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Forming behavior and microstructural evolution during single point incremental forming process of AA-6061 aluminum alloy sheet

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Abstract

AA-6061 aluminum alloy is extensively used in automobile and aerospace industries due to its high strength-to-weight ratio. However, this material shows limited formability in age-hardened condition at room temperature. Therefore, a new forming method known as single point incremental forming (SPIF) to deform the sheet was adopted. The SPIF experiments and finite element method (FEM) simulation were performed to form the sheet into the desired conical shape. Digital image correlation (DIC) method was used to measure the major and minor strains post deformation experimentally, and results were compared with FEM results. Detailed microstructural study was performed to understand the deformation behavior of AA-6061 aluminum alloy sheets during SPIF. It is observed that plastic anisotropy has strong effect on microstructure and texture development in different directions of AA-6061 alloy sheet during SPIF. It is also observed that volume fraction of goss and S texture components remains stable, whereas volume fraction of cube and brass texture changes significantly.

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Acknowledgements

The authors gratefully acknowledge the financial support provided for this work by the National Centre for Aerospace Innovation and Research, IIT Bombay, Powai, Mumbai, India.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Indian Institute of Technology Bombay, Powai, Mumbai, 400076, India

    Vivek Kumar Barnwal, Asim Tewari & Sushil K. Mishra

  2. National Centre for Aerospace Innovation and Research, Indian Institute of Technology Bombay, Powai, Mumbai, 400076, India

    Vivek Kumar Barnwal & Asim Tewari

  3. Graduate Institute of Ferrous Technology, Pohang University of Science and Technology (POSTECH)- 77 Cheongam-ro, Nam-gu, Pohang, Gyeongbuk, 37673, South Korea

    Vivek Kumar Barnwal

  4. Department of Metallurgical Engineering and Materials Science, Indian Institute of Technology Bombay, Powai, Mumbai, 400076, India

    Shanta Chakrabarty & K. Narasimhan

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  1. Vivek Kumar Barnwal
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  2. Shanta Chakrabarty
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  4. K. Narasimhan
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  5. Sushil K. Mishra
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Correspondence to Vivek Kumar Barnwal.

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Barnwal, V.K., Chakrabarty, S., Tewari, A. et al. Forming behavior and microstructural evolution during single point incremental forming process of AA-6061 aluminum alloy sheet. Int J Adv Manuf Technol 95, 921–935 (2018). https://doi.org/10.1007/s00170-017-1238-5

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  • DOI: https://doi.org/10.1007/s00170-017-1238-5

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