Abstract
Alloy 2060, a new generation of aluminum–lithium (Al-Li) alloy, is widely used for aviation structural parts due to its high-specific strength and high-specific stiffness. However, poor formability of Al-Li alloy is commonly exhibited at room temperature. In this paper, the formability of Al-Li alloy 2060 was studied under the conditions of elevated temperatures. The Marciniak–Kuczynski (M–K) model was developed to effectively predict the forming limit curves (FLCs) under hot stamping conditions. Firstly, the hot tensile test was conducted to investigate the high-temperature deformation behaviors, and the Fields–Backofen equation was calibrated to represent the flow stress of the alloy. Then, the isothermal hemispherical punch tests were proposed to obtain the FLCs of Al-Li alloy 2060. Finally, the FLC predicted by the M–K model was input into the deep drawing finite element simulation model to verify the accuracy of the prediction results and predict the possible fracture of the hot stamping parts. The cup-shaped deep drawing test and the thin-walled shell part hot stamping test were carried out to verify the accuracy of the FLCs and the formability of the Al-Li alloy 2060. The results show that the true stress increases with the strain rate increasing and decreases with the temperature increasing. The established M–K model can accurately predict the FLCs of alloy 2060. It is also found that the initial thickness imperfection factor f0 is an important parameter that determines the change of FLC. Comparing the experimental and simulation results, it is concluded that the established M–K model would be adaptable in the FE simulation to estimate if the fracture of parts occurs. The simulation model considered the FLC can predict the fracture, thinning, and wrinkle of the parts. The stamping depth increases with the deformation temperature increasing and the blank holder force decreasing.
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Funding
This work is funded by the National Natural Science Foundation of China (Grant No. 51705018). This work is supported by the Fundamental Research Funds for the Central Universities (Grant No. FRF-BD-20-08A, FRF-BD-19-003A).
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Jing Zhou: investigation, validation, methodology, funding acquisition, writing—original draft. Xiaoming Yang: software, investigation, writing—reviewing and editing. Baoyu Wang: supervision, resources. Jiapeng Wang: investigation, writing—reviewing and editing.
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Zhou, J., Yang, X., Wang, B. et al. M–K model based forming limit prediction of aluminum–lithium alloy 2060 and its application in hot stamping. Int J Adv Manuf Technol 127, 5293–5306 (2023). https://doi.org/10.1007/s00170-023-11898-w
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DOI: https://doi.org/10.1007/s00170-023-11898-w