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Investigations into Enhanced Formability of AA5083 Aluminum Alloy Sheet in Single-Point Incremental Forming

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Abstract

In this article, formability of aluminum alloy AA5083-sheet in single point incremental forming (SPIF) is investigated through forming limit curves (FLCs) and maximum formable wall angle considering different forming parameters and conditions. Theoretical FLCs were predicted for SPIF and conventional forming utilizing deformation instability and Marciniak-Kuczynski methods, respectively, and validated by experiments. SPIF was found to give better formability compared to the conventional one in terms of the limit strain values from varying plane strain to equi-biaxial stretching modes of deformations. Groove depth at the onset of fracture in incremental sheet forming test was observed to be more for higher forming speed, i.e., at higher tool rotational speed and feed and for lower incremental depth. The maximum formable wall angle was improved for lower step depth but not significantly increased for higher forming speed. The forming limit strains and maximum forming wall angle were found to increase for incremental forming at elevated temperature. Microstructure studies revealed grain refinement in the deformed sheet in SPIF forming, and microhardness values in the deformed sheets were observed to increase for incrementally formed parts compared to that of the as-received sheet.

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Abbreviations

\(\sigma_{\phi }^{X}\) :

Meridional stress in zone X (MPa)

\(\sigma_{\theta }^{X}\) :

Circumferential stress in zone X (MPa)

\(\sigma_{t}^{X}\) :

Thickness stress in zone X (MPa)

\(\varepsilon_{\phi }^{X}\) :

Meridional strain in zone X

\(\varepsilon_{\theta }^{X}\) :

Circumferential strain in zone X

\(\varepsilon_{t}^{X}\) :

Thickness strain in zone X

\(F_{\phi }^{X}\) :

Meridional force in zone X (N)

\(F_{\theta }^{X}\) :

Circumferential force in zone X (N)

\(F_{t}^{X}\) :

Thickness force in zone X (N)

\(\alpha\) :

Meridional angle (radian)

\(\beta\) :

Forming/wall angle (radian)

\(\theta_{0}\) :

Circumferential contact angle (radian)

\(r_{\text{t}}\) :

Tool radius (mm)

\(r\) :

Distance to tool center (mm)

\(t_{0}\) :

Initial sheet thickness (mm)

\(t\) :

Instantaneous sheet thickness (mm)

\(A_{\text{t}}\) :

Transition area between CZ & NZ (mm2)

\(\bar{\sigma }\) :

Equivalent stress (MPa)

\(\bar{\varepsilon }\) :

Equivalent strain

\(N\) :

Tool rotational speed (rpm)

\(f_{t}\) :

Feed rate of tool (mm/min)

\(\Delta z\) :

Incremental step depth (mm)

\(k\) :

Strength coefficient

\(n\) :

Strain hardening exponent

\(\varepsilon_{0}\) :

Prestrain

\(a\) :

Material parameter in Hosford 79’s yield criterion

\(R\) :

Anisotropy coefficient

\(r_{0}\) :

Anisotropy coefficient at 0º to RD

\(r_{45}\) :

Anisotropy coefficient at 45º to RD

\(r_{90}\) :

Anisotropy coefficient at 90º to RD

\(\theta_{0}^{\prime }\) :

Initial groove angle

\(f_{0}\) :

Initial imperfection factor

\(f\) :

Imperfection factor

\(t_{0}^{Y}\) :

Initial sheet thickness in zone Y (mm)

\(\sigma_{nn}^{X}\) :

Stress component in n direction for groove coordinate of zone X

\(\sigma_{nt}^{X}\) :

Stress component in t direction for groove coordinate of zone X

\(\sigma_{nn}^{Y}\) :

Stress component in t direction for groove coordinate of zone Y

\(\sigma_{nt}^{Y}\) :

Stress component in t direction for groove coordinate of zone Y

\(\sigma_{1}^{Y}\) :

Stress in rolling direction in zone Y (MPa)

\(\sigma_{2}^{Y}\) :

Stress in transverse direction in zone Y (MPa)

\(F_{nn}^{X}\) :

Normal force per unit width in zone X (N/mm)

\(F_{nt}^{X}\) :

Shear force per unit width in zone X (N/mm)

\(F_{nn}^{Y}\) :

Normal force per unit width in zone Y (N/mm)

\(F_{nt}^{Y}\) :

Shear force per unit width in zone Y (N/mm)

\(\varepsilon_{1}\) :

Major strain

\(\varepsilon_{2}\) :

Minor strain

\(\sigma_{1}^{Y}\) :

Stress in rolling direction in zone Y (MPa)

\(d\varepsilon_{nn}^{X}\) :

Strain increment in n direction for groove coordinate of zone X

\(d\varepsilon_{nn}^{Y}\) :

Strain increment in n direction for groove coordinate of zone Y

\(d\varepsilon_{tt}^{X}\) :

Strain increment in t direction for groove coordinate of zone Y

\(d\varepsilon_{tt}^{Y}\) :

Strain increment in t direction for groove coordinate of zone Y

\(d\varepsilon_{nt}^{X}\) :

Shear strain increment for groove coordinate of zone X

\(d\varepsilon_{nt}^{Y}\) :

Shear strain increment for groove coordinate of zone Y

\(d\bar{\varepsilon }^{Y}\) :

Equivalent strain increment in zone Y

\(\varepsilon_{3}^{X}\) :

Thickness strain in zone Y

\(\varepsilon_{3}^{Y}\) :

Thickness strain in zone Y

\(z_{\text{d}}\) :

Deformation depth (mm)

\(z_{\text{f}}\) :

Fracture depth (mm)

\(t_{\text{f}}\) :

Final deformed sheet thickness (mm)

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Acknowledgments

The authors are thankful and gratefully acknowledge the financial support of DST-SERB, India from the Project ECR/2016/001134.

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  1. Mechanical Engineering Department, National Institute of Technology Patna, Bihar, 800 005, India

    Gautam Kumar & Kuntal Maji

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Kumar, G., Maji, K. Investigations into Enhanced Formability of AA5083 Aluminum Alloy Sheet in Single-Point Incremental Forming. J. of Materi Eng and Perform 30, 1289–1305 (2021). https://doi.org/10.1007/s11665-021-05455-3

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