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Analytical model for temperature prediction in friction stir–assisted incremental forming with synchronous bonding of dissimilar sheet metals

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Abstract

In the present work, a novel process of friction stir–assisted incremental forming with synchronous bonding of dissimilar sheet metals DC05 and AA5052-H32 has been conducted. The separate dissimilar sheet layers are bonded together to become a laminate sheet with a part simultaneously fabricated by incremental forming. Since the temperature level is a great concern to affect the formability, an analytical heat generation and transfer model is established for temperature prediction combined with different process parameters. Iterative formulae are implemented and the numerical results are obtained to reflect the evolution of maximum temperature during the whole processing period. It is found that larger step down, rotational speed, and forming angle with lower feeding rate will significantly cause higher process temperature, which proves that the proposed model satisfies the need of a prior of the process window. Micro IMC distribution is experimentally measured at different positions to verify the effect of temperature, which also shows good applicability. The proposed temperature prediction model is also valuable for other incremental sheet forming processes with high-speed tool rotation.

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Abbreviations

A ij :

Circumferential area of loop (mm2)

S ij :

Meridian cross-sectional area of loop (mm2)

μ :

Coefficient of friction

T pj :

Temperature of the tool during a loop (°C)

N :

Number of node

j:

Index of loops

i:

Index of nodes in circumferential direction

k:

Index of elements on a loop

Δz :

Depth of step down (mm)

Κ m :

Thermal conductivity of material (W/(mm K))

Q ij :

Heat generated by friction and deformation (J)

Q rotate :

Heat generated by rotation (J)

T r :

Room temperature (°C)

N k :

Iterative times for a loop

\( {\mathrm{d}}_{i{i}^{\hbox{'}}} \) :

Distance between two loops (mm)

rp :

Tool radius (mm)

tj :

Time for performing a loop (s)

\( \overline{\sigma} \) :

Equivalent stress (MPa)

hf :

Final height of sheet (mm)

t0 :

Initial sheet thickness (mm)

σ s :

Yield stress (MPa)

δ :

Percent of energy transformation

β :

Forming angle (°)

C m :

Specific heat of material (J/(g K))

Κ p :

Thermal conductivity of tool (W/(mm K))

ΔT ij :

Temperature variation for a node in a loop (°C)

Δtj :

Iterative time for a loop (s)

T melt :

Melting temperature (°C)

rij :

Radius of a loop (mm)

\( {\mathrm{q}}_{{{}_{ii}}^{\prime}}^j \) :

Heat flow between two nodes in a loop (J)

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Funding

This study was financially supported by the National Natural Science Foundation of China (NSFC) under grant no. 51675332 and Program of Shanghai Excellent Academic Research Leadership (19XD1401900).

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Author notes

  1. Renhao Wu and Meng Li contributed equally to this work.

Authors and Affiliations

  1. Department of Plasticity Technology, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai, 200030, China

    Renhao Wu, Meng Li, Sheng Cai, Xinmei Liu, Mei Yang, Wenshuai Huang & Jun Chen

  2. National Engineering Research Center of Die & Mold CAD, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai, 200030, China

    Renhao Wu, Meng Li, Sheng Cai, Xinmei Liu, Mei Yang, Wenshuai Huang & Jun Chen

Authors
  1. Renhao Wu
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  2. Meng Li
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  3. Sheng Cai
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  4. Xinmei Liu
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  5. Mei Yang
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  6. Wenshuai Huang
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  7. Jun Chen
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Correspondence to Jun Chen.

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Wu, R., Li, M., Cai, S. et al. Analytical model for temperature prediction in friction stir–assisted incremental forming with synchronous bonding of dissimilar sheet metals. Int J Adv Manuf Technol 107, 2177–2187 (2020). https://doi.org/10.1007/s00170-020-05144-w

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  • DOI: https://doi.org/10.1007/s00170-020-05144-w

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