Journal
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
Volume 253, Issue -, Pages 195-203Publisher
ELSEVIER SCIENCE SA
DOI: 10.1016/j.jmatprotec.2017.09.037
Keywords
Aluminum alloy; Local-thickened plates; Hot forming; Friction; Metal flow control
Funding
- National Natural Science Foundation of China [51725504, 51435007]
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Obtaining square cups with the radius at the bottom corner lower than the thickness of original plate via a single-step hot forming process is a challenge. In this paper, a processing way was proposed by combining local thickened plate and friction control, to manufacture square cups with small corner radii. Through finite element (FE) simulations, the metal flow during hot forming of square cups was optimized by varying the shape of the local thickened section and adjusting the friction conditions at the interfaces between blank and tools. It was found that the filling ratio of the bottom corner can be significantly improved by increasing the friction coefficient at the interfaces between the blank and the upper punch, and that between the blank and the central zone of counter punch. The established flow dividing surface (FDS) model is capable for describing the variation of metal flow with the friction coefficients. Base on the simulation results, hot forming experiments were also carried out, and square cups with small radii of 2 mm at the bottom corners were successfully manufactured.
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