Material behavior of AA5754 was investigated under different forming process conditions, including two loading conditions (uniaxial tensile and biaxial bulge), several strain rates (constant strain rates at 0.0013 and 0.013/s, and variable strain rate profiles: increasing and decreasing profiles), and several temperature levels (ambient up to 260°C). Additional warm hydroforming experiments were conducted using a closed-die set up to understand the forming limits of AA5754. The results from tensile and hydraulic bulge tests as well as closed-die hydroforming experiments suggested that, in general, formability of AA5754 can be significantly improved with slow forming rates (<0.02/s), high forming temperature (<200°C), and biaxial loading (hydroforming) that can delay strain localization (necking). However, the effect of forming rate did not reveal any significant gain in formability for temperatures below 200°C. The effect of variable strain rate control was found to be significant only at elevated temperatures (>200°C), where increasing strain rate resulted in lower formability and decreasing strain rate improved the maximum attainable dome height at temperatures above 200°C. Finally, the material flow curves obtained from the tensile and bulge tests were shown to provide reasonably accurate predictions for cavity filling ratios (∼ 3-15 error) in finite element analyses.
|Journal||Journal of Manufacturing Science and Engineering, Transactions of the ASME|
|Publication status||Published - 1 Dec 2011|
ASJC Scopus subject areas
- Control and Systems Engineering
- Mechanical Engineering
- Computer Science Applications
- Industrial and Manufacturing Engineering