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Hot granules medium pressure forming process of AA7075 conical parts

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Abstract

High strength aluminum alloy plate has a low elongation at room temperature, which leads to the forming of its components need a high temperature. Liquid or gas is used as the pressure-transfer medium in the existing flexible mould forming process, the heat resistance of the medium and pressurizing device makes the application of aluminum alloy plate thermoforming restricted. To solve this problem, the existing medium is replaced by the heat-resisting solid granules and the general pressure equipments are applied. Based on the pressure-transfer performance test of the solid granules medium, the feasibility that the assumption of the extended Drucker-Prager linear model can be used in the finite element analysis is proved. The constitutive equation, the yield function and the theoretical forming limit diagram(FLD) of AA7075 sheet are established. Through the finite element numerical simulation of hot granules medium pressure forming(HGMF) process, not only the influence laws of the process parameters, such as forming temperature, the blank-holder gap and the diameter of the slab, on sheet metal forming performance are discussed, but also the broken area of the forming process is analyzed and predicted, which are coincided with the technological test. The conical part whose half cone angle is 15° and relative height H/d 0 is 0.57, is formed in one process at 250°C. The HGMF process solves the problems of loading and seal in the existing flexible mould forming process and provides a novel technology for thermoforming of light alloy plate, such as magnesium alloy, aluminium alloy and titanium alloy.

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Author information

Authors and Affiliations

  1. College of Vehicles and Energy, Yanshan University, Qinhuangdao, 066004, China

    Guojiang Dong

  2. Key Laboratory of Advanced Forging & Stamping Technology and Science of Ministry of Education, Yanshan University, Qinhuangdao, 066004, China

    Changcai Zhao, Yaxin Peng & Ying Li

Authors
  1. Guojiang Dong
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  2. Changcai Zhao
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  3. Yaxin Peng
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  4. Ying Li
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Corresponding author

Correspondence to Changcai Zhao.

Additional information

Supported by National Natural Science Foundation of China(Grant Nos. 51305386, 51305385), and Hebei Provincial Natural Science Foundation of China(Grant No. E2013203093)

DONG Guojiang, born in 1978, is currently an associate professor at College of Vehicles and Energy, Yanshan University, China. He received his PhD degree from Yanshan Universtiy, China, in 2014. His main research direction is special forming technique of tube and panel.

ZHAO Changcai, born in 1964, is currently a professor and a PhD candidate supervisor at Key Laboratory of Advanced Forging & Stamping Technology and Science of Ministry of Education, Yanshan University, China. His main research direction is special forming technique of tube and panel.

PENG Yaxin, born in 1988, is currently a master candidate at Key Laboratory of Advanced Forging & Stamping Technology and Science of Ministry of Education, Yanshan University, China.

LI Ying, born in 1989, is currently a master candidate at Key Laboratory of Advanced Forging & Stamping Technology and Science of Ministry of Education, Yanshan University, China.

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Dong, G., Zhao, C., Peng, Y. et al. Hot granules medium pressure forming process of AA7075 conical parts. Chin. J. Mech. Eng. 28, 580–591 (2015). https://doi.org/10.3901/CJME.2015.0217.019

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  • DOI: https://doi.org/10.3901/CJME.2015.0217.019

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