Research Papers

Warm Hydromechanical Deep Drawing of AA 5754-O and Optimization of Process Parameters

[+] Author and Article Information
Doğan Acar

Department of Mechanical Engineering,
Karadeniz Technical University,
Kanuni Campus,
Trabzon 61080, Turkey
e-mail: dgnacar@ktu.edu.tr

Mevlüt Türköz

Department of Mechanical Engineering,
Selçuk University,
Alaeddin Keykubat Campus,
Konya 42250, Turkey
e-mail: mevlutturkoz@selcuk.edu.tr

Hasan Gedikli

Department of Mechanical Engineering,
Karadeniz Technical University,
Kanuni Campus,
Trabzon 61080, Turkey
e-mail: hgedikli@ktu.edu.tr

Hüseyin Selçuk Halkacı

Department of Mechanical Engineering,
Selçuk University,
Alaeddin Keykubat Campus,
Konya 42250, Turkey
e-mail: shalkaci@selcuk.edu.tr

Ömer Necati Cora

Department of Mechanical Engineering,
Karadeniz Technical University,
Kanuni Campus,
Trabzon 61080, Turkey
e-mail: oncora@ktu.edu.tr

1Corresponding author.

Contributed by the Materials Division of ASME for publication in the JOURNAL OF ENGINEERING MATERIALS AND TECHNOLOGY. Manuscript received October 4, 2016; final manuscript received June 30, 2017; published online September 13, 2017. Assoc. Editor: Ashraf Bastawros.

J. Eng. Mater. Technol 140(1), 011012 (Sep 13, 2017) (8 pages) Paper No: MATS-16-1283; doi: 10.1115/1.4037524 History: Received October 04, 2016; Revised June 30, 2017

Warm hydromechanical deep drawing (WHDD) has increasingly been implemented by automotive industry due to its various benefits including mass reduction opportunities in auto body-in-white components and improved formability for lightweight alloys. In the first part of the current study, WHDD of AA 5754-O was studied. In order to obtain the highest formability, an optimization study was performed for AA 5754-O WHDD process parameters (tool temperature, hydraulic pressure (HP), and blank holder force (BHF) loading profiles) through finite element analysis (FEA) + experimentation approach. Results showed that the optimal temperature for punch is 25 °C and 300 °C for die and blank holder. In addition, HP was found to be more effective on formability when compared to BHF. Both fast increasing HP and blank holder loading profiles contributes to higher formability.

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Fig. 1

Experimental setup [22]

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Fig. 2

(a) Dimensions of the HDD test setup and (b) thermal boundary conditions

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Fig. 3

FEA model: (a) exploded parts and mesh discretization and (b) structural boundary conditions of the blank

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Fig. 4

Flow curves obtained from hydraulic bulge tests at different temperatures [31]

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Fig. 5

Comparison of thickness variation for WHDD cup for different material models and experimental results

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Fig. 6

Material model validation by comparing numerical and experimental tensile test results

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Fig. 7

Comparison of thickness variations along the centerline for validation of established FE model

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Fig. 8

Surface responses for (a) showing the integral effects of TD, TBH, and TP on thickness change, (b) safe zone (upper triangular region), and risky zone (lower region)

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Fig. 9

Analyses results for WHDD cup in (a) safe zone (TP: 25; TD: 260 °C) and (b) risky zone (TP: 25; TD: 140 °C) (legend for displacement is in meters)

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Fig. 10

Loading profiles used in optimization for (a) BHF and (b) HP

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Fig. 11

Response surface for loading profiles' optimization

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Fig. 12

Comparison of thickness change for the blank along the curvilinear distance with optimum loading profile combination

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Fig. 13

Cups drawn with optimized process conditions and loading profiles (BHF_3 and HP_3)

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Fig. 14

Loading profiles with different coefficients (±%10): (a) BHF and (b) HP

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Fig. 15

Effect of loading profiles on formed blank: (a) integral effect of BHF and HP and (b) singular effect of HP



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