Impact of Loading Rate in Hot Tube Gas Forming of AA6063

ADMT Journal

مقاله 7، دوره 12، شماره 1، خرداد 2019، صفحه 59-66   

نوع مقاله: Original Article

نویسندگان

Mastafa Rajaee¹؛ Seyed Jamal Hosseinipour^{* 2}؛ Hamed Jamshidi Aval²

¹Department of Mechanical Engineering, Babol Noshirvani University of Technology, Iran

²Department of Materials and Industrial Engineering, Babol Noshirvani University of Technology, Iran

چکیده

In this paper, the manufacturing of a cylindrical AA6063 step tube via hot metal gas forming (HMGF) process is studied both experimentally and numerically. The goal is to investigate the effect of loading rate on the specimen profile and thickness distribution. ABAQUS finite element software is used for the numerical simulation. Experiments were carried out at 580°C in two conditions; first, without axial feeding and then with an axial feeding of 14 mm at a maximum pressure of 0.5 MPa. The studied parameters are the pressure rate and the axial feeding rate. The results show that in the non-axial feeding mode, the thickness distribution in the die cavity region was non-uniform and a rupture occurred at a pressure of 0.6 MPa. The reduction of the pressure rate has no significant effect on the rupture pressure. In the case of axial feeding, by choosing the pressure rate of 0.001 MPa/s and the axial feeding rate of 0.1 mm/s, wrinkling has been created in the specimens. However, at a pressure rate of 0.005 MPa/s and an axial feeding rate of 0.02 mm/s, the specimens are raptured. Under low pressure rate of 0.001 MPa/s and low axial feeding rate of 0.02 mm/s, the thickness in the die cavity area has decreased. A suitable die filling and thickness distribution are obtained at a pressure rate of 0.005 MPa/s and axial feeding rate of 0.1 mm/s.

کلیدواژه‌ها

AA6063؛ Hot Metal Gas Forming؛ Loading Rate؛ Tubular Parts

مراجع

[1]     Novotny, S., Geiger, M., Process Design for Hydroforming of Lightweight Metal Sheets at Elevated Temperatures, Materials Processing Technology, Vol. 138, No. 1, 2003, pp. 594-599, DOI. 10.1016/S0924-0136(03)00042-6.

[2]     Liu, G., Zhang, W., He, Z., Yuan, S., and Lin, Z., Warm Hydroforming of Magnesium Alloy Tube with Large Expansion Ratio Within Non-Uniform Temperature Field, Nonferrous Metals Society of China, Vol. 22, No. 1, 2012, pp. 408-415, DOI. 10.1016/S1003-6326(12)61739-7.

[3]     Hashemi, J., Liaghat, G. H., and Azizi, R., Forming Limit Diagram of Aluminum AA6063 Tubes at High Temperatures by Bulge Tests, Mechanical Science Technology, Vol. 28, No. 11, 2014, pp. 4745–4752, DOI. 10.1007/s12206-014-1041-2.

[4]     Dykstra, B., Pfaffmann, G., and Wu, X., Hot Metal Gas Forming – the Next Generation Process for Manufacturing Vehicle Structural Components, SAE Technical Paper, Vol. 1, No. 10, 1999, pp. 3229-3237, DOI. 10.4271/1999-01-3229.

[5]     Keigler, M., Bauer H., Harrison, D., and De Silva, A. K., Enhancing the Formability of Aluminium Components via Temperature Controlled Hydroforming, Materials Processing Technology, Vol. 167, No. 2-3, 2005, pp. 363-370, DOI. 10.1016/j.jmatprotec.2005.06.024.

[6]     Nazzal, M. A., Abu Farha, F. K., Finite Element Modeling of Superplastic Forming of Tubular Shapes, Key Engineering Materials, Vol. 433, No. 1, 2010, pp. 179-184, DOI. 10.4028/www.scientific.net/KEM.433.179

[7]     Lin, Y., He, Z., Yuan, S., and Wu, J., Formability Determination of AZ31B Tube for IHPF Process at Elevated Temperature, Transaction of Nonferrous Metals Society of China, Vol. 21, No. 2, 2011, pp. 851-856, DOI. 10.1016/S1003-6326(11)60792-9.

[8]     Damours, G., Beland, J. F., Warm Forming Simulation of 7075 Aluminium Alloy Tubes Using LS-DYNA, 8th European LS-DYNA Users Conference, Strasbourg, 2011, pp. 1-14.

[9]     He, Z., Fan, X., Shao, F., Zheng, K., Wang, Z., and Yuan, S., Formability and Microstructure of AA6061 Al Alloy Tube for Hot Metal Gas Forming at Elevated Temperature, Transaction of Nonferrous Metals Society of China, Vol. 22, No. 1, 2012, pp. 364-369, DOI. 10.1016/S1003-6326(12)61732-4.

[10]  He, Z., Teng, B., Che, C., Wang, Z., Zheng, K., and Yuan, S., Mechanical Properties and Formability of TA2 Extruded Tube for Hot Metal Gas Forming at Elevated Temperature, Transaction of Nonferrous Metals Society of China, Vol. 22, No. 1, 2012, pp. 479-484, DOI. 10.1016/S1003-6326(12)61749-X.

[11]  Maeno, T., Mori, K., and Fujimoto, K., Development of The Hot Gas Bulging Process for Aluminium Alloy Tube Using Resistance Heating, Key Engineering Materials, Vol. 410-411, No. 1, 2009, pp. 315–323, DOI. 10.4028/www.scientific.net/KEM.410-411.315.

[12]  Maeno, T., Mori, K., and Unou, C., Optimisation of Condition in Hot Gas Bulging of Aluminium Alloy Tube Using Resistance Heating Set into Dies, Key Engineering Materials, Vol. 473, 2011, No. 1, pp. 69-74, DOI. 10.4028 /www.scientific .net/KEM .473.69.

[13]  Maeno, T., Mori, K., and Fujimoto, K., Hot Gas Bulging of Sealed Aluminium Alloy Tube Using Resistance Heating, Manufacturing Review, 2014, Vol. 1, No. 1, pp. 1-6, DOI. 10.1051/mfreview/2014004.

[14]  Paula, A., Strano, M., The Influence of Process Variables on The Gas Forming and Press Hardening of Steel Tubes, Materials Processing Technology, Vol. 228, No. 1, 2016, pp. 160–169, DOI. 10.1016/j.jmatprotec.2015.02.038.

[15]  Shamsi Sarband, A., Hosserinipour, S. J., Bakhshi Jooybari, M., and Shakeri, M., The Effect of Geometric Parameters of Conical Cups on The Preform Shape in Two-Stage Superplastic Forming Process, Materials Engineering and Performance, Vol. 22, No. 12, 2013, pp. 3601–3611, DOI. 10.1007/s11665-013-0636-6.

[16]  Hojjati, M. H., Zoorabadi, M., and Hosserinipour, S. J., Optimization of Superplastic Hydroforming Process of Aluminium Alloy 5083, Materials Processing Technology, Vol. 205, No. 1-3, 2008, pp. 482–488, DOI. 10.1016/j.jmatprotec.2007.11.208.

[17]          Hajinejad Sorkhi, M., Hosseinipour, S. J., and Jamshidi Aval H., Formability of 6063 Aluminium Alloy Tube at High Temperature Using Multi-Bulge Test by Hot Metal Gas Forming Process, Modares Mechanical Engineering, Vol. 16, No. 1, 2016, pp. 185-192 (in Persian).