Analysis of wall thickness evolution and forming quality of sheet metal manufactured by wrinkles-free forming method

IF 2.6 3区材料科学 Q2 ENGINEERING, MANUFACTURING International Journal of Material Forming Pub Date : 2024-07-08 DOI:10.1007/s12289-024-01846-8

Liyan Wang, Xu Luan, Shuangyu Liu, Xi Wang

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Abstract

Sheet metal wrinkles-free forming method is a novel sheet metal forming technology which deforms a blank to the target part using low-melting point alloy (LMA) without the blank holder, increasing materials utilization rate and reducing the trimming process. The LMA medium used as a blank holder inhibiting wrinkles transfers forming load onto the surface of sheet metal, deforming and flowing as the deformation of the sheet metal, which affects the plastic flow state of the sheet metal. This paper aims to investigate the effect of the rheological behavior of LMA on the wall thickness distribution of sheet metal, combining numerical simulation and experiments. The stress–strain relationship is obtained by high-temperature tensile test of LMA under different temperature conditions, and numerical modeling of sheet metal forming with LMA medium is established by ABAQUS software. The influence of the process parameters on the surface pressure distribution of the sheet metal is investigated. The effect of forming temperature and medium layer thickness on the thinning is analyzed for revealing the intrinsic correlation of the surface pressure distribution and the thinning. Furthermore, the research on influence of the LMA medium rheological behavior on the distribution of the wall thickness of the formed part is performed. The experimental results are consistent with the numerical simulation results.

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无皱成形法制造的金属板的壁厚演变和成形质量分析

钣金无皱纹成形方法是一种新型的钣金成形技术，它利用低熔点合金（LMA）使坯料在无坯料支架的情况下变形为目标零件，提高了材料利用率，减少了切边工序。作为抑制皱纹的坯料夹持器的 LMA 介质将成形载荷传递到金属板材表面，随着金属板材的变形而变形和流动，从而影响金属板材的塑性流动状态。本文旨在结合数值模拟和实验，研究 LMA 的流变行为对金属板材壁厚分布的影响。通过不同温度条件下 LMA 的高温拉伸试验得到应力-应变关系，并利用 ABAQUS 软件建立了以 LMA 为介质的金属板材成形的数值模型。研究了工艺参数对板材表面压力分布的影响。分析了成形温度和介质层厚度对减薄的影响，揭示了表面压力分布与减薄的内在联系。此外，还研究了 LMA 介质流变行为对成形部件壁厚分布的影响。实验结果与数值模拟结果一致。

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来源期刊

International Journal of Material Forming ENGINEERING, MANUFACTURING-MATERIALS SCIENCE, MULTIDISCIPLINARY

CiteScore

5.10

自引率

4.20%

发文量

审稿时长

>12 weeks

期刊介绍： The Journal publishes and disseminates original research in the field of material forming. The research should constitute major achievements in the understanding, modeling or simulation of material forming processes. In this respect ‘forming’ implies a deliberate deformation of material. The journal establishes a platform of communication between engineers and scientists, covering all forming processes, including sheet forming, bulk forming, powder forming, forming in near-melt conditions (injection moulding, thixoforming, film blowing etc.), micro-forming, hydro-forming, thermo-forming, incremental forming etc. Other manufacturing technologies like machining and cutting can be included if the focus of the work is on plastic deformations. All materials (metals, ceramics, polymers, composites, glass, wood, fibre reinforced materials, materials in food processing, biomaterials, nano-materials, shape memory alloys etc.) and approaches (micro-macro modelling, thermo-mechanical modelling, numerical simulation including new and advanced numerical strategies, experimental analysis, inverse analysis, model identification, optimization, design and control of forming tools and machines, wear and friction, mechanical behavior and formability of materials etc.) are concerned.