Deformation characteristics and inertial effect of complex aluminum alloy sheet part under impact hydroforming: experiments and numerical analysis

doi:10.1007/s40436-022-00430-0

Advances in Manufacturing ›› 2023, Vol. 11 ›› Issue (2): 311-328.doi: 10.1007/s40436-022-00430-0

• ARTICLES • 上一篇

Deformation characteristics and inertial effect of complex aluminum alloy sheet part under impact hydroforming: experiments and numerical analysis

Liang-Liang Xia^1,2, Shi-Hong Zhang^1,2, Yong Xu^1,2, Shuai-Feng Chen^1,2, Boris B. Khina³, Artur I. Pokrovsky³

1. Shi-changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences, Shenyang, 110016, People's Republic of China;
2. School of Materials Science and Engineering, University of Science and Technology of China, Hefei, 230000, People's Republic of China;
3. Physical-Technical Institute, National Academy of Science of Belarus, 220141, Minsk, Belarus

收稿日期:2022-05-04 修回日期:2022-06-20 发布日期:2023-05-20
通讯作者: Shi-Hong Zhang,E-mail:shzhang@imr.ac.cn E-mail:shzhang@imr.ac.cn
作者简介:Liang?Liang Xia is a Ph.D. candidate at the Shi-changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences. His research focuses on precise sheet metal forming of complex-shaped parts, including finite element modelling, development and design of plastic forming processes and optimization of FEM and experiment.
Shi?Hong Zhang is a Professor at the Shi-changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences. He has been actively involved in advanced metal forming technology research for decades. His research interests include development of advanced metal forming technologies (impact hydroforming, pulsating hydroforming, stamping, rolling, cross wedge rolling, pilgering, and stretch forming processes); fnite element modelling of metal forming processes; materials modelling & characterization; microstructure evolution and analysis; predicting of rolling texture by vpsc and cpfem; formulation and determination of constitutive equations; multiscale mechanics of materials; sheet metal formability (prediction and improvement); modelling of anisotropic behaviour of Mg and Al alloys; modelling of strain path change efect; cold/warm deformation of Mg and Al alloys; high strain rate deformation and fracture mechanics.
Yong Xu is a Professor at the Shi-changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences. His research interests include the development of advanced fexible forming technologies and machines for complex shaped thin-walled components, microstructure evolution and mechanical properties of high-performance alloys, finite element simulation and multiscale modelling.
Shuai?Feng Chen is an Associate Professor at the Shi-changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences. His research interests include the fabrication and processing of advanced high-performance light-weight alloys, development of plastic theory and forming method, multiscale modelling the microstructure and texture evolution in fullchain process.
Boris B. Khina is an Associate Professor at the Physical-Technical Institute, National Academy of Science of Belarus. His research interests include development of new, original mathematical models and computer simulation of solid-state diffusion, phase and structure formation, heat transfer and reaction kinetics during synthesis of advanced materials and coatings for deeper understanding of underlying physical/chemical mechanisms and developing new and improving existing technologies.
Artur I. Pokrovsky is an Associate Professor at the Physical-Technical Institute, National Academy of Science of Belarus. His research interests include development of novel materials and technologies of their production and processing, and application of the developments in industry; impact hydroforming of metal-sheet materials, study of structure, phase and structural transformations of cast irons subjected to hot plastic deformation.
基金资助:
The authors would like to acknowledge the support of the National Natural Science Foundation of China (Grant No. 51875548), International Cooperation and Exchange Programme (Grant No. 52111530293) and the Youth Innovation Promotion Association of the Chinese Academy of Sciences (Grant No. 2019195).

Deformation characteristics and inertial effect of complex aluminum alloy sheet part under impact hydroforming: experiments and numerical analysis

Liang-Liang Xia^1,2, Shi-Hong Zhang^1,2, Yong Xu^1,2, Shuai-Feng Chen^1,2, Boris B. Khina³, Artur I. Pokrovsky³

1. Shi-changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences, Shenyang, 110016, People's Republic of China;
2. School of Materials Science and Engineering, University of Science and Technology of China, Hefei, 230000, People's Republic of China;
3. Physical-Technical Institute, National Academy of Science of Belarus, 220141, Minsk, Belarus

Received:2022-05-04 Revised:2022-06-20 Published:2023-05-20
Contact: Shi-Hong Zhang,E-mail:shzhang@imr.ac.cn E-mail:shzhang@imr.ac.cn
Supported by:
The authors would like to acknowledge the support of the National Natural Science Foundation of China (Grant No. 51875548), International Cooperation and Exchange Programme (Grant No. 52111530293) and the Youth Innovation Promotion Association of the Chinese Academy of Sciences (Grant No. 2019195).

摘要/Abstract

摘要： Impact hydroforming (IHF), as a novel sheet metal forming technology with the advantages of high strain rate forming and flexible liquid loading, is highly suitable for efficiently manufacturing aluminum complex-shaped sheet parts. In this paper, deformation characteristics of complex sheet parts under IHF are systematically investigated. The mechanical properties of 2024 aluminum alloy under a wide range of strain rates (10^?3 s^?1–3.3×10³ s^?1) were studied. It indicated that the elongation of 2024 aluminum alloy was improved by 116.01% under strain rates of 3.306?×?10³ s^?1, referring to 10^?3 s^?1. Further, a complex-shaped part with symmetrical and asymmetrical structures was selected. The deformation characteristics of sheet and role of inertial effect under IHF were investigated with well-developed solid–liquid coupling finite element (SLC-FE) model with high accuracy. Differentiating deformation tendency is found for symmetrical structure with notably prior deformation at central zone, showing a “bulging” profile at initial forming stage. Whereas, synchronous deformation is presented for asymmetrical structure with a “flat” profile. Additionally, distinctive inertial effect was observed at different positions change for both symmetrical and asymmetrical structures, in which lower values were resulted at their central regions. Meanwhile, the inertial effect evolved with the impacting speed. Specially, larger difference of inertial effect was observed with increasing impacting speed.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-022-00430-0

关键词: 2024 aluminum alloy, Impact hydroforming, High strain rate, Inertial effect

Abstract: Impact hydroforming (IHF), as a novel sheet metal forming technology with the advantages of high strain rate forming and flexible liquid loading, is highly suitable for efficiently manufacturing aluminum complex-shaped sheet parts. In this paper, deformation characteristics of complex sheet parts under IHF are systematically investigated. The mechanical properties of 2024 aluminum alloy under a wide range of strain rates (10^?3 s^?1–3.3×10³ s^?1) were studied. It indicated that the elongation of 2024 aluminum alloy was improved by 116.01% under strain rates of 3.306?×?10³ s^?1, referring to 10^?3 s^?1. Further, a complex-shaped part with symmetrical and asymmetrical structures was selected. The deformation characteristics of sheet and role of inertial effect under IHF were investigated with well-developed solid–liquid coupling finite element (SLC-FE) model with high accuracy. Differentiating deformation tendency is found for symmetrical structure with notably prior deformation at central zone, showing a “bulging” profile at initial forming stage. Whereas, synchronous deformation is presented for asymmetrical structure with a “flat” profile. Additionally, distinctive inertial effect was observed at different positions change for both symmetrical and asymmetrical structures, in which lower values were resulted at their central regions. Meanwhile, the inertial effect evolved with the impacting speed. Specially, larger difference of inertial effect was observed with increasing impacting speed.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-022-00430-0

Key words: 2024 aluminum alloy, Impact hydroforming, High strain rate, Inertial effect

Liang-Liang Xia, Shi-Hong Zhang, Yong Xu, Shuai-Feng Chen, Boris B. Khina, Artur I. Pokrovsky. Deformation characteristics and inertial effect of complex aluminum alloy sheet part under impact hydroforming: experiments and numerical analysis[J]. Advances in Manufacturing, 2023, 11(2): 311-328.

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Deformation characteristics and inertial effect of complex aluminum alloy sheet part under impact hydroforming: experiments and numerical analysis

Deformation characteristics and inertial effect of complex aluminum alloy sheet part under impact hydroforming: experiments and numerical analysis

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