientific.net/amr.189-193.2770.
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The steel wheel centre discs are usually stamped by multi-stage sheet metal forming. The stage number and the content of every stage decide if the structure-pieces can be formed successfully and the final forming quality. In this paper, the forming characteristics of wheel centre disc were analyzed firstly and the reasonable two-stage stamping scheme of drawing and inverse-drawing are adopted. The numerical simulations of multi-stage stamping process are performed and connected together through deformation transmission. By means of FLD and changes of sheet metal chickness, the formability is analyzed and the forming process is optimized. The feasibility of multi-stage forming process simulation and the validity of the optimized scheme were verified by stamping in practice.
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Hussain, Ghulam, Nasir Hayat, and Lin Gao. "Role of Material Properties in Improving Sheet Formability in SPIF Process." Advanced Materials Research 139-141 (October 2010): 600–604. http://dx.doi.org/10.4028/www.scientific.net/amr.139-141.600.
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Single point incremental forming (SPIF) is a novel sheet metal forming process. Owing to unique deformation mechanism, this process improves the sheet formability as compared to the conventional stamping process. In the current paper, the mechanical properties and spifability (i.e. formability in SPIF) of a wide range of materials were tested. The mechanical properties were mainly determined through tensile testing and the spifability was evaluated using Varying Wall Angle Conical Frustum (VWACF) test. Each mechanical property was drawn against the improvement in sheet formability (i.e. difference of spifability and stampability) and the sole most influential property was identified. It was found that the improvement in formability increases with the increasing of true thickness strain at tensile fracture.
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Jansen, Yann, Roland E. Logé, Marc Milesi, Stephan Manov, and Elisabeth Massoni. "Using Cross Stamping to Test Zinc Sheets Formability." Key Engineering Materials 504-506 (February 2012): 65–70. http://dx.doi.org/10.4028/www.scientific.net/kem.504-506.65.
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Sheet metal formability has been studied for a half century. The sheet formability is mostly described by the Forming Limit Diagram (FLD). A prediction of this FLD is a source of interest for industrial companies. Indeed knowing the FLD of a material allows optimization of the production processes which leads to money saving. Nevertheless, the formability tests (tensile, bulge and Nakazima tests) which give the experimental FLD do not really represent the process that the sheet will undergo in industrial conditions. The paper therefore focuses on a cross stamping test. The material of interest is a Zinc sheet. FLD prediction is reported for a wide variety of metals [1] but literature about Zinc is nearly non existent. The studied Zinc sheets exhibit a highly anisotropic mechanical behaviour due to the hcp lattice structure and the inherited rolling texture. This anisotropic behaviour results in an anisotropic formability. The Zinc sheet FLD is influenced by the orientation of the rolling direction during the process. Experimental cross stamping of this material allows describing the studied material behaviour in a large range of mechanical solicitations from tensile to biaxial tension. The experimental results are compared with the finite element simulation and permit to understand where and why failures appear, which leads to a better understanding of Zinc anisotropic formability.
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Afzeri, M. S. Shahdan, and H. Shah Qasim. "Effect of Addendum Parameters to the Formability of Aluminum AL 6303." Advanced Materials Research 264-265 (June 2011): 206–11. http://dx.doi.org/10.4028/www.scientific.net/amr.264-265.206.
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Procedure of die design is mostly based on iterative try and error to obtain final design with good stamping formability. The stamping formability of sheet metal part is possible to be improved by adding addendum features at die model. In this paper discusses the effect of drawbars toward the formability of stamping process of aluminum AL6063. Effect of addendum size is evaluated Finite Element Simulation to prevent wrinkling and tearing. Simulation model is constructed by designing a simple die, punch and binder using variety drawbar diameters. The model further evaluated using LS-Dyna software interfaced by forming tool of LS-Prepost. Formability of the model is evaluated through yield stress, major strain and minor strain data. From the result of evaluation obtained that without draw beat, major/minor strain is above FLD while the formability is improved by applying 5 mm draw bead diameter.
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Zeng, Xin, Bi You Peng, Lin Zhi Liao, and Yan Kui Cheng. "Application Research and Analysis of Bending Springback of Semi-Circular Arc Stamping Parts Based on DYNAFORM." Applied Mechanics and Materials 543-547 (March 2014): 3931–34. http://dx.doi.org/10.4028/www.scientific.net/amm.543-547.3931.
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Springback in the sheet metal stamping technology is a hot research subject in the sheet metal forming field. This article takes the semi-circular arc stamping parts as the objects of research. It aims at improving precision of the flanging forming parts and decreasing the bending springback. It analyzes the forming technology and deformation characteristics of flanging forming theoretically. Besides, it adopts the numerical simulation method to carry out research on the key factors influencing the forming process of semi-circular arc stamping parts (flanging and then bending) and the springback deformation, in order to find out the optimum production process scheme for semi-circular arc stamping parts.
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del Prete, Antonio, Gabriele Papadia, and Teresa Primo. "Sheet Metal Forming Process Design Rules Development." Key Engineering Materials 473 (March 2011): 765–72. http://dx.doi.org/10.4028/www.scientific.net/kem.473.765.
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Finite element analysis (FEA) is a powerful tool to evaluate the formability of stamping parts during process and die design development procedures. However, in order to achieve good product quality and process reliability, FEA application has to be performed many times exploring different process parameters combinations. Meanwhile, it is very difficult to perform an exhaustive process design definition when many parameters play a fundamental role to define such a complex problem. So, under the needs of reduction in: design time, development cost and parts weight, there is an urgent need to develop and apply more efficient methods in order to improve the current design procedures. For a generic component it is clear how its shape, among several parameters, has a direct influence on its feasibility. Starting from this assumption, the authors have developed a new approach grouping components upon their shapes analyzing component formability within a given “component family”. Nowadays, it exists only a process designer “sensitivity” that produces a ranking upon shape/feasibility ratio. Having as reference industrial test cases, the authors have defined appropriate shape parameters in order to have dimensionless coefficients representative for the given geometries. In particular, the components have been classified using a parameters set defining similarity families: related to geometrical aspects and to constitutive material. From the geometrical point of view the following parameters have been defined: family name, shape factor, punch radius-thickness ratio, die radius-thickness ratio, while for the constitutive material a code has been defined. FEA has been extensively used in order to: define, investigate and validate each shape parameter with a proper comparison to the macro feasibility of the chosen component geometry. The feasibility configuration definition, for a given shape, has been made through an appropriate study of the influence of each process variable on the properly process performances.
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Xiang, H. Y., and Yue Xian Zhong. "Forming Defects Analysis of Auto-Panel Stamped Part with Experimental Strain Approach." Materials Science Forum 471-472 (December 2004): 503–7. http://dx.doi.org/10.4028/www.scientific.net/msf.471-472.503.
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This document explains and demonstrates an experimental method to determine principal plastic strains in industrially stamped sheet panels. The principal strains distribution after a given stamping process can be obtained using computer aided grid experimental method. In contrast with FLD (Forming Limit Diagram) obtained by the material testing, the measured results of strain distribution can be used to determine the sheet metal’s formability allowing to determine at which point the sheet metal cracks or uneven stretch occurs and other forming defects. The main principle and related theory of this approach are discussed. One automobile panel stamped part as a practical case was studied, the strain distribution of the part after a given stamping process was measured and calculated, a demonstration of how to deal with the results in comparison with FLD to determine and solve forming problems is analyzed.
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Jiang, Binghe, Jianghua Huang, Hongping Ma, Huijun Zhao, and Hongchao Ji. "Multi-Objective Optimization of Process Parameters in 6016 Aluminum Alloy Hot Stamping Using Taguchi-Grey Relational Analysis." Materials 15, no. 23 (November 24, 2022): 8350. http://dx.doi.org/10.3390/ma15238350.
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The hot stamping technology of aluminum alloy is of great significance for realizing the light weight of the automobile body, and the proper process parameters are important conditions to obtain excellent aluminum alloy parts. In this paper, the thermal deformation behavior of 6016 aluminum alloy at a high temperature is experimentally studied to provide a theoretical basis for a finite element model. With the help of blank stamping finite element software, a numerical model of a 6016 aluminum alloy automobile windshield beam during hot stamping was established. The finite element model was verified by a forming experiment. Then, the effect of the process parameters, including blank holder force, die gap, forming temperature, friction coefficient, and stamping speed on aluminum alloy formability were investigated using Taguchi design, grey relational analysis (GRA), and analysis of variance (ANOVA). Stamping tests were arranged at temperatures between 480 and 570 °C, blank holder force between 20 and 50 kN, stamping speed between 50 and 200 mm/s, die gap between 1.05 t and 1.20 t (t is the thickness of the sheet), and friction coefficient between 0.15 and 0.60. It was found that the significant factors affecting the forming quality of the hot-stamped parts were blank holder force and stamping speed, with influence significance of 28.64% and 34.09%, respectively. The optimal parameters for hot stamping of the automobile windshield beam by the above analysis are that the die gap is 1.05 t, the blank temperature is 540 °C, the coefficient of friction is 0.15, stamping speed is 200 mm/s, and blank holder force is 50 kN. The optimized maximum thickening rate is 4.87% and the maximum thinning rate is 9.00%. The optimization method used in this paper and the results of the process parameter optimization provide reference values for the optimization of hot stamping forming.
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Jaafar, Roseleena, Farrahshaida Mohd Salleh, Izdihar Tharazi, and Abdul Rahman Omar. "Reducing Non-Value Added Process for an Automotive Component Using Finite Element Modeling." Advanced Materials Research 576 (October 2012): 737–41. http://dx.doi.org/10.4028/www.scientific.net/amr.576.737.
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The research work focuses on sheet metal stamping process simulation of an automotive component known as bracket assembly upper spring made from low carbon steel and has axis-symmetrical cup shape that employs four multi-stage drawing processes. Non-value added drawing stages (optimization process) reduced and portrayed from the formability simulation result using finite element modeling (FEM) method. The modified design, with reduction of one draw stage, showed that the risk of the component to form cracks is lesser, the material elements are further away from the failure zone of the forming limit diagram (FLD) and it meets the requirement for minimum thickness. The FEM simulation was able to predict the formability and optimize the design of a sheet metal forming process that lowered the product cost and improve cycle time.
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Zhao, Pengjing, Qi Wu, Yo-Lun Yang, and Zhanghua Chen. "Process Optimization of the Hot Stamping of AZ31 Magnesium Alloy Sheets Based on Response Surface Methodology." Materials 16, no. 5 (February 24, 2023): 1867. http://dx.doi.org/10.3390/ma16051867.
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Hot stamping is an important manufacturing process for sheet metal parts. However, it is easy to produce defects such as thinning and cracking in the drawing area during the stamping process. In this paper, the finite element solver ABAQUS/Explicit was used to establish the numerical model of the magnesium alloy hot-stamping process. The stamping speed (2~10 mm/s), the blank-holder force (3~7 kN), and the friction coefficient (0.12~0.18) were selected as the influencing factors. Taking the maximum thinning rate obtained through simulation as the optimization objective, the response surface methodology (RSM) was applied to optimize the influencing factors in sheet hot stamping at a forming temperature of 200 °C. The results showed that the maximum thinning rate of sheet metal was most influenced by the blank-holder force, and the interaction between the stamping speed and the blank-holder force/friction coefficient had a great influence on the maximum thinning rate. The optimal value of the maximum thinning rate of the hot-stamped sheet was 7.37%. Through the experimental verification for the hot-stamping process scheme, the maximum relative error between the simulation and the experimental results was 8.72%. This proves the accuracy of the established finite element model and the response surface model. This research provides a feasible optimization scheme for the analysis of the hot-stamping process of magnesium alloys.
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Jung, Dong Won, Dong Hong Kim, Bong Chun Kim, Dae Lim Ko, and Duc Toan Nguyen. "A Development of Lancing Engineering Method for Lamp-CAN Stamping Process by Using Forming Analysis." Advanced Materials Research 337 (September 2011): 443–47. http://dx.doi.org/10.4028/www.scientific.net/amr.337.443.
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The products manufactured by the Sheet metal process are widely used in automobile and aircraft industries due to their high strength and superior surface characteristics. In this study, to improve the formability of the lamp-can, forming process was conducted using the Lancing engineering method. Lancing process is a press operation in which the work-piece is sheared and cut with one strike of the die to be a single-line cut or split, without removing any metal. Finite element method (FEM) was used to predict and investigate the improvement of formability of a lam-can with lancing process. As a result, it is believed that the Lancing process used in lamp-can forming would be helpful in the development of high-quality forming products because it can make material flow run well.
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Sun, Shao Li, Zi Jian Wang, Xiao Chun Yao, Yi Lin Wang, and Yi Sheng Zhang. "The Process Optimization to Prevent the Local Wrinkles of Hot Stamping Parts and the Design of Tools." Advanced Materials Research 1063 (December 2014): 301–4. http://dx.doi.org/10.4028/www.scientific.net/amr.1063.301.
Full textAbstract:
During the process of hot stamping, due to the deformations of sheet metals are mainly bending and shallow drawing, as well as to prevent the temperature strikingly drop caused by the local contact of sheet metal and die, the hot stamping tool usually does not set up blank-holder. And this leads to the occurrence of local wrinkles in some types of hot stamping parts, which affect the quality of the parts. Through the hot stamping tool design and process test of a car ́s B pillar, it discovered that the local wrinkle in the part ́s big end is more severe. As a result the program was modified by taking advantage of the forming principle of the counter punch to improve the design of upper tool (die), which eliminated the local wrinkle in the big end and improved the contact cooling efficiency, consequently ensured the hot forming parts ́ quality and reduced the production rhythm.
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Kopec, Mateusz, Kehuan Wang, Yaoqi Wang, Liliang Wang, and Jianguo Lin. "Feasibility study of a novel hot stamping process for Ti6Al4V alloy." MATEC Web of Conferences 190 (2018): 08001. http://dx.doi.org/10.1051/matecconf/201819008001.
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To investigate the feasibility of a novel hot stamping process for the Ti6Al4V titanium alloy using low temperature forming tools, mechanical properties of the material were studied using hot tensile tests at a temperature range of 600 - 900°C with a constant strain rate of 1s-1. Hot stamping tests were carried out to verify the feasibility of this technology and identify the forming window for the material. Results show that when the deformation temperature was lower than 700°C, the amount of elongation was less than 20%, and it also had little change with the temperature. However, when the temperature was higher than 700°C, a good ductility of the material can be achieved. During the forming tests, parts failed at lower temperatures (600°C) due to the limited formability and also failed at higher temperatures (950°C) due to the phase transformation. The post-form hardness firstly decreased with the temperature increasing due to recovery and then increased due to the phase transformation. Qualified parts were formed successfully between temperatures of 750 - 850°C, which indicates that this new technology has a great potential in forming titanium alloys sheet components.
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Ko, Dae-Hoon, Jae-Hong Kim, Dae-Cheol Ko, and Byung-Min Kim. "Improvement of Weldment Properties by Hot Forming Quenching of Friction Stir Welded TWB Sheet." Advances in Mechanical Engineering 6 (January 1, 2014): 257510. http://dx.doi.org/10.1155/2014/257510.
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The purpose of this study is to improve the mechanical properties and formability of friction stir welded tailor-welded blanks (TWBs) of Al6061 alloy with a new forming method called hot forming quenching (HFQ) in which solid-solution heat-treated aluminum sheets are formed at elevated temperature. Forming and quenching during HFQ are simultaneously performed with the forming die for the solid-solution heat-treated sheet. In this study, specimens of aluminum TWBs were prepared by friction stir welding (FSW) with a butt joint. The effectiveness of FSW joining was evaluated by observation of the macrostructure for different sheet thicknesses. In order to evaluate the formability of TWBs by HFQ, a hemisphere dome stretching test of the limit dome height achieved without specimen failure was performed with various tool temperatures. A Vickers test was also performed to measure weldment hardness as a function of position. The formability and mechanical properties of products formed by HFQ are compared with those formed by conventional forming methods, demonstrating the suitability of HFQ for sheet metal forming of friction stir welded TWBs.
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Sharma, Vikrant, Ashish Gohil, and Bharat Modi. "Experimental Investigation of Single Point Incremental Forming of Aluminum Sheet in Groove Test." Applied Mechanics and Materials 867 (July 2017): 177–83. http://dx.doi.org/10.4028/www.scientific.net/amm.867.177.
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Incremental sheet forming is one of the latest processes in sheet metal forming industry which has drawn attention of various researchers. It has shown improved formability compared to stamping process. Single Point Incremental Forming (SPIF) process requires only hemispherical tool and no die is required hence, it is a die-less forming process. In this paper experimental investigation on SPIF for Aluminium sheet has been presented. A groove test on Vertical Machining Centre has been performed. Factors (Step depth, Blank holder clamping area, Backing plate radius, Program strategy, Feed rate and Tool diameter) affecting the process are identified and experiments are carried out using fractional factorial design of experiments. Effect of the factors on fractured depth, forming time and surface finish have been analyzed using Minitab 17 software.
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Bharti, Sahil, Deepu Raneesh, Hariharan Krishnaswamy, and Sushanta Kumar Panigrahi. "Analytical approach to damage prediction in incremental sheet metal forming." IOP Conference Series: Materials Science and Engineering 1238, no. 1 (May 1, 2022): 012024. http://dx.doi.org/10.1088/1757-899x/1238/1/012024.
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Abstract Incremental sheet metal forming (ISF) is known to exhibit higher formability compared to conventional stamping. It is established that the mechanism of failure during ISF is by fracture occurring at higher effective strain than the local necking observed in traditional forming processes. The deformation limit in ISF is therefore estimated numerically using a suitable continuum damage model. However, simulation of incremental forming process including the damage model is often computationally expensive. In the present work, a simpler alternative combining finite element simulation and numerical solution outside finite element software is utilized. The finite element simulation is performed ignoring the damage model. The stress and strain history thus obtained in critical locations is utilized to estimate the damage evolution. The proposed method is useful when utilizing uncoupled continuum damage models. The proposed method is validated for typical cases by comparing it against the predictions from finite element method. Excellent correlation is observed between the proposed method and finite element simulation results.
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Ge, Rui, An Long, and Yin Chen. "Effect of Heating Parameters on the Part’s Properties in Hot Stamping Process." Advanced Materials Research 557-559 (July 2012): 2417–22. http://dx.doi.org/10.4028/www.scientific.net/amr.557-559.2417.
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In the automotive industry, the hot forming of high strength steels offers the possibility to obtain significant reduction of weight without affecting the structural performances of final products. Compared with conventional sheet metal forming, the proper design of hot stamping process chain requires the deep knowledge of both interface phenomena and material behavior at high temperatures in order to obtain the desired properties of final products in terms of microstructure and strength characteristics. The work presented in this paper aims at accurately evaluate the effect of heating parameters on the properties of final sheet components produced in hot forming operations. Different from that in the lab, all the samples and parts used for the experimental test were produced in the production line, which can objectively show the manufacturing properties and microstructure character of products in mass. Microstructure evaluation, hardness measurement and dimensional accuracy test after hot stamping were performed and considered. The best heating parameters for the researched hot stamping B-Pillar’s production were obtained through the above research.
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Miranda, SS, DJ Cruz, RL Amaral, AD Santos, J. César de Sá, and JV Fernandes. "Assessment of scatter on material properties and its influence on formability in hole expansion." Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications 235, no. 6 (February 15, 2021): 1262–70. http://dx.doi.org/10.1177/1464420721994868.
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The plastic deformation included in the technological processes of sheet metal forming allows the production of different components with different geometries. Therefore, the formability of metallic materials is an essential feature in stamping processes. One of the inevitable scattering sources when considering these processes is the variability of material properties, which can change from coil to coil, from batch to batch and from supplier to supplier. This constitutes a significant obstacle in improving the quality of any manufacturing process. The current study investigates the formability and the mechanical characterization of a defined advanced high strength steel grade, considering different suppliers, coils, and batches in order to evaluate its influence on the results of the sheet metal forming process. A microstructure analysis is also considered to understand the impact of micro-scale variables (e.g. grain size) in macro-scale behavior. Additionally, numerical simulations were taken into consideration to evaluate the influence of mechanical characterization in the results.
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Simoncini, Michela, Lorenzo Panaccio, and Archimede Forcellese. "Bending and Stamping Processes of FSWed Thin Sheets in AA1050 Alloy." Key Engineering Materials 622-623 (September 2014): 459–66. http://dx.doi.org/10.4028/www.scientific.net/kem.622-623.459.
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The present investigation aims at studying post-welding forming operations of friction stir welded AA1050 aluminium thin sheets. A preliminary investigation has allowed to define the rotational and welding speed values leading to friction stir welded joints with high mechanical properties. Then, formability and elastic springback were evaluated using the hemispherical punch and bending tests, respectively. A microstructural investigation has allowed to relate the mechanical properties of joints to microstructure. Finally, the friction stir welded assemblies were subjected to air bending and stamping experiments in order to evaluate their attitude to undergo to sheet metal forming operations.
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Bruschi, Stefania, Andrea Ghiotti, and Francesco Michieletto. "Formability Characteristics of AA5083 Sheets under Hot Forming Conditions." Key Engineering Materials 549 (April 2013): 356–63. http://dx.doi.org/10.4028/www.scientific.net/kem.549.356.
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The production of aluminum alloy components through sheet forming processes conducted at elevated temperatures is gaining more and more interest as it gives raise to the possibility of a significant enhancement of the metal formability characteristics, compared to room temperature forming. Aluminum alloy AA5083 blanks, which present a limited formability at room temperature, are usually formed through superplastic forming at elevated temperature: however, this processing route is too slow to be applicable for large batch production, typical for instance of the automotive industry. The paper is aimed at exploring the formability characteristics of the AA5083 when deformed at elevated temperature, but in a range of strain rates higher than those usually applicable in superplastic forming. To this aim, uni-axial tensile tests were carried out, in order to record the material formability characteristics as a function of temperature and strain rate, and to correlate them with the developed microstructural features. It is shown that it is possible to work at higher strain rates, still preserving a significant formability, even without using a conventional fine-grained superplastic alloy.
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Horn, Alexander, and Marion Merklein. "Investigation of diffusion behavior of carburized sheet metal in hot stamping." MATEC Web of Conferences 190 (2018): 08004. http://dx.doi.org/10.1051/matecconf/201819008004.
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Today’s manufacturing of structural car body parts faces several challenges, like forming accuracy and passenger safety. Besides these two requirements, lightweight design plays an important role. One possibility to fulfill these partially rivalling demands is the application of hot stamped parts. The combination of hot forming and in die quenching reduces not only springback, but also results in tensile strengths of up to 1500 MPa. This makes a simultaneous reduction of sheet thickness and therefore weight reduction possible. Further development enabled a tailored adjustment of mechanical properties, for example by applying different cooling conditions along the parts. One of the biggest issues of these state of the art processes is the formation of a transition zone due to heat transfer. A promising approach to adjust the mechanical properties with a minimized transition zone is the carburization of sheet metal. Therefore, the parts are coated with graphite, heat treated and subsequently quenched. In this work, the time variant process of carbon diffusion is investigated. Sheets with two different thicknesses are carburized and quenched. The resulting mechanical properties are analyzed using uniaxial tensile tests and microhardness measurements. The results are correlated with the carbon content measured by EDX-analysis.
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Horn, Alexander, and Marion Merklein. "Investigation of diffusion behavior of carburized sheet metal in hot stamping." Manufacturing Review 6 (2019): 16. http://dx.doi.org/10.1051/mfreview/2019017.
Full textAbstract:
Today, manufacturing of structural car body parts faces several challenges, like forming accuracy, passenger safety and lightweight design. One possibility to fulfill these partially rivalling demands is the application of hot stamped components. The combination of hot forming and in-die quenching reduces not only springback, but also results in tensile strengths of more than 1500 MPa. Besides conventional hot stamping, the process can be adapted to manufacture parts with tailored properties. One of the biggest issues of these state-of-the-art processes is the formation of extensive transition zones due to heat transfer. A promising approach to adjust the mechanical properties with a minimized transition zone is tailored carburization of sheet metal. Therefore, the parts are locally coated with graphite, heat treated and subsequently quenched. In this work, the time variant process of carbon diffusion is investigated. Sheets with two different thicknesses are carburized and quenched. The resulting mechanical properties are analyzed using uniaxial tensile tests and microhardness measurements. On this basis, a process window is identified. Furthermore, the applicability of EDX and WDX analysis for the measurement of carbon concentration is investigated within this work.
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Mori, Kenichiro. "Application of Servo Presses to Sheet Metal Forming." Key Engineering Materials 473 (March 2011): 27–36. http://dx.doi.org/10.4028/www.scientific.net/kem.473.27.
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Mechanical AC servo presses having high flexibility for control of motion have been recently developed. In these presses driven by servo motors, the slide motion is accurately controlled by real-time feedback of ram position measured with sensors like the conventional machine tools, and thus complicated motion is attainable. The application of servo presses to sheet metal forming processes is reviewed in the present paper. The springback in bending was reduced by bottoming and re-striking. In deep drawing, the forming limit of high strength steel sheets was improved by detaching tools from the sheet, and the wrinkling was prevented by applying a stepwise motion. A hot stamping process using rapid resistance heating and a servo press was developed to produce ultra-high strength steel parts.
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Wang, Wei, Yu Liu, Peng Fei Wen, and Jun Tong. "Numerical Simulation on the Shape of Stamping Part about Hot Forming and Quenching." Applied Mechanics and Materials 328 (June 2013): 450–56. http://dx.doi.org/10.4028/www.scientific.net/amm.328.450.
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With the application of ultra high strength steel in vehicle manufacturing field, the hot forming method which is used to form the high strength sheet at high temperature and cool rapidly in dies to obtain the final part has been studied extensively. In this paper, The FE model that contained thermal mechanical-microstructure and strain model represented by a mixture law for hot forming was discussed, and further been applied to hot forming and quenching process simulation of 22MnB5 metal sheet of U-shape constant section part. The computed results of final part shape and hardness after cooled in air, in water without dies and cooled within dies were compared respectively.
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Braun, A., G. Matthiesen, and G. Hirt. "Entwicklung eines Hochtemperatur-Bulgetests*/Development of a high-temperature bulge test – Enhanced material testing for hot sheet metal forming." wt Werkstattstechnik online 109, no. 01-02 (2019): 100–104. http://dx.doi.org/10.37544/1436-4980-2019-01-02-102.
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Das Presshärten von Stahl ermöglicht der Automobilindustrie die Herstellung von hochfesten Bauteilen mit vergleichsweise komplexen Geometrien. Vor allem crashrelevante Bauteile werden häufig pressgehärtet. Durch Umformsimulationen können Presshärteprozesse schnell und kostengünstig ausgelegt werden, wenn genaue Materialdaten vorliegen. Daher wurde im Rahmen des IGF-Projekts 19229 N ein Bulgetest entwickelt, welcher eine Materialprüfung unter den Bedingungen des Presshärtens ermöglicht. Hot-stamping of steel enables the automotive industry to produce high-strength components featuring complex geometries. Especially crash relevant components are often hot-stamped. While forming simulations enable the exact and cost-efficient design of hot-stamping processes, they require exact material data. Therefore, a bulge test has been developed within the IGF project 19229 N, which enables material testing under hot-stamping conditions.
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Tian, Xiao Wei, Yi Sheng Zhang, Zheng Wang, Hong Qing Li, Liang Wang, Bin Zhu, and Jian Li. "Design of a Tribo-Simulator for the High Strength Steel Friction and Wear Investigation in Hot Stamping." Advanced Materials Research 421 (December 2011): 147–50. http://dx.doi.org/10.4028/www.scientific.net/amr.421.147.
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Hot stamping has become the main technology to produce complex-shaped high-strength steel components. However, hot sheet metal forming can cause high rates of die wear and the scratching of the productions. A hot drawing tribo-simulator was designed to investigate the friction and wear behavior of high strength steel at elevate temperature. The value of the friction coefficient was obtained to examine the function of the tribo-simulator. The results prove that the coefficient of friction in hot stamping can be measured using this tribo-simulator. Moreover, the coefficient of friction is able to be used in finite element simulation to improve the accuracy of the modeling results and it is also an important indicator to evaluate the tribological behavior between the die and sheet metal.