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

Abstract

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.

TrendMD

References

1. Heinz A, Haszler A, Keidel C et al (2000) Recent development in aluminum alloys for aerospace applications. Mater Sci Eng A Struct 280:102–107
2. El-Aty AA, Xu Y, Guo XZ et al (2018) Strengthening mechanisms, deformation behavior, and anisotropic mechanical properties of Al-Li alloys: a review. J Adv Res 10:49–67
3. Zheng KL, Politis DJ, Wang LL et al (2018) A review on forming techniques for manufacturing lightweight complex-shaped aluminum panel components. Int J Lightweight Mat Manu 1:55–80
4. Mori K, Patwari AU, Maki S (2004) Improvement of formability by oscillation of internal pressure in pulsating hydroforming of tube. CIRP Ann Manuf Technol 53:215–218
5. Xu Y, Zhang SH, Cheng M et al (2012) In situ X-ray diffraction study of martensitic transformation in austenitic stainless steel during cyclic tensile loading and unloading. Scr Mater 67:771–774
6. Xu Y, Ma Y, Zhang SH et al (2016) Numerical and experimental study on large deformation of thin-walled tube through hydroforging process. Int J Adv Manuf Technol 87:1885–1890
7. Chu GN, Sun L, Wang GD et al (2019) Axial hydro-forging sequence for variable-diameter tube of 6063 aluminum alloy. J Mater Process Technol 272:87–99
8. Xia LL, Xu Y, El-Aty AA et al (2019) Deformation characteristics in hydro-mechanical forming process of thin-walled hollow component with large deformation: experimentation and finite element modeling. Int J Adv Manuf Technol 104:4705–4714
9. Feng H, Han C (2020) Deformation behavior in the hydroforming of overlapping tubular blanks. Int J Mach Tools Manuf 158:103624. https://doi.org/10.1016/j.ijmachtools.2020.103624
10. Shamchi SP, Melo FJMQ, Tavares PJ et al (2019) Thermomechanical characterization of Alclad AA2024-T3 aluminum alloy using split Hopkinson tension bar. Mech Mater 139:103198. https://doi.org/10.1016/j.mechmat.2019.103198
11. Yu HP, Jin YY, Hu L et al (2020) Mechanical properties of the solution treated and quenched Al-Cu-Li alloy (AA2195) sheet during high strain rate deformation at room temperature. Mater Sci Eng A Struct 793:139880. https://doi.org/10.1016/j.msea.2020.139880
12. Tomasz T (2020) Recent developments and trends in sheet metal forming. Metals 10:779. https://doi.org/10.3390/met10060779
13. Cheng TC, Lee RS (2018) The influence of grain size and strain rate effects on formability of aluminum alloy sheet at high-speed forming. J Mater Process Technol 253:134–159
14. Barik SK, Narayanan RG, Sahoo N (2020) Prediction of forming of AA5052-H32 sheetsunder impact loading and experimental validation. J Mater Eng Perform 29:3941–3960
15. Liu B, Li Z, Xu F et al (2011) Influence and sensitivity of inertial effect on void growth behavior inductile metals. Key Eng Mater 462/463:449–454
16. Rajendran AM, Fyfe IM (1982) Inertia effects on the ductile failure of thin rings. J Appl Mech 49(1):31–36
17. Shenoy VB, Freund LB (1999) Necking bifurcations during high strain rate extension. J Mech Phys Solids 47:2209–2233
18. Nilsson K (2001) Effects of inertia on dynamic neck formation in tensile bars. Eur J Mech A/Solids 20:713–729
19. Su HL, Huang L, Li JJ et al (2021) Formability of AA 2219-O sheet under quasi-static, electromagnetic dynamic, and mechanical dynamic tensile loadings. J Mater Process Technol 70:125–135
20. Zheng QL, Yu HP, Cai XH (2020) Formability and deformation behavior of DP600 steel sheets during a hybrid quasi-static/dynamic forming process. Int J Adv Manuf Technol 110:2169–2180
21. Zheng QL, Yu HP (2021) Influence of scale board on the dispersion deformation behavior of DP600 steel sheets during electrohydraulic forming. Int J Adv Manuf Technol 114:757–769
22. Zheng QL, Yu HP (2020) Hyperplasticity mechanism in DP600 sheets during electrohydraulic free forming. J Mater Process Technol 279:116582. https://doi.org/10.1016/j.jmatprotec.2019.116582
23. Yu HP, Zheng QL (2021) Plasticity enhancement mechanism of DP600 steel sheets during uniaxial quasi-static/dynamic forming. J Mater Process Technol 294:117138. https://doi.org/10.1016/j.jmatprotec.2021.117138
24. Oliveira DA, Worswick MJ, Finn M et al (2005) Electromagnetic forming of aluminum alloy sheet: Free-form and cavity fill experiments and model. J Mater Process Technol 170:350–362
25. Avrillaud G, Mazars G, Cantergiani E et al (2021) Examples of how increased formability through high strain rates can be used in electro-hydraulic forming and electromagnetic forming industrial applications. J Manuf Mater Process 5:96. https://doi.org/10.3390/jmmp5030096
26. Hassannejadasl A, Green DE, Golovashchenko SF et al (2014) Numerical modelling of electrohydraulic free-formingand die-forming of DP590 steel. J Mater Process Technol 16:391–404
27. Cui XH, Mo JH, Fang JX et al (2015) Variation of thickness distribution during electromagnetic sheet bulging. Int J Adv Manuf Technol 80:515–521
28. Feng F, Li JJ, Chen RC et al (2018) Effect of die geometry on the formability of 5052 aluminum alloy in electromagnetic impaction deformation. Materials 11:1379. https://doi.org/10.3390/ma11081379
29. Ma Y, Xu Y, Zhang SH et al (2018) Investigation on formability enhancement of 5A06 aluminum sheet by impact hydroforming. CIRP Ann-Manuf Technol 67:281–284
30. Skews BW, Kosing OE, Hattingh RJ (2004) Use of a liquid shock tube as a device for the study of material deformation under impulsive loading conditions. Proc Inst Mech Eng Part C-J Eng Mech Eng Sci 218:39–51
31. Deshpande VS, Heaver A, Fleck NA (2006) An underwater shock simulator. Proc R Soc A-Math Phys Eng Sci 462:1021–1041
32. Espinosa HD, Lee S, Moldovan N (2006) A novel fluid structure interaction experiment to investigate deformation of structural elements subjected to impulsive loading. Exp Mech 46:805–824
33. Huang W, Jia B, Zhang W et al (2016) Dynamic failure of clamped metallic circular plates subjected to underwater impulsive loads. Int J Impact Eng 94:96–108
34. Marai M, Lang LH, Wang SH et al (2014) Investigation on the effect of Liquid Hammer geometry to the pressure distribution of innovative hybrid impact hydroforming. Adv Mat Res 941/944:1843–1849
35. Wang SH, Lang LH, Lin LJ (2014) Investigation on the energy efficiency of innovative hybrid impact hydroforming. Adv Mat Res 989/994:1282–1285
36. Chen DY, Xu Y, Zhang SH et al (2021) A novel method to evaluate the high strain rate formability of sheet metals under impact hydroforming. J Mater Process Technol 287:116553. https://doi.org/10.1016/j.jmatprotec.2019.116553
37. El-Aty AA, Xu Y, Zhang SH et al (2019) Impact of high strain rate deformation on the mechanical behavior, fracture mechanisms and anisotropic response of 2060 Al-Cu-Li alloy. J Adv Res 18:19–37
38. Liu W, Zhou HB, Li JQ et al (2022) Comparison of Johnson-Cook and Cowper-Symonds models for aluminum alloy sheet by inverse identification based on electromagnetic bulge. Int J Mater Form. https://doi.org/10.1007/s12289-022-01656-w
39. Johnson GR, Cook WH (1985) Fracture characteristics of 3 metals subjected to various strains, strain rates, temperatures and pressures. Eng Fract Mech 21:31–48
40. Kapoor R, Nemat-Nasser S (1998) Determination of temperature rise during high strain rate deformation. Mech Mater 27:1–12
41. Tan JQ, Zhan M, Liu S et al (2015) A modified Johnson-Cook model for tensile flow behaviors of 7050–T7451 aluminum alloy at high strain rates. Mater Sci Eng A Struct 631:214–219
42. Deng HK, Mao YF, Li GY et al (2019) A study of electromagnetic free forming in AA5052 using digital image correlation method and FE analysis. J Mater Process Technol 37:595–605
43. Liu DH, Yu HP, Li CF (2009) Quasi-static-dynamic formability of AA5052-O sheet under uniaxial and plane-strain tension. Trans Nonferrous Met Soc China 19:318–325