7/28/2019 Warm Forming Edit1

http://slidepdf.com/reader/full/warm-forming-edit1 1/11

1

ERC 

NSM 

Research & Development Update

Warm Forming of Al, Ti and Mg alloy Sheet

Engineering Research Center for Net Shape Manufacturing (ERC/NSM)

www.ercnsm.org

The Ohio State University 

7/28/2019 Warm Forming Edit1

http://slidepdf.com/reader/full/warm-forming-edit1 2/11

2

ERC 

NSM Background

A fundamental understanding of warm forming of Al, Ti and Mg

alloys will benefit various industries (automotive, aerospace,

defense, electronics, medical etc.).

Technology for Warm forming of Al, Ti and Mg alloy sheets is

developed (in co-operation with University of Virginia, University

of Darmstadt (Germany), University of Hanover (Germany), Aida

Dayton Technologies, support by NSF).

7/28/2019 Warm Forming Edit1

http://slidepdf.com/reader/full/warm-forming-edit1 3/11

3

ERC 

NSM 

1. Use FE modeling and experiments to determine,

1. material properties (elevated temperature hydraulic bulge test and property

variation within sheet and tube).

2. tool design guidelines (minimum punch & die radii, optimum heating

techniques).3. process design guidelines (BHF, forming velocity, optimum tool

temperatures, lubrication, loading paths).

2. Implement results in industrial applications.

Objectives

7/28/2019 Warm Forming Edit1

http://slidepdf.com/reader/full/warm-forming-edit1 4/11

4

ERC 

NSM 

phd

dh

td

t0

Rh

Rd

Fc Fc

Warm Forming of Al, Ti and Mg

Alloy Sheets

Material properties for Mg alloy using submerged hydraulic bulge tool

Material: AZ31-O Mg alloy

Thickness (t0): 1.2 mm

Initial Sheet

Bulged Sheet

Tooling at Univ. of Darmstadt, Germany

7/28/2019 Warm Forming Edit1

http://slidepdf.com/reader/full/warm-forming-edit1 5/11

5

ERC 

NSM 

Deformation of AZ31-O Mg alloysheet at 225oC

Bulge Height : 12mm Bulge Height : 40 mm

Deformation of AZ31-O Mg alloysheet at room temperature

Elevated temperature hydraulic bulge test is used to obtain stress-strain curves at

various temperature and strain rates under biaxial state of deformation

Warm Forming of Al, Ti and Mg

Alloy Sheets

Material properties for Mg alloy using submerged hydraulic bulge tool

7/28/2019 Warm Forming Edit1

http://slidepdf.com/reader/full/warm-forming-edit1 6/116

ERC 

NSM Warm Forming of Al, Ti and Mg

Alloy SheetsTool and process design guidelines to improve formability

 Aida Servo Press (used in warm forming of Al, Mg and Ti sheet)

Power Source Balancer tankMain gear 

Servomotor 

Capacitor 

Drive Shaft

7/28/2019 Warm Forming Edit1

http://slidepdf.com/reader/full/warm-forming-edit1 7/117

ERC 

NSM 

Stage 1

Stages in warm deepdrawing

Warm Forming of Al, Ti and Mg

Alloy SheetsTool and process design guidelines to improve formability

Stage 2 Stage 3

AIDA tooling

to warm form

Al, Mg and Ti

alloy sheet

Heated toolCooled punch

Die Holder 

Upper Tool

Die Ring

Lower Tool

Cartridge Heaters

Blank Holder 

Punch

Cartridge Heaters

7/28/2019 Warm Forming Edit1

http://slidepdf.com/reader/full/warm-forming-edit1 8/118

ERC 

NSM Warm Forming of Al, Ti and Mg

Alloy Sheets

Warm deep drawing tool in the press

 AIDA NC 110 tonservo press

Tool and process design guidelines to improve formability

7/28/2019 Warm Forming Edit1

http://slidepdf.com/reader/full/warm-forming-edit1 9/119

ERC 

NSM Warm Forming of Al, Ti and Mg

Alloy Sheets

AL 5754- O

2.5250

2.1RT

2.9300

LDRT (oC)

2.5275

2.1RT

2.9275

LDRT (oC)

AL 5052-H32

Preliminary results (Velocity range : 5-50mm/sec)

Process parameters/ FE Simulation / Rectangular cup / Ti alloy parts

Note : RT: Room temperature, LDR : Limit draw ratio

7/28/2019 Warm Forming Edit1

http://slidepdf.com/reader/full/warm-forming-edit1 10/1110

ERC 

NSM Warm Forming of Al, Ti and Mg

Alloy Sheets

2.6275

-RT

3.2275

LDRT (oC)

Mg AZ31-O

Preliminary results (Velocity range : 5-50mm/sec)

Process parameters/ FE Simulation / Rectangular cup

Note : RT: Room temperature, LDR : Limit draw ratio

2.5310

LDRT (oC)

Ti (Grade 1)

7/28/2019 Warm Forming Edit1

http://slidepdf.com/reader/full/warm-forming-edit1 11/1111

ERC 

NSM Warm Forming of Al, Ti and Mg

Alloy Sheets

Status

1) Experimental work and analysis are in progress

2) Several graduate students (PhD/MSc) are working on this project 

We are continuously looking for;

a) industry cooperation and potential application of technology for new product development 

b) industry support, suggestions and interest are most welcome

Contact: Serhat Kaya, PhD Student ( kaya.8@osu.edu , 614-292-1785)

Prof. Taylan Altan, ( altan.1@osu.edu , 614-292-5063)