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Extension of Process Limits in High‐Strength Aluminum Forming by Local Contact Heating

Sellner, Erik ; Xu, Yikai ; Groche, Peter (2023)
Extension of Process Limits in High‐Strength Aluminum Forming by Local Contact Heating.
In: Advanced Engineering Materials, 2023, 25 (15)
doi: 10.26083/tuprints-00024663
Article, Secondary publication, Publisher's Version

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Item Type: Article
Type of entry: Secondary publication
Title: Extension of Process Limits in High‐Strength Aluminum Forming by Local Contact Heating
Language: English
Date: 7 November 2023
Place of Publication: Darmstadt
Year of primary publication: 2023
Place of primary publication: Weinheim
Publisher: Wiley-VCH
Journal or Publication Title: Advanced Engineering Materials
Volume of the journal: 25
Issue Number: 15
Collation: 10 Seiten
DOI: 10.26083/tuprints-00024663
Corresponding Links:
Origin: Secondary publication DeepGreen
Abstract:

The aluminum alloy EN AW‐7075 T6 is used in the automotive sector for its favorable strength‐to‐weight ratio. However, the limited cold formability is currently addressed by energy‐ and time‐consuming temperature‐assisted processes. In order to limit the effort to critical forming areas only, the state‐of‐the‐art shows promising results for increasing the blank temperature in the range of warm forming. The design of new processes in an industrial context requires appropriate numerical simulation with inherent complexity due to time‐ and temperature‐dependent effects. Herein, the potential of a newly developed tool setup and process chain with integrated local contact heating of the EN AW‐7075 T6 blank is investigated on the basis of a curved hat profile. A thermomechanically coupled FE model of the process is developed and validated. The influence of the local heating layout is analyzed in experimental forming tests and a corresponding process window is derived. The influence of local heating on the occurring failure mechanisms is discussed based on simulation results. The equivalent plastic strain evolution is successfully used to evaluate the local heating dependent failure behavior. A significant increase in the overall formability of the part is achieved by the proposed process chain.

Uncontrolled Keywords: high-strength aluminum, local contact heating, thermomechanically coupled simulation, warm forming
Identification Number: 2201940
Status: Publisher's Version
URN: urn:nbn:de:tuda-tuprints-246632
Additional Information:

Special Issue: Structural Materials

Classification DDC: 600 Technology, medicine, applied sciences > 620 Engineering and machine engineering
Divisions: 16 Department of Mechanical Engineering > Institute for Production Engineering and Forming Machines (PtU)
Date Deposited: 07 Nov 2023 12:48
Last Modified: 21 Nov 2023 09:07
SWORD Depositor: Deep Green
URI: https://tuprints.ulb.tu-darmstadt.de/id/eprint/24663
PPN: 513350470
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