Abstract
According to current development trends for automotive body parts, light weight is a key issue in improving fuel efficiency and CO2 reduction. Compared to steel and aluminum, magnesium has a relatively low specific gravity. However, it is challenging to use magnesium to produce a product at room temperature because magnesium has a Hexagonal Close-Packed (HCP) crystal structure. Therefore, the structure is not suitable for plastic deformation without using a heating system. As a result, a magnesium sheet and die need to be heated from 250 to 300°C. Unfortunately, this procedure has positive and negative effects. It increases not only the material’s elongation, but also the friction between the material and die during warm forming. Furthermore, lubricant cannot be used due to corrosion occurring on the surface of a part after manufacturing. To overcome these challenges, we developed a “Partition panel,” which is a warm-formed part with a non-lubricated die with a Diamond-Like Carbon (DLC) coating. A one-quarter sized prototype was successfully produced with the DLC-coated non-lubricated die, and its characteristics were verified through an evaluation of the friction coefficient and mechanical properties.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Shin, H. W., “A Feasibility Study to Replace Steel Made Hood Panels by Magnesium Alloy Made Hood Panels,” Int. J. Precis. Eng. Manuf., Vol. 13, No. 11, pp. 2011–2016, 2012.
Zhang, K. F., Yin, D. L., and Wu, D. Z., “Formability of AZ31 Magnesium Alloy Sheets at Warm Working Conditions,” International Journal of Machine Tools and Manufacture, Vol. 46, No. 11, pp. 1276–1280, 2006.
Ambrogio, G., Filice, L., and Gagliardi, F., “Formability of Lightweight Alloys by Hot Incremental Sheet Forming,” Materials & Design, Vol. 34, pp. 501–508, 2012.
Zhang, H., Huang, G., Kong, D., Sang, G., and Song, B., “Influence of Initial Texture on Formability of AZ31B Magnesium Alloy Sheets at different Temperatures,” Journal of Materials Processing Technology, Vol. 211, No. 10, pp. 1575–1580, 2011.
Quan, G. Z., Ku, T. W., and Kang, B. S., “Improvement of Formability for Multi-Point Bending Process of AZ31B Sheet Material using Elastic Cushion,” Int. J. Precis. Eng. Manuf., Vol. 12, No. 6, pp. 1023–1030, 2011.
Chen, F. K. and Huang, T. B., “Formability of Stamping Magnesium-Alloy AZ31 Sheets,” Journal of Materials Processing Technology, Vol. 142, No. 3, pp. 643–647, 2003.
Yoshihara, S., Yamamoto, H., Manabe, K., and Nishimura, H., “Formability Enhancement in Magnesium Alloy Deep Drawing by Local Heating and Cooling Technique,” Journal of Materials Processing Technology, Vol. 143, pp. 612–615, 2003.
Cho, C. J. and Kim, K. P., “Development of the Deep Drawing Die for Mg-Alloy Sheet Metal,” Proc. of KSPE Autumn Conference, pp. 459–460, 2012.
Lee, M. H., Kim, H. Y., Kim, H. J., Kim, H. K., and Oh, S. I., “Forming Analysis for Warm Deep Drawing Process of Magnesium Alloy Sheet,” Transactions of Materials Processing, Vol. 16, No. 5, pp. 401–405, 2007.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Nam, JD., Cha, SH., Ahn, MS. et al. Development of non-lubricated die for magnesium sheet forming of car body part. Int. J. Precis. Eng. Manuf. 15, 1125–1129 (2014). https://doi.org/10.1007/s12541-014-0446-2
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12541-014-0446-2