Abstract
This paper presents the method to shape a deep conical cup with multi-step laser shocking forming. Finite element method was employed to simulate the process of three-step laser shocking forming (TSLSF), and the process of sheet deformation at each step was analyzed. Especially, sheet deformation behaviors including deforming velocity, strain, residual stress, and geometrical shape were discussed in detail. The sheet-forming experiments were carried out to validate the simulation results. The numerical predictions of the deformed sheet shape in each step were compared and discussed with the corresponding experimental forming values. The experimental results display that three geometrical cups have been fabricated by TSLSF. The experimental results are well accordance with the corresponding numerical predicted data, which validates the established prediction model of sheet forming. It also indicates that MSLSF is a feasible forming process when the flat sheet needs to be formed into a deep-depth workpiece.
Similar content being viewed by others
References
Hak-GonSong N, Song W, Kang B, Kim J (2015) Two-step electromagnetic forming process using spiral forming coils to deform sheet metal in a middle-block die. Int J Adv Manuf Technol 76(9-12):1691–1703. https://doi.org/10.1007/s00170-014-6392-4
Zimniak Z (2000) Problems of multi-step forming sheet metal process design. J Mater Process Technol 106(1-3):152–158. https://doi.org/10.1016/S0924-0136(00)00607-5
Wang J, Goel A, Yang F, Gau JT (2009) Blank optimization for sheet metal forming using multi-step finite element simulations. Int J Adv Manuf Technol 40(7-8):709–720. https://doi.org/10.1007/s00170-008-1383-y
Niehoff HS, Vollertsen F (2005) Non-thermal laser stretch-forming. Adv Mater Res 6–8:433–440. https://doi.org/10.4028/www.scientific.net/amr.6-8.433
Yang C, Ye Z, Lu J, Jiang Y (2011) Laser shock forming of SUS304 stainless steel sheet with elliptical spot. Int J Adv Manuf Technol 56(9-12):987–993. https://doi.org/10.1007/s00170-011-3232-7
Wang X, Zhang D, Gu C, Shen Z, Qiu T, Gu Y, Liu H (2015) Investigation of a combined embossing and blanking process using laser shock wave. Int J Mater Form 8(2):317–325. https://doi.org/10.1007/s12289-014-1171-1
Zheng C, Sun S, Ji Z, Wang W, Liu J (2010) Numerical simulation and experimentation of microscale laser bulge forming. Int J Mach Tools Manuf 50:1048–1056. https://doi.org/10.1016/j.apsusc.2010.08.099
Nagarajan B, Castagne S, Wang Z, Zheng HY, Nadarajan K (2017) Influence of plastic deformation in flexible pad laser shock forming – experimental and numerical analysis. Int J Mater Form 10(1):109–123. https://doi.org/10.1007/s12289-015-1264-5
Zhang D, Lin Y, Gu C, Shen Z, Liu H, Wang X (2015) A mold-free laser shock micro-drawing forming process using Plasticine as the flexible support. Int J Adv Manuf Technol 79(1-4):265–272. https://doi.org/10.1007/s00170-015-6809-8
Zheng C, Zhang X, Liu Z, Ji Z, Yu X, Song L (2018) Investigation on initial grain size and laser power density effects in laser shock bulging of copper foil. Int J Adv Manuf Technol 96(1-4):1483–1496. https://doi.org/10.1007/s00170-018-1722-6
Li J, Cheng GJ (2010) Multiple-pulse laser dynamic forming of metallic thin films for microscale three dimensional shapes. J Appl Phys 108(1):013107. https://doi.org/10.1063/1.3457869
Zhang X, Zhang Y, Zhang Y, Pei S, Huang Z, Deng L, Li S (2018) Numerical and experimental investigations of laser shock forming aluminum alloy sheet with mold. Int J Mater Form 11(1):101–112. https://doi.org/10.1007/s12289-016-1333-4
Jiang Y, Huang Y, Jin H, Gu Y, Ren A, Huang L, Qian X (2013) Research on precision control of sheet metal forming by laser shock waves with semi-die. Opt Laser Technol 45:598–604. https://doi.org/10.1016/j.optlastec.2012.05.025
Zhang X, She J, Li S, Duan S, Zhou Y, Yu X, Zheng R, Zhang B (2015) Simulation on deforming progress and stress evolution during laser shock forming with finite element method. J Mater Process Technol 220:27–35. https://doi.org/10.1016/j.jmatprotec.2015.01.004
Liu H, Lu M, Wang X, Shen Z, Gu C, Gu Y (2015) Micro-punching of aluminum foil by laser dynamic flexible punching process. Int J Mater Form 8(2):183–196. https://doi.org/10.1007/s12289-013-1159-2
Hanna W, Frank V (2009) Investigations of forming behaviour in laser shock forming. Steel Res Int 80:323–328. https://doi.org/10.2374/SRI08SP148
Gao H, Ye C, Cheng GJ (2009) Deformation behaviors and critical parameters in microscale laser dynamic forming. J Manuf Sci Eng Trans ASME 131(5):051011. https://doi.org/10.1115/1.4000100
Fabbro R, Fournier J, Ballard P, Devaux D, Virmont J (1990) Physical study of laser-produced plasma in confined geometry. J Appl Phys 68(2):775–784. https://doi.org/10.1063/1.346783
Voothaluru R, Richard LC, Cheng GJ (2012) Finite element analysis of the variation in residual stress distribution in laser shock peening of steels. J Manuf Sci Eng Trans ASME 134(6):61010. https://doi.org/10.1115/1.4007780
Zhang W, Yao YL (2002) Micro scale laser shock processing of metallic components. J Manuf Sci Eng Trans ASME 124(2):369–378. https://doi.org/10.1115/1.1445149
Zhang X, Zhang Y, Yin Y, Zhang Y, Li S, Duan S, Huang Z, Chen B, Pei S, Wang H (2017) Simulation of the forming process of conical cup shaped by laser-induced shock waves. Int J Adv Manuf Technol 91(5-8):1619–1630. https://doi.org/10.1007/s00170-016-9633-x
Zhang X, Li H, Duan S, Yu X, Feng J, Wang B, Huang ZL (2015) Modeling of residual stress field induced in Ti-6Al-4V alloy plate by two sided laser shock processing. Surf Coat Technol 280:163–173. https://doi.org/10.1016/j.surfcoat.2015.09.004
Funding
This work is supported by the National Natural Science Foundation of China (Grant No. 51675002), the State Key Laboratory of Materials Processing and Die & Mould Technology, Huazhong University of Science and Technology (Grant No. P2017-007), the Natural Science Foundation of Anhui province (Grant No. 1708085ME110), Anhui Provincial Key Research and Development Program (201904a05020065) and Anhui University Scientific Research Project (KJ2019A0084).
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Zhang, X., Ji, X., Ji, K. et al. Effect of multi-step laser shocking on forming behaviors of metal sheet shaped into a deep conical cup. Int J Adv Manuf Technol 104, 4183–4193 (2019). https://doi.org/10.1007/s00170-019-04113-2
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-019-04113-2