Characteristics of drawing process of AA5182 aluminum alloy sheet during rubber-pad forming

Xu, Junrui; Zhang, Jing; Cui, Junjia; Zhang, Xu

doi:10.1007/s00170-018-1616-7

Cited by 12 publications

(6 citation statements)

References 20 publications

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“…5 GPa in electromagnetic forming due to the tool-sheet interaction. Flexible-die forming methods, e.g., hydroforming and rubber pad forming, apply not only in-plane stresses but also normal stresses to the sheet surface [10]. Brooke [11] showed that the normal stress on the sheet surface in the hydroforming of automotive industry components is nearly 50 MPa.…”

Section: Introductionmentioning

confidence: 99%

Analytical approach to investigate the effects of through-thickness stress on springback in bending of isotropic sheet metal

Movahedi,

Gerdooei

2024

Int J Adv Manuf Technol

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Within contemporary sheet metal forming processes like electromagnetic forming, the sheet experiences pronounced out-of-plane compression stress. This study focuses on the predicting the springback in the bending of an isotropic sheet metal in the presence of through-thickness compressive normal stress. In the analytical method, the longitudinal stress distribution across sheet thickness was calculated via equilibrium equations and the associated ow rule in incremental plasticity based on the power law hardening model, obtaining the reverse bending moment. During the unloading phase, the external load was lifted, and the springback angle was estimated by assuming linear elastic behavior and neglecting the Bauschinger effect, employing the superposition method. A case study was conducted on an aluminum alloy sheet for different compressive stresses and bend curvatures. Subsequently, the reverse bending moments and springback angles obtained for each case were compared to the numerical outcomes from nite element (FE) modeling. Analytical results indicate that elevating the compressive normal stress on the sheet surface to 75% and 100% of the yield stress will lead to a reduction in springback by 17.4% and 32%, respectively. At the compressive normal stress of 75% of the yield stress, the numerical model exhibited a 4.4% difference from the analytical model. For the validation of the analytical model, a four-point bending test was conducted with varying initial bend curvatures and angles. This involved comparing the experimental springback angle and curvature with both numerical and analytical predictions. In comparison, both the numerical and analytical models demonstrated strong agreement with the experimental results.

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Section: Introductionmentioning

confidence: 99%

Analytical approach to investigate the effects of through-thickness stress on springback in bending of isotropic sheet metal

Movahedi,

Gerdooei

2024

Int J Adv Manuf Technol

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show abstract

“…Belhassen et al(2016) established a coupled model of elasto-plastic damage to predict the impacts Tao, Xuefeng Xu, Xiao, Wei, Feng, Jiajun Xu and Zhao, Journal of Advanced Mechanical Design, Systems, and Manufacturing, Vol.17, No.2, 2023 of parameters (hardness of rubber, type of rubber) on the variation of the thickness, springback, and damage of aluminum sheet metal by ABAQUS software. Xu et al(2018) conducted experimental studies of rubber-pad forming process of AA5182 aluminum alloy sheet, reporting that the load force increases quickly with decreasing of rubber pad height.…”

Section: Introductionmentioning

confidence: 99%

Research on wrinkling in rubber forming of the convex flange with 2A12 aluminum alloy sheet

Tao

XIAO

et al. 2023

JAMDSM

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The orthogonal experiment was established to reduce the wrinkling of convex flange rubber forming with 2A12 aluminum alloy sheet. The impact factors consisted of the feed of master-cylinder, the hardness of the rubber, and the radius of the die. The rubber forming was simulated for the quantities, widths, and heights of the wrinkles in ABAQUS software, where the results was analyzed by gray correlation. Theoretically the greatest influence on the wrinkles is the feed of master-cylinder that the more the feed is, the smaller the wrinkles are. However, neither in the simulation nor in the experiment, all the wrinkles of the convex flanged parts still could not be flattened when the master-cylinder was fed to the rubber's compression limit. Aiming to further eliminate wrinkling, a new method called multi-stage rubber forming was proposed, in which four extra-cylinders were added to the broadside of the container to enhance the forming force. Both the numerical simulation and experiment were taken into the multi-stage rubber forming, proving that multi-stage rubber forming could effectively reduce the wrinkling in rubber forming of the convex flange, as the feed of the extra-cylinders increased risks of the wrinkles. When the feed of the extra-cylinders was set 8 mm while the master-cylinder 34 mm, the wrinkle of the convex curve bending edge could be eliminated smoothly.

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“…For example, Zhang and Wang [17] stated that thinning and springback of a double-curved part formed by rubber flexible die could be dramatically reduced compared with these of stamped part. Xu et al [18] investigated deformation behaviors of AA5182 aluminum alloy sheets in the rubber pad forming process. Deformation characteristics, i.e.…”

Section: Introductionmentioning

confidence: 99%

Improved forming accuracy through controlling localized sheet metal deformation in the friction-assisted stretch bending process

Xiang

Shu

Wang

et al. 2021

Int J Adv Manuf Technol

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Tension-dominated stress state in the stretch bending process probably leads to localized tensile stress, especially in the manufacture of thin-walled, high-strength, or complex-shaped components. That results in nonuniform residual stress distribution and inferior shape accuracy. In this paper, a friction-assisted stretch bending (FASB) process is proposed to deal with this problem. A rubber sheet is attached with sheet metal to generate tangential friction at rubber/metal interface. The tangential friction assists in modifying stress distribution in the loading process. Finite element analysis was conducted to determine the effects of process parameters on deformation behaviors of the sheet metal. The results show that a rubber sheet with hardness ranging from Shore 57D to 70D and a rubber/metal thickness ratio (ξ) value around 1.0 can effectively reduce sheet metal thinning and decrease springback in the stretching and bending stress states. By taking the simulated process parameters as a reference, fuselage profiles with variable bending curvature and sections were successfully manufactured. Maximum thinning ratio of the formed part was 6.1%, and the section deviation after unloading was reduced by 52.9%, on average, compared with conventional stretch bending. The improved forming accuracy can be attributed to the relatively uniform distribution of longitudinal stress. That results in uniform elastic recovery in longitudinal direction. Further industrial application of the FASB process for the manufacture of large-sized and complex-shaped parts will be expectable.

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Characteristics of drawing process of AA5182 aluminum alloy sheet during rubber-pad forming

Cited by 12 publications

References 20 publications

Analytical approach to investigate the effects of through-thickness stress on springback in bending of isotropic sheet metal

Analytical approach to investigate the effects of through-thickness stress on springback in bending of isotropic sheet metal

Research on wrinkling in rubber forming of the convex flange with 2A12 aluminum alloy sheet

Improved forming accuracy through controlling localized sheet metal deformation in the friction-assisted stretch bending process

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