Warm Forming of Al, Ti and Mg alloy Sheet ppt

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 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). 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 4 ERC NSM p h d d h t d t 0 R h R d F c F c 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 (t 0 ): 1.2 mm Initial Sheet Bulged Sheet Tooling at Univ. of Darmstadt, Germany 5 ERC NSM Deformation of AZ31-O Mg alloy sheet at 225 o C Bulge Height : 12mm Bulge Height : 40 mm Deformation of AZ31-O Mg alloy sheet 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 6 ERC NSM Warm Forming of Al, Ti and Mg Alloy Sheets Tool and process design guidelines to improve formability Aida Servo Press (used in warm forming of Al, Mg and Ti sheet) Power Source Balancer tank Main gear Servomotor Capacitor Drive Shaft 7 ERC NSM Stage 1 Stages in warm deep drawing Warm Forming of Al, Ti and Mg Alloy Sheets Tool and process design guidelines to improve formability Stage 2 Stage 3 AIDA tooling to warm form Al, Mg and Ti alloy sheet Heated tool Cooled punch Die Holder Upper Tool Die Ring Lower Tool Cartridge Heaters Blank Holder Punch Cartridge Heaters 8 ERC NSM Warm Forming of Al, Ti and Mg Alloy Sheets Warm deep drawing tool in the press AIDA NC 110 ton servo press Tool and process design guidelines to improve formability 9 ERC NSM Warm Forming of Al, Ti and Mg Alloy Sheets AL 5754- O 2.5250 2.1RT 2.9300 LDRT ( o C) 2.5275 2.1RT 2.9275 LDRT ( o C) 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 10 ERC NSM Warm Forming of Al, Ti and Mg Alloy Sheets 2.6275 -RT 3.2275 LDRT ( o C) 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 ( o C) Ti (Grade 1) [...].. .Warm Forming of Al, Ti and Mg Alloy Sheets ERC NSM 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:... 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) 11 . deformation Warm Forming of Al, Ti and Mg Alloy Sheets Material properties for Mg alloy using submerged hydraulic bulge tool 6 ERC NSM Warm Forming of Al, Ti and Mg Alloy Sheets Tool and process design. 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. in warm forming of Al, Mg and Ti sheet) Power Source Balancer tank Main gear Servomotor Capacitor Drive Shaft 7 ERC NSM Stage 1 Stages in warm deep drawing Warm Forming of Al, Ti and Mg Alloy