Engineering and Technology Journal

Effect of tool profile on micro hardness, forming limit, and final thickness in incremental hole flanging process of DC01 steel and AA1050 sheet metals

Document Type : Research Paper

Authors

Mechanical and Manufacturing Engineering Department, Technical College of Engineering, Sulaimani Polytechnic University, Sulaimani, Kurdistan Region, Iraq.

Abstract

The present study delves into the incremental hole flanging process applied to AA1050 and DC01 sheet metals with 0.7 and 1 mm thicknesses. Employing a distinctive lathe-based fixture, the process utilizes a proposed tool profile and fixture incorporating mutually spinning and rolling motions. The investigation covers three forming angles (72°, 90°, and 45°) and three different rotational forming speeds (170, 350, and 525 RPM). The primary objective is to assess the impact of tool forming angle, forming speeds on microhardness, thickness ratio, and forming limit diagram. The study employs a microhardness test, measurements of flange height, and final thickness. Results revealed hardness and thickness variations depending on material type sheet thickness, showing a critical forming speed at which a critical change in variation trend occurs irrespective of forming angle. Forming speed and tool profile were selected carefully to produce a maximum forming limit and a large amount of plastic deformation with no failure of metals. Hardness distribution experienced smooth variation, and the maximum increase in post hardness didn’t exceed 73% without evidence of crack formation at the end of the process. As well as the thickness distribution shows a uniform variation along the flange profile with a maximum thickness reduction of 40% and 51% for 1 mm DC01 and AA1050 sheets, respectively. Finally, based on the proposed tool geometry and holding arrangement adopted in the present work, results indicated a good enhancement in forming limit is satisfied with no obvious large thinning occurring due to change in deformation modes can be used successfully in incremental hole flanging process.

Graphical Abstract

Highlights

  • Maximum hardness was 73% and 15% for DC01 0.7, 1mm at72° and 90°, respectively.
  • Highest hardness was 6%, 8% for AA1050 at forming angle of 90° for 0.7 and 1 mm.
  • Maximum thickness reduction of 40%, 51%for1mmDC01 and AA1050 thicknesses.
  • Variation flange-thickness can be controlled by careful selection of process parameters in hole flanging.

Keywords

Main Subjects

References
  1. Borrego, D. Morales-Palma, J. A. López-Fernández, A. J. Martínez-Donaire, G. Centeno, C. Vallellano, Hole-flanging of AA7075-O sheets: conventional process versus SPIF, Procedia Manuf., 50 (2020) 236-240. https://doi.org/10.1016/j.promfg.2020.08.044
  2. Saidi, B. Experimental and numerical study of the hot incremental forming process of titanium sheets, PhD. Thesis, University of Technology of Troyes; National School of Engineers of Tunis, Tunisia, 2018. https://theses.hal.science/tel-03211429
  3. Gatea, H. Ou, G. McCartney, Review on the influence of process parameters in incremental sheet forming, Int. J. Adv. Manuf. Technol., 87 (2016) 479-499. https://doi.org/10.1007/s00170-016-8426-6
  4. Fang, B. Lu, J. Chen, D. Xu, H. Ou, Analytical and experimental investigations on deformation mechanism and fracture behavior in single point incremental forming, J. Mater. Process. Technol., 214 (2014) 1503-1515. https://doi.org/10.1016/j.jmatprotec.2014.02.019
  5. Kumar, M. Ahmed, S. K. Panthi, Effect of punch profile on deformation behaviour of AA5052 sheet in stretch flanging process, Arch. Civ. Mech. Eng., 20 (2020) 1-17. https://doi.org/10.1007/s43452-020-00016-2
  6. Durante, A. Formisano, A. Langella, F. M. Minutolo, The influence of tool rotation on an incremental forming process, J. Mater. Process. Technol., 209 (2009) 4621-4626. https://doi.org/10.1016/j.jmatprotec.2008.11.028
  7. I. Besong, J. Buhl, M. Bambach, Increasing formability in hole-flanging through the use of punch rotation based on temperature and strain rate dependent forming limit curves, Int. J. Mater. Form., 15 (2022) 37. https://doi.org/10.1007/s12289-022-01684-6
  8. Laugwitz, H. Voswinckel, G. Hirt, M. Bambach, Development of tooling concepts to increase geometrical accuracy in high speed incremental hole flanging, Int. J. Mater. Form., 11 (2018) 471-477. https://doi.org/10.1007/s12289-017-1356-5
  9. Silva, P. Teixeira, A. Reis, P. Martins, On the formability of hole-flanging by incremental sheet forming, J. Mater. Des. Appl., 227 (2013) 91–99. https://doi.org/10.1177/1464420712474210
  10. K. Gandla, S. Pandre, K. Suresh, N. Kotkunde, A critical analysis of formability and quality parameters for forming a dome shape using multi-stage strategies in incremental forming process, J. Mater. Res. Technol., 19 (2022) 1037-1048. https://doi.org/10.1016/j.jmrt.2022.05.064
  11. Montanari, V. Cristino, M. B. Silva, P. A. Martins, A new approach for deformation history of material elements in hole-flanging produced by single point incremental forming, Int. J. Adv. Manuf. Tech., 69 (2013) 1175-1183. https://doi.org/10.1007/s00170-013-5117-4
  12. Cristino, L. Montanari, M. Silva, A. Atkins, P. Martins, Fracture in hole-flanging produced by single point incremental forming, Int. J. Mech. Scien., 83 (2014) 146-154. https://doi.org/10.1016/j.ijmecsci.2014.04.001
  13. Laugwitz, H. Voswinckel, G. Hirt, M. Bambach, Development of tooling concepts to increase geometrical accuracy in high speed incremental hole flanging, Int. J. Mater. Form., 11 (2018) 471-477. https://doi.org/10.1007/s12289-017-1356-5
  14. T. Mezher, S. M. Khazaal, N. S. Namer, R. A. Shakir, A comparative analysis study of hole flanging by incremental sheet forming process of AA1060 and DC01 sheet metals, J. Eng. Sci. Technol., 16 (2021) 4383-4403. https://jmerd.net/Paper/Vol.44,No.1(2021)/337-345.pdf
  15. T. Mezher, O. S. Barrak, S. A. Nama, R. A. Shakir, Predication of Forming Limit Diagram and Spring-back during SPIF process of AA1050 and DC04 Sheet Metals, J. Mech. Eng. Res. Dev., 44 (2021) 337-345.
  16. Vasile, S.-G. Racz, O. Bologa, Experimental and numerical investigations of the steel sheets formability with hydroforming, MATEC Web of Conferences, 94, 2017, 02016. https://doi.org/10.1051/matecconf/20179402016
  17. Centeno, M. Silva, V. Cristino, C. Vallellano, P. Martins, Hole-flanging by incremental sheet forming, Int. J. Mach. Tools Manuf., 59 (2012) 46-54. https://doi.org/10.1016/j.ijmachtools.2012.03.007
  18. T. Mezher, R. A. Shakir, Modelling and evaluation of the post-hardness and forming limit diagram in the single point incremental hole flanging (SPIHF) process using ANN, FEM and experimental, Results Eng., 20 (2023) 101613. https://doi.org/10.1016/j.rineng.2023.101613
  19. B. Puche, Analysis of single stage SPIF process applied to the hole flanging operation, PhD Thesis, Universidad de Sevilla, 2018.
  20. Baptiste, D. L. Clark, P. Matin, Designing a Strain Measurement System based on Circle Grid Analysis for Sheet Metal Forming Applications, ASEE Annual Conference & Exposition, , Columbus, Ohio, 2017. https://doi.org/10.18260/1-2--28125
  21. ASTM E92-17: Standard Test Methods for Vickers Hardness and Knoop Hardness of Metallic, ASTM Int., 82 (2018) 1-27. https://doi.org/10.1520/E0092-17.2
  22. Peshekhodov, M. Dykiert, M. Vucetic, B.-A. Behrens, Evaluation of common tests for fracture characterisation of advanced high-strength sheet steels with the help of the FEA, in IOP Conference Series: Materials Science and Engineering, 159, 2016, 012014. https://doi.org/10.1088/1757-899X/159/1/012014
  23. Mohammadtaheri, A new metallographic technique for revealing grain boundaries in aluminum alloys, Metallogr. Microstruct. Anal., 1 (2012) 224-226. https://doi.org/10.4172/jma.1000110
  24. ASTM E2218-15, Standard test method for determining forming limit curves, ASTM Book of Standards, (2015) 1-15. https://doi.org/10.1520/E2218-15
  25. Yu, L., Liu, J., Ge, R., Wei, X., Peng, Z., Chen, M., & Liu, J.. Fracture characteristics and mechanisms of DP780 dual-phase steel under different strain states. Forging Technology, 47, (2022) 48-55. https://doi.org/10.13330/j.issn.1000-3940.2022.08.037
Engineering and Technology Journal

Articles in Press, Corrected Proof
Available Online from 14 April 2024
Files
Share
Export Citation
Statistics