nach oben

International Journal of Material Forming

Erschienen in:

01.05.2022 | Original Research

Forming limit analysis of friction stir tailor welded AA5083 and AA7075 sheets in single point incremental forming

verfasst von: Gautam Kumar, Kuntal Maji

Erschienen in: International Journal of Material Forming | Ausgabe 3/2022

Einloggen

Aktivieren Sie unsere intelligente Suche, um passende Fachinhalte oder Patente zu finden.

search-config

KI-gestützte Suche

Aus

Abstract

Formability of friction stir welded dissimilar aluminium alloy sheets namely AA5083 and AA7075 in single point incremental forming (SPIF) is investigated in this article. Initially friction stir tailor welded blanks (FS-TWB) were made by varying different process parameters such as tool shoulder diameter, welding speed, and tool rotational speed following a central composite experimental design. A combination of lower rotational speed, higher weld speed and a moderate tool shoulder diameter was found to produce optimal weld quality in terms of ultimate tensile strength (UTS) and percentage elongation (PE) obtained through response surface method. Deformation instability method and incremental sheet forming tests were employed to predict forming limit curve (FLC) and maximum formable wall angle for the FS-TWBs with optimal weld quality. Formability of FS-TWBs were seen to be comparable to that of the base sheet materials. Formability of the incrementally formed FS-TWB could be attributed to the microstructures of the deformed welded zone containing varying grain sizes effected by severe plastic deformation and dynamic recrystallization. Fracture morphology revealed that forming fracture strains limited by the combined modes of ductile and brittle modes fractures in FS-TWB during SPIF.

Vorheriger Artikel A new friction welding process for soft packaging applications

Nächster Artikel Regularization of shear banding and prediction of size effects in manufacturing operations: A micromorphic plasticity explicit scheme

Sie haben noch keine Lizenz? Dann Informieren Sie sich jetzt über unsere Produkte:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

über 102.000 Bücher
über 537 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Finance + Banking
Management + Führung
Marketing + Vertrieb
Maschinenbau + Werkstoffe
Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

Jetzt informieren

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

über 67.000 Bücher
über 390 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Maschinenbau + Werkstoffe

Jetzt Wissensvorsprung sichern!

Jetzt informieren

Nur mit Berechtigung zugänglich

Duflou JR, Habraken AM, Cao J, Malhotra R, Bambach M, Adams D, Vanhove H, Mohammadi A, Jeswiet J (2018) Single point incremental forming: state-of-the-art and prospects. Int J Mater Form 11:743–773. https://doi.org/10.1007/s12289-017-1387-yCrossRef

Merklein M, Johannes M, Lechner M, Kuppert A (2014) A review on tailored blanks—Production, applications and evaluation. J Mater Process Technol 214:151–164. https://doi.org/10.1016/j.jmatprotec.2013.08.015CrossRef

Bahemmat P, Haghpanahi M, Givi MKB, Seighalani KR (2012) Study on dissimilar friction stir butt welding of AA7075-O and AA2024-T4 considering the manufacturing limitation. Int J Adv Manuf Technol 59:939–953. https://doi.org/10.1007/s00170-011-3547-4CrossRef

Ahmed MMZ, Ataya S, El-Sayed Seleman MM, Ammar HR, Ahmed E (2017) Friction stir welding of similar and dissimilar AA7075 and AA5083. J Mater Process Technol 242:77–91. https://doi.org/10.1016/j.jmatprotec.2016.11.024CrossRef

Entesari S, Abdollah-zadeh A, Habibi N, Mehri A (2017) Experimental and numerical investigations into the failure mechanisms of friction stir welded AA7075-T6 thin sheets. J Manuf Process 29:74–84. https://doi.org/10.1016/j.jmapro.2017.07.012CrossRef

Donatus U, Thompson GE, Momoh MI, Maledi NB, Tsai IL, Ferreira RO, Liu Z (2018) Variations in stir zone and thermo mechanically affected zone of dissimilar friction stir weld of AA5083 and AA6082 alloys. Trans Nonferrous Met Soc China 28:2410–2418. https://doi.org/10.1016/S1003-6326(18)64887-3CrossRef

Ahmed S, Saha P (2020) Selection of optimal process parameters and assessment of its effect in micro-friction stir welding of AA6061-T6 sheets. Int J Adv Manuf Technol 106:3045–3061. https://doi.org/10.1007/s00170-019-04840-6CrossRef

Kumar S, Kumar S (2015) Multi-response optimization of process parameters for friction stir welding of joining dissimilar Al alloys by gray relation analysis and Taguchi method. J Braz Soc Mech Sci Eng 37:665–674. https://doi.org/10.1007/s40430-014-0195-2CrossRef

Shojaeefard MH, Behnagh RA, Akbari M, Givi MKB, Farhani F (2013) Modelling and Pareto optimization of mechanical properties of friction stir welded AA7075/AA5083 butt joints using neural network and particle swarm algorithm. Mater Des 44:190–198. https://doi.org/10.1016/j.matdes.2012.07.025CrossRef

10.

Ma ZY, Feng AH, Chen DL, Shen J (2017) Recent advances in friction stir welding/processing of aluminum alloys: microstructural evolution and mechanical properties. Crit Rev Solid State Mater Sci 0–0:1–65. https://doi.org/10.1080/10408436.2017.1358145CrossRef

11.

Leitão C, Emílio B, Chaparro BM, Rodrigues DM (2009) Formability of similar and dissimilar friction stir welded AA 5182–H111 and AA 6016–T4 tailored blanks. Mater Des 30:3235–3242. https://doi.org/10.1016/j.matdes.2008.12.005CrossRef

12.

Babu NBK, Davidson MJ, Rao AN, Balasubramanian K, Govindaraju M (2014) Effect of differential heat treatment on the formability of aluminium tailor welded blanks. Mater Des 55:35–42. https://doi.org/10.1016/j.matdes.2013.10.004CrossRef

13.

Habibi M, Hashemi R, Tafti MF, Assempour A (2018) Experimental investigation of mechanical properties, formability and forming limit diagrams for tailor-welded blanks produced by friction stir welding. J Manuf Process 31:310–323. https://doi.org/10.1016/j.jmapro.2017.11.009CrossRef

14.

Parente M, Safdarian R, Santos AD, Loureiro A, Vilaca P, Jorge RMN (2016) A study on the formability of aluminum tailor welded blanks produced by friction stir welding. Int J Adv Manuf Technol 83:2129–2141. https://doi.org/10.1007/s00170-015-7950-0CrossRef

15.

Kesharwani RK, Panda SK, Pal SK (2015) Experimental investigations on formability of aluminum tailor friction stir welded blanks in deep drawing process. J Mater Eng Perform 24:1038–1049. https://doi.org/10.1007/s11665-014-1361-5CrossRef

16.

Do V, Pham Q, Kim Y (2017) Identification of forming limit curve at fracture in incremental sheet forming. Int J Adv Manuf Technol 92:4445–4455. https://doi.org/10.1007/s00170-017-0441-8CrossRef

17.

Ai S, Lu B, Chen J, Long H, Ou H (2017) Evaluation of deformation stability and fracture mechanism in incremental sheet forming. Int J Mech Sci 124–125:174–184. https://doi.org/10.1016/j.ijmecsci.2017.03.012CrossRef

18.

Fang Y, Lu B, Chen J, Xu DK, Ou H (2014) Analytical and experimental investigations on deformation mechanism and fracture behavior in single point incremental forming. J Mater Process Technol 214:1503–1515. https://doi.org/10.1016/j.jmatprotec.2014.02.019CrossRef

19.

Maji K, Kumar G (2020) Inverse analysis and multi-objective optimization of single-point incremental forming of AA5083 aluminum alloy sheet. Soft Comput 24(6):4505–4521. https://doi.org/10.1007/s00500-019-04211-zCrossRef

20.

Kumar G, Maji K (2021) Investigations into enhanced formability of AA5083 aluminium alloy sheet in single point incremental forming. J Mater Eng Perform 30:1289–1305. https://doi.org/10.1007/s11665-021-05455-3CrossRef

21.

Kumar G (2021) ‘Formability analysis of tailored blanks in single point incremental forming’, PhD thesis, National Institute of Technology, Patna, India. https://doi.org/10.5281/zenodo.5884656.

22.

Alinaghian I, Ranjbar H, Beheshtizad MA (2017) Forming limit investigation of AA6061 friction stir welded blank in a single point incremental forming process: RSM approach. Trans Indian Inst Met 70(9):2303–2318. https://doi.org/10.1007/s12666-017-1093-yCrossRef

23.

Silva MB, Skjoedt M, Vilaca P, Bay N, Martins PAF (2009) Single point incremental forming of tailored blanks produced by friction stir welding. J Mater Process Technol 209:811–820. https://doi.org/10.1016/j.jmatprotec.2008.02.057CrossRef

24.

Liu Z, Li Y, Meehan PA (2013) Experimental investigation of mechanical properties, formability and force measurement for AA7075-O aluminum alloy sheets formed by incremental forming. Int J Precis Eng Manuf 14–11:1891–1899. https://doi.org/10.1007/s12541-013-0255-zCrossRef

25.

Tayebi P, Fazli A, Asadi P, Soltanpour M (2019) Formability analysis of dissimilar friction stir welded AA 6061 and AA 5083 blanks by SPIF process. CIRP J Manuf Sci Technol 25:50–68. https://doi.org/10.1016/j.cirpj.2019.02.002CrossRef

26.

Liu Z (2018) Heat-assisted incremental sheet forming: a state-of-the-art review. Int J Adv Manuf Technol 98:2987–3003. https://doi.org/10.1007/s00170-018-2470-3CrossRef

27.

Singh SA, Priyadarshi S, Tandon P (2021) Comparative study of incremental forming and elevated temperature incremental forming through experimental investigations on AA 1050 sheet. J Manuf Sci Eng 143(6):064501–064507. https://doi.org/10.1115/1.4049093CrossRef

28.

Maji K, Kumar S, Kumar G (2019) Experimental study on the effects of incremental forming and friction stir welding on formability of AA5083 sheet. J Phys Conf Ser 1240(1):012090. https://doi.org/10.1088/1742-6596/1240/1/012090CrossRef

29.

Kumar G, Saurabh, Roshan M, Nandan K, Maji K (2019) An experimental study on single point incremental forming of AA5083 sheet using response surface methodology. In: Shunmugam M., Kanthababu M. (eds.) Adv. in Form., Mach. & Auto., Lec. Note. On Multidis. Ind. Eng. Springer, Singapore, pp. 91–103. https://doi.org/10.1007/978-981-32-9417-2_7.

30.

Gatea S, Lu B, Chen J, Ou H, McCartney G (2019) Investigation of the effect of forming parameters in incremental sheet forming using a micromechanics based damage model. Int J Mater Form 12:553–574. https://doi.org/10.1007/s12289-018-1434-3CrossRef

31.

Basak S, Prasad KS, Sidpara AM, Panda SK (2019) Single point incremental forming of AA6061 thin sheet: calibration of ductile fracture models incorporating anisotropy and post forming analyses. Int J Mater Form 12:623–642. https://doi.org/10.1007/s12289-018-1439-yCrossRef

32.

Wernicke S, Hahn M, Gerstein G, Nürnberger F, Tekkaya AE (2021) Strain path dependency in incremental sheet-bulk metal forming. Int J Mater Form 14:547–561. https://doi.org/10.1007/s12289-020-01537-0CrossRef

33.

Abbasi M, Bagheri B, Abdollahzadeh A, Moghaddam AO (2021) A different attempt to improve the formability of aluminum tailor welded blanks (TWB) produced by the FSW. Int J Mater Form 14:1189–1208. https://doi.org/10.1007/s12289-021-01632-wCrossRef

34.

Carlone P, Thuillier S, Andrade-Campos A, Alves de Sousa RJ, Valente R (2021) Incremental forming of friction-stir welded aluminium blanks: an integrated approach. Int J Mater Form 14:1121–1137. https://doi.org/10.1007/s12289-021-01628-6CrossRef

35.

Trzepiecinski T, Oleksik V, Pepelnjak T, Najm SM, Paniti I, Maji K (2021) Emerging trends in single point incremental sheet forming of lightweight metals. Metals 11(8):1188. https://doi.org/10.3390/met11081188CrossRef

36.

Kumar G, Maji K (2022) Investigations on formability of tailor laminated sheets in single point incremental forming. Proc Inst Mech Eng Part B J Eng Manuf. https://doi.org/10.1177/09544054221076244CrossRef

37.

Montgomery DC (2001) Design and analysis of experiments. 5th Edition, John Wiley & Sons Ltd., New York. https://doi.org/10.1002/qre.458.

38.

Maji K, Pratihar DK, Nath AK (2014) Analysis of pulsed laser bending of sheet metal using neural networks and neuro-fuzzy system. Proc Inst Mech Eng Part B J Eng Manuf 228(9):1015–1026. https://doi.org/10.1177/0954405414522212CrossRef

39.

Kumar A, Maji K (2020) Selection of process parameters for near-net shape deposition in wire arc additive manufacturing by genetic algorithm. J Mater Eng Perform 29:3334–3352. https://doi.org/10.1007/s11665-020-04847-1CrossRef

40.

Ait-Amokhtar H, Fressengeas C, Bouabdallah K (2015) On the effects of the Mg content on the critical strain for the jerky flow of Al-Mg alloys. Mater Sci Eng A 631:209–213. https://doi.org/10.1016/j.msea.2015.02.055CrossRef

Titel: Forming limit analysis of friction stir tailor welded AA5083 and AA7075 sheets in single point incremental forming
verfasst von: Gautam Kumar
Kuntal Maji
Publikationsdatum: 01.05.2022
Verlag: Springer Paris
Erschienen in: International Journal of Material Forming / Ausgabe 3/2022
Print ISSN: 1960-6206
Elektronische ISSN: 1960-6214
DOI: https://doi.org/10.1007/s12289-022-01675-7

Premium Partner

Marktübersichten

Die im Laufe eines Jahres in der „adhäsion“ veröffentlichten Marktübersichten helfen Anwendern verschiedenster Branchen, sich einen gezielten Überblick über Lieferantenangebote zu verschaffen.

Zur Marktübersicht

Springer Professional

Abstract

Bitte loggen Sie sich ein, um Zugang zu Ihrer Lizenz zu erhalten.

Sie haben noch keine Lizenz? Dann Informieren Sie sich jetzt über unsere Produkte:

Springer Professional "Wirtschaft+Technik"

Springer Professional "Technik"

Weitere Artikel der Ausgabe 3/2022

Advancements in extrusion and drawing: a review of the contributes by the ESAFORM community

Tailored Forming of hybrid bulk metal components

Temperature and strain dependent fracture of AlSi coating in hot stamping of press hardening steel

Regularization of shear banding and prediction of size effects in manufacturing operations: A micromorphic plasticity explicit scheme

Advances in composite forming through 25 years of ESAFORM

Prediction of springback after bending under tension

Premium Partner

Marktübersichten