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Process optimization and mechanism analysis on electropulse-assisted incremental forming of AZ31B magnesium alloy sheet

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Abstract

Based on a self-design comprehensive experimental platform, the experimental investigation on electropulse-assisted incremental forming (EAIF) was carried out. By means of the response surface methodology, the interactive influence rules and significances of different processing parameters on formability of AZ31B sheet metal were investigated. The experimental results show that, compared to other processing parameters, the electropulse parameters are the most significant factor, and with the increase of electropulse parameters, the forming limit of sheet metal increases obviously. In addition, an interaction effect was found between the electropulse parameters and the feed rate/tool diameter, as well as between the feed rate and the step size. Through the comprehensive optimization and analysis, there was an optimal formability for sheet metal when the electropulse parameters, feed rate, step size, and tool diameter were set in 80 V/400 Hz, 800 mm/min, 0.2 mm, and 8 mm, respectively. The research on strain state shows that the linear loading mode of rectangular pyramid presents the plane strain state, while the circular loading mode in cone model presents a tendency of biaxial stretch, and the ultimate strain has reached 150%. Benefitting from the electro-plastic effect, the high-energy electropulse can promote the dynamic recrystallization and restrain the crack growth in materials, so compared with the conventional incremental forming, the EAIF under optimal processing condition can greatly improve the forming limit of AZ31B sheet metal.

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The datasets used or analyzed during the current study are available from the corresponding author on reasonable request.

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Funding

The authors would like to acknowledge the financial support from Natural Science Foundations of Shandong Province under Grant no. ZR2019BEE060, ZR2019MEE008 and ZR2020ME001.

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Authors and Affiliations

  1. School of Mechanical-Electronic and Vehicle Engineering, Weifang University, Weifang, 261061, China

    Wenke Bao, Junbo Liu, Wenqing Wei & Haijian Ma

  2. Associated Engineering Research Center of Mechanics and Mechatronic Equipment, Shandong University, Weihai, 264209, China

    Jun Gao & Xingrong Chu

Authors
  1. Wenke Bao
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  2. Jun Gao
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  4. Junbo Liu
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Contributions

Wenke Bao: Main processing experiment, the conception and design of the study, original manuscript preparation. Jun Gao: Reviewing and supervising the final version. Xingrong Chu: Editing and revising of the manuscript. Junbo Liu: Measurement experiments and analysis. Wenqing Wei: Software analysis and data processing. Haijian Ma: Microscopic experiments and analysis.

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Correspondence to Wenke Bao.

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Bao, W., Gao, J., Chu, X. et al. Process optimization and mechanism analysis on electropulse-assisted incremental forming of AZ31B magnesium alloy sheet. Int J Adv Manuf Technol 119, 329–342 (2022). https://doi.org/10.1007/s00170-021-08214-9

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