Development of a novel forming tool for the production of high-strength aluminum components with tailored properties

N Rigas, M Merklein
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Abstract

Because of growing environmental and technical requirements, the efficient manufacturing of components with tailored properties using recyclable materials is mandatory. The combination of high-strength aluminum alloys and thermal-assisted forming operations is an innovative method for the production of components with varying mechanical properties. By locally adjusting the cooling rates during a thermo-mechanical forming operation, it is possible to modify the microstructure and precipitation conditions. A subsequent aging operation causes different microstructural and mechanical characteristics. This allows both deep-drawing and adjustment of the component properties in one single step. For this reason, this contribution focuses on the production of components with tailored properties. With the aid of a non-contact measuring system, previous investigations have proved that mechanical material properties can be adapted during a forming process by adjusting the cooling rates. In this contribution, this knowledge is transferred to a novel temperature-controlled rectangular cup tool. A variation of the local tool temperature and holding duration in the tool will be carried out. Then, the mechanical and microstructural properties of the manufactured components will be characterized through hardness and DSC investigations. In addition, the influence of different tool temperatures on the component temperature, the sheet thickness distribution and process forces will be investigated. As a result, it has been demonstrated that mechanical, process-related and geometric advantages can be achieved by using locally temperature-controlled forming tools.
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开发用于生产具有特定性能的高强度铝部件的新型成型工具
由于环境和技术要求的不断提高,使用可回收材料高效制造具有特定性能的部件已成为当务之急。将高强度铝合金与热辅助成型操作相结合,是生产具有不同机械性能部件的创新方法。在热机械成型操作过程中,通过局部调整冷却速率,可以改变微观结构和沉淀条件。随后的老化操作会产生不同的微观结构和机械特性。这样就可以在一个步骤中实现深冲和调整部件性能。因此,本论文的重点是生产具有定制特性的部件。借助非接触式测量系统,以往的研究已经证明,在成型过程中,通过调整冷却速度可以调整材料的机械性能。在本论文中,这一知识被应用于新型温控矩形杯模具。我们将改变模具的局部温度和保温时间。然后,将通过硬度和 DSC 研究对制造部件的机械和微观结构特性进行表征。此外,还将研究不同工具温度对部件温度、板厚分布和加工力的影响。结果表明,使用局部温控成型工具可以获得机械、工艺和几何方面的优势。
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