Skip to main content
SpringerLink
Log in

Error analysis of FLC experimental data at warm/hot stamping conditions

  • Published:
Chinese Journal of Mechanical Engineering Submit manuscript

Abstract

Forming limit curves(FLCs) are commonly used for evaluating the formability of sheet metals. However, it is difficult to obtain the FLCs with desirable accuracy by experiments due to that the friction effects are non-negligible under warm/hot stamping conditions. To investigate the experimental errors, experiments for obtaining the FLCs of the AA5754 are conducted at 250°C. Then, FE models are created and validated on the basis of experimental results. A number of FE simulations are carried out for FLC test-pieces and punches with different geometry configurations and varying friction coefficients between the test-piece and the punch. The errors for all the test conditions are predicted and analyzed. Particular attention of error analysis is paid to two special cases, namely, the biaxial FLC test and the uniaxial FLC test. The failure location and the variation of the error with respect to the friction coefficient are studied as well. The results obtained from the FLC tests and the above analyses show that, for the biaxial tension state, the friction coefficient should be controlled within 0.15 to avoid significant shifting of the necking location away from the center of the punch; for the uniaxial tension state, the friction coefficient should be controlled within 0.1 to guarantee the validity of the data collected from FLC tests. The conclusions summarized are beneficial for obtaining accurate FLCs under warm/hot stamping conditions.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. SHU Da, SUN Baode, WANG Jun, et al. Melt purity-property relationships in casting aluminum alloys[J]. Special Casting & Nonferrous Alloys, 1992, 12(2): 52–56. (in Chinese)

    Google Scholar 

  2. XU Zhengbing, ZOU Yongzhi, ZENG Jianmin. New inclusion assessment method in aluminum alloys-electrochemical method for inclusion assessment[J]. Chinese Journal of Mechanical Engineering. 2011, 24(1): 160–166.

    Article  Google Scholar 

  3. BOLT P J, LAMBOO N A P M, ROZIER P J C M. Feasibility of warm drawing of aluminium products[J]. Journal of Materials Processing Tech., 2001, 115(1): 118–121.

    Article  Google Scholar 

  4. SHEHATA F, PAINTER M J, PEARCE R. Warm forming of aluminium/magnesium alloy sheet[J]. Journal of Materials Processing Tech., 1978, 2(3): 279–290.

    Google Scholar 

  5. LI D, GHOSH A K. Biaxial warm forming behavior of aluminum sheet alloys[J]. Journal of Materials Processing Tech., 2003, 145(3): 281–293.

    Article  Google Scholar 

  6. FINCH D M, WILSON S P, DORN J E. Deep drawing aluminum alloys at elevated temperatures. Part I. Deep drawing cylindrical cups[J]. ASM Trans. Quart., 1946, 36: 254–289.

    Google Scholar 

  7. FINCH D M, WILSON S P, DORN J E. Deep drawing aluminum alloys at elevated temperatures. Part II. Deep drawing boxes[J]. ASM Trans. Quart., 1946, 36: 290–310.

    Google Scholar 

  8. NAKA T, YOSHIDA F. Deep drawability of type 5083 aluminium-magnesium alloy sheet under various conditions of temperature and forming speed[J]. Journal of Materials Processing Tech., 1999, 89: 19–23.

    Article  Google Scholar 

  9. NAKA T, TORIKAI G, HINO R et al. The effects of temperature and forming speed on the forming limit diagram for type 5083 aluminum magnesium alloy sheet[J]. Journal of Materials Processing Tech., 2001, 113(1): 648–653.

    Article  Google Scholar 

  10. KEELER S P, BACKOFEN W A. Plastic instability and fracture in sheets stretched over rigid punches[J]. ASM Trans. Quart., 1963, 56: 25–48.

    Google Scholar 

  11. SHI Z, WANG Y, LIN J. An investigation, using standard experimental techniques, to determine FLCs at elevated temperature for aluminium alloys[C]//YUAN S J, VOLLERSTEN F, WANG A R, et al. The 3rd International Conference on New Forming Technology. Harbin, China: August 26–28, 2012: 100–104.

    Google Scholar 

  12. BUTUC M C, GRACIO J J, BARATA DA ROCHA A. A theoretical study on forming limit diagrams prediction[J]. Journal of Materials Processing Technology, 2003, 142(3): 714–724.

    Article  Google Scholar 

  13. HSU E, CARSLEY J E, VERMA R. Development of forming limit diagrams of aluminum and magnesium sheet alloys at elevated temperatures[J]. Journal of Materials Engineering and Performance, 2008, 17: 288–296.

    Article  Google Scholar 

  14. International Standards Organizations. ISO 12004-1:2008, Metallic materials-sheet and strip-determination of forming-limit curves–Part 1: Measurement and application of forming-limit diagrams in the press shop[S]. 2008.

    Google Scholar 

  15. International Standards Organizations. ISO 12004-2:2008, Metallic materials-sheet and strip-determination of forming-limit curves–Part 2: Determination of forming-limit curves in the laboratory [S]. 2008.

    Google Scholar 

  16. WANG Hui. Acquisition method of forming limit diagram and its application in Sheet metal forming[D]. Nanjing: Electrical and Mechanical College, Nanjing University of Aeronautics and Astronautics, 2011. (in Chinese)

    Google Scholar 

  17. RAGHAVAN K S. A simple technique to generate in-plane forming limit curves and selected applications[J]. Metall. Mater. Trans. A, 1995, 26(8): 2075–2084.

    Article  Google Scholar 

  18. BOISSIÈRE R, VACHER P, BLANDIN J J. Influence of the punch geometry and sample size on the deep-drawing limits in expansion of an aluminium alloy[J]. International Journal of Material Forming, 2010, 3(1): 135–138.

    Article  Google Scholar 

  19. BRESSAN J D. Influence of thickness size in sheet metal forming[J]. International Journal of Material Forming, 2008, 1(1): 117–119.

    Article  Google Scholar 

  20. BLECK W, DENG ZHI, PAPAMANTELLOS K et al. A comparative study of the forming-limit diagram models for sheet steels[J]. Journal of Materials Processing Tech., 1998, 83(1): 223–230.

    Article  Google Scholar 

  21. MARCINIAK Z, KUCZYNISK K, POKORA T. Influence of the plastic properties of a material on the forming limit diagram for sheet metal in tension[J]. International Journal of Mechanical Sciences, 1973, 15(10): 789–800.

    Article  Google Scholar 

  22. LIU Yulin, CHEN Wenliang, BAO Yidong, Optimization design for blank shape based on adaptive response surface method[J]. Journal of Jiangsu University, 2012, 33(3): 322–327. (in Chinese)

    Google Scholar 

  23. National Standardization Technical Committees. GB/T 15825.8-1995 Sheet metal formability and test methods—Forming limit diagram(FLD) test[S]. 1995. (in Chinese)

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. State Key Laboratory of Automotive Dynamic Simulation, Jilin University, Changchun, 130022, China

    Weimin Zhuang & Mengxi Zhang

  2. Department of Aeronautics, Imperial College, London, SW7 2AZ, UK

    Yanhong Chen

Authors
  1. Weimin Zhuang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Mengxi Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yanhong Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Weimin Zhuang.

Additional information

Supported by National Natural Science Foundation of China(Grant No. 51375201), Jilin Province Science and Technology Development Plan(Grant No. 20130101048JC), and Open Research Fund of Shanghai Key Laboratory of Digital Manufacturer for Thin-walled Structure(Grant No. 2013001)

ZHUANG Weimin, born in 1970, is a professor at Jilin University, China. She received her PhD degree from Jilin University, China, in 2005. Her research interests include car body structure optimization, finite element analysis and metal forming technologies.

ZHANG Mengxi, born in 1989, is currently a MS candidate at College of Automotive Engineering, Jilin University, China. She received her bachelor degree from College of Jilin University, China, in 2012. Her research interests include finite element analysis and metal forming technologies.

CHEN Yanhong, born in 1983, is currently a PhD candidate at Department of Aeronautics, Imperial College London, UK. He received his master degree from College of Automotive Engineering, Jilin University, China, in 2012. His research interests include finite element method, meshfree methods, and woven composites.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zhuang, W., Zhang, M. & Chen, Y. Error analysis of FLC experimental data at warm/hot stamping conditions. Chin. J. Mech. Eng. 27, 730–737 (2014). https://doi.org/10.3901/CJME.2014.0515.094

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.3901/CJME.2014.0515.094

Keywords

Search

Navigation