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Influence of process parameters and defect analysis in hot deep drawing process of aluminum alloy AA6082

AA6082铝合金热冲压过程中工艺参数的影响和失效研究

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Abstract

In this study, a novel punch toolset was developed to investigate the hot stamping of AA6082-T4 sheet. The effect of the process parameters, including forming temperature, punching velocity, friction coefficient, and blank holder force (BHF) on formability was quantified using Taguchi design, analysis of variance (ANOVA) and mathematical statistics. The finite element (FE) model has been established in software Pamstamp for simulation and analysis of their effects on the minimum thickness and thickness variation of the hot-stamped component. The major factors influencing the minimum thickness of the hot-stamped part has been found to be BHF and friction coefficient with influence significance of 35.3% and 34.88%, respectively. Additionally, punch velocity and BHF affect the thickness deviation significantly with influence significance of 40.43% and 35.42%, respectively. Furthermore, a serious thinning occurs on the punch corner region of the hot-stamped cup when the BHF is larger than 2.4 kN. The thickness deviation of the hot-formed cup has been found to be firstly decreased and then increased with the increase of punch velocity. Low friction coefficient between punch and blank led to crack at bottom centre of the cup. Moreover, different type, phenomenon and mechanism of defects occurring during hot stamping process, such as crack and wrinkling, were discussed. The crack mode was dimple-dominated ductile fracture, which was induced by micro-void nucleation, growth and coalescence.

摘要

通过新设计的铝合金热冲压装置进行AA6082-T4铝合金热冲压研究. 研究的工艺参数包括成形温度、 冲压速度、 摩擦系数和压边力. 通过Taguchi实验设计、 方差分析和数理统计相结合的方法量化了工艺参数对成形性的影响程度. 采用有限元软件Pamstamp建立了仿真模型, 用来分析工艺参数对最小厚度和厚度均匀性的影响. 通过分析可知, 压边力和摩擦系数对零件厚度最小值的影响最显著, 影响程度分别为35.3%和34.88%. 冲压速度和压边力对厚度均匀性的影响最显著, 影响程度分别为40.43%和35.42%. 当压边力超过2.4 kN时, 在热冲压零件凸模圆角处会产生严重的减薄. 随着冲压速度的增加, 热冲压零件的厚度均匀性先下降后上升. 板料与凸模之间过低的摩擦系数会导致杯形件底部中心发生破裂. 同时研究了铝合金热冲压零件的缺陷, 比如破裂和起皱的种类、 现象和机理. 断裂形式主要为以韧窝为主的韧性断裂, 主要由微孔洞形核, 长大和聚合导致.

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Authors and Affiliations

  1. Research Institute of Technology of Shougang Group Co., Ltd., Beijing, 100043, China

    Wen-yu Ma  (马闻宇), Jian-wei Yang  (杨建炜) & Jun Zhang  (章军)

  2. Shougang-Imperial Lab for Lightweight Steel Based Systems for Impact Resistant Automotive Applications, London, SW7 2AZ, UK

    Wen-yu Ma  (马闻宇), Qi Rong  (荣琦), Jian-wei Yang  (杨建炜) & Jun Zhang  (章军)

  3. School of Mechanical Engineering, University of Science and Technology Beijing, Beijing, 100083, China

    Bao-yu Wang  (王宝雨)

  4. Imperial College London, London, SW7 2AZ, UK

    Qi Rong  (荣琦)

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  1. Wen-yu Ma  (马闻宇)
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Correspondence to Wen-yu Ma  (马闻宇).

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Ma, Wy., Wang, By., Rong, Q. et al. Influence of process parameters and defect analysis in hot deep drawing process of aluminum alloy AA6082. J. Cent. South Univ. 29, 883–897 (2022). https://doi.org/10.1007/s11771-022-4984-y

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