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Research Papers

Effects of Interfacial Friction Distribution on the Superplastic Forming of AA5083

[+] Author and Article Information
Mohammad I. Albakri

 Masdar Institute of Science and Technology, 54224, Masdar City, Abu Dhabi, United Arab Emirates e-mail: malbakri@masdar.ac.ae

Firas S. Jarrar

Mechanical Engineering Department,  University of Jordan, Amman, Jordan e-mail: f.jarrar@ju.edu.jo

Marwan K. Khraisheh

 Masdar Institute of Science and Technology, Abu Dhabi, United Arab Emirates e-mail: mkhraisheh@masdar.ac.ae

J. Eng. Mater. Technol 133(3), 031008 (Jul 18, 2011) (6 pages) doi:10.1115/1.4004159 History: Received December 27, 2010; Revised April 25, 2011; Published July 18, 2011; Online July 18, 2011

This paper studies the effects of interfacial friction distribution on the integrity of superplastic formed parts. For that purpose, the deformation of AA5083 superplastic aluminum alloy into a long rectangular box is investigated. The die surface is divided into five regions for local application of friction coefficients. The commercial finite element code, ABAQUSTM , is used to carry out the forming simulations and calculate the thickness distribution, forming time, and forming pressure profile for different combinations of friction coefficients. It is found that friction distribution at the die-sheet interface strongly affects the metal flow during the forming process, which has a direct impact on deformation stability and strain localization. With the proposed optimal variable friction distribution, the quality of the formed parts has been enhanced, while reducing the required forming time.

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Copyright © 2011 by American Society of Mechanical Engineers
Topics: Friction , Thickness
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Figures

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Figure 1

(a) Midsection view of the rectangular box die, the sheet and the clamping device and (b) two dimensional FE model showing the layered continuum elements of the sheet

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Figure 2

Predicted thickness profile of the formed sheet with different values of friction coefficients

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Figure 3

Particle path of the sheet during deformation with different friction conditions, (a) μ = 0.0 and (b) μ = 0.5

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Figure 4

Forming pressure profile with different values of friction coefficients

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Figure 5

Die cross section showing the three regions where different friction coefficients are applied

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Figure 6

Thinning factor contours of the formed sheet when different friction coefficients are applied at Regions 1, 2, and 3 of the die surface (see Fig. 5). (a) Friction coefficient at Region 2 is 0.0. (b) Friction coefficient at Region 2 is 0.2. (c) Friction coefficient at Region 2 is 0.4.

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Figure 7

The five regions die used for the refined friction study

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Figure 8

Thinning factor contours of the formed sheet with different friction coefficients applied at Regions 2.A and 2.B of the die surface (see Fig. 7)

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Figure 9

Predicted thickness profile of the formed sheet with different friction distributions

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