Abstract
This paper presents a methodology to effectively determine the optimal process parameters for warm forming of lightweight materials using finite element analysis (FEA) and design of experiments (DOE). The accuracy and effectiveness of FEA are verified through comparisons of the achievable part depth values and forming limits predicted from FEA with those from experimental measurements in a wide range of warm-forming conditions. A DOE approach along with FEA is proposed to offer rapid and relatively accurate design of warm-forming process, especially for large parts that require 3D FEA. In addition, strain distributions on the formed part are obtained under a variety of process conditions to gain a better understanding of the warm-forming mechanisms and further investigate the effects of forming temperature, friction condition, forming speed, and blank holding pressure on forming performance. Results of this study reveal that much-improved formability can be efficiently gained with a well-controlled warm-forming parameters.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Mildenberger U, Khare A (2000) Planning for an environment-friendly car. Technovation 20:205–214
Taub A (2000) Automotive materials—technical trends and challenges. Management briefing seminars 2000, Traverse City, MI, USA
Berviller L, Bigot R, Martin P (2006) Technological information concerning the integrated design of “net-shape” forged parts. Int J Adv Manuf Technol 31:247–257
Vazquez V, Altan T (2000) Die design for flashless forging of complex parts. J Mater Process Technol 98:81–89
Dean TA (2000) The net-shape forming of gears. Mater Des 21:271–278
Shehata F, Painter MJ, Pearce R (1978) Warm forming of aluminum/magnesium alloy sheet. J Mech Work Technol 2:279–290
Li D, Ghosh A (2004) Biaxial warm forming behavior of aluminum sheet alloys. J Mater Process Technol 145:281–293
Doege E, Droder K (2001) Sheet metal forming of magnesium wrought alloys—formability and process technology. J Mater Process Technol 115:14–19
Takata K, Ohwue T, Saga T, Kikuchi M (2000) Formability of Al-Mg alloys at warm temperatures. Mater Sci Forum 331–337:631–636
Li D, Ghosh A (2003) Tensile deformation behavior of aluminum alloys at warm forming temperature. Mater Sci Eng A 352:279–286
Ayres RA (1979) Alloying aluminum with magnesium for ductility at warm temperatures (25 to 350°C). Metall Trans A 10:279–290
Naka T, Yoshida F (1999) Deep drawability of type 5083 aluminum–magnesium alloy sheet under various conditions of temperature and forming speed. J Mater Process Technol 89(90):19–23
Bolt PJ, Lamboo NAPM, Rozier PJCM (2001) Feasibility of warm drawing of aluminum products. J Mater Process Technol 115:118–121
Jinta M, Sakai Y, Oyagi M, Yoshizawa S, Matsui K, Noda K (2000) Press forming analysis of aluminum auto body panel: wrinkle behavior in 5000 and 6000 series aluminum alloy sheet forming. JSAE Rev 21:407–409
DOE-USAMP project on warm forming of aluminum. meeting notes and presentations 2002-2003, www.doe.gov/eerl
Takuda H, Mori K, Masuda I, Abe Y, Matsuo M (2002) Finite element simulation of warm deep drawing of aluminum alloy sheet when accounting for heat conduction. J Mater Process Technol 120:412–418
Palaniswamy H, Ngaile G, Altan T (1999) Finite element simulation of magnesium alloy sheet forming at elevated temperatures. J Mater Process Technol 146:52–60
Droder K (1999) Analysis on forming of thin magnesium sheet. University of Hanover, Dissertation
Bigot R, Leleu S, Martin P (2003) Forming machine qualification by analysis of manufactured parts geometry: application to aluminium forming process. Int J Adv Manuf Technol 21:476–482
Fourment L, Balan T, Chenot JL (1996) Optimal design for non-steady metal forming processes—II. application of shape optimization in forging. Int J Numer Methods Eng 39:51–65
Pilani R, Narasimhan K, Maiti SK, Singh UP, Data PP (2000) A hybrid intelligent systems approach for die design in sheet metal forming. Int J Adv Manuf Technol 16:370–375
Antonio CAC, Dourado NM (2002) Metal-forming process optimization by inverse evolutionary search. J Mater Process Technol 121:403–413
Kim HS, Koç M, Ni J, Ghosh A (2006) Finite element modeling and analysis of warm forming of aluminum alloys-validation through comparisons with experiments and determination of a failure criterion. J Manuf Sci Eng Trans ASME 128:613–621
Peace GS (1993) Taguchi methods: a hands-on approach. Addison-Wesley, Reading, MA
Schiff D, Dagostino RB (1996) Practical engineering statics. Wiley, Inc
Park SH (1996) Robust design and analysis for quality engineering. Chapman and Hall, New York
Szacinski AM, Thomson PF (1991) Wrinkling behavior of aluminum sheet during forming at elevated temperature. Mater Sci Technol 7:37–41
Sugamata M, Kaneko J, Usagawa H, Suzuki M (1987) Effect of forming temperature on deep drawability of aluminum alloy sheets. Proceedings of the 2nd International Conference on Technology of Plasticity: 1275-1281
Naka T, Hino R, Yoshida F (2000) Deep drawability of 5083 Al-Mg alloy sheet at elevated temperature and its prediction. Key Eng Mater 177–180:485–490
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Kim, H.S. A combined FEA and design of experiments approach for the design and analysis of warm forming of aluminum sheet alloys. Int J Adv Manuf Technol 51, 1–14 (2010). https://doi.org/10.1007/s00170-010-2620-8
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-010-2620-8