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Improving the Room Temperature Formability of Magnesium AZ31B Alloy Sheets during the Incremental Sheet Forming Process
https://orcid.org/https://orcid.org/0000-0003-3622-2329
Incremental sheet forming (ISF) uses a simple CNC milling machine to produce 3D geometries at very low cost and time using the CAD geometry of the parts. Due to the localised plastic deformation of the process, it can be used to make it easier to shape materials that are hard to shape, such as magnesium and titanium. Magnesium AZ31B alloy sheets of 1.5 mm thickness were formed at room temperature using the conventional Erichsen cupping and ISF process to quantify the maximum room temperature formability of the alloy. Using the conventional Erichsen cupping test, a maximum forming depth of 2.88 mm was obtained. ISF was performed using the helical toolpath strategy up to fracture for three different feed rates (F) (50, 1000, and 2500 mm/min), spindle speeds (S) (50, 500, and 3000 rpm), and pitch sizes (P) (0.1, 0.5, and 2.5 mm). A maximum forming depth of 8.86 mm was obtained for the process parameter condition—F50S3000P0.5 during the ISF process. It was observed that the formability of the alloy was reduced with increasing feed rate and pitch size, whereas it was enhanced while increasing the spindle speed. The starting material possessed a strong basal texture, which does not favour the activation of (10–12) tension twins during the uniaxial stretching of the conventional process. In contrary, the enormous frictional heat generated at high spindle speed (3000 RPM) and the plane strain and biaxial stretching nature of the ISF process resulted in the activation of newer twins during the ISF process, thereby improving the formability of the alloy sheets up to 8.86 mm. This shows that the ISF process is capable of forming hard-to-shape materials, like magnesium, at room temperature without compromising their excellent ambient temperature mechanical properties. It is also imperative that the ISF process can be used as a substitute to the conventional forming process and form Mg AZ31 sheets at room temperature at very low cost and lead time, thereby widening its usage in the automotive sectors. The higher formability of AZ31B sheets at room temperature imparted by the ISF process will be useful to down-gauge the input sheet metal thickness, thereby improving the fuel efficiency and reducing carbon emission in the automotive sector.
Improving the Room Temperature Formability of Magnesium AZ31B Alloy Sheets during the Incremental Sheet Forming Process
https://orcid.org/https://orcid.org/0000-0003-3622-2329
Incremental sheet forming (ISF) uses a simple CNC milling machine to produce 3D geometries at very low cost and time using the CAD geometry of the parts. Due to the localised plastic deformation of the process, it can be used to make it easier to shape materials that are hard to shape, such as magnesium and titanium. Magnesium AZ31B alloy sheets of 1.5 mm thickness were formed at room temperature using the conventional Erichsen cupping and ISF process to quantify the maximum room temperature formability of the alloy. Using the conventional Erichsen cupping test, a maximum forming depth of 2.88 mm was obtained. ISF was performed using the helical toolpath strategy up to fracture for three different feed rates (F) (50, 1000, and 2500 mm/min), spindle speeds (S) (50, 500, and 3000 rpm), and pitch sizes (P) (0.1, 0.5, and 2.5 mm). A maximum forming depth of 8.86 mm was obtained for the process parameter condition—F50S3000P0.5 during the ISF process. It was observed that the formability of the alloy was reduced with increasing feed rate and pitch size, whereas it was enhanced while increasing the spindle speed. The starting material possessed a strong basal texture, which does not favour the activation of (10–12) tension twins during the uniaxial stretching of the conventional process. In contrary, the enormous frictional heat generated at high spindle speed (3000 RPM) and the plane strain and biaxial stretching nature of the ISF process resulted in the activation of newer twins during the ISF process, thereby improving the formability of the alloy sheets up to 8.86 mm. This shows that the ISF process is capable of forming hard-to-shape materials, like magnesium, at room temperature without compromising their excellent ambient temperature mechanical properties. It is also imperative that the ISF process can be used as a substitute to the conventional forming process and form Mg AZ31 sheets at room temperature at very low cost and lead time, thereby widening its usage in the automotive sectors. The higher formability of AZ31B sheets at room temperature imparted by the ISF process will be useful to down-gauge the input sheet metal thickness, thereby improving the fuel efficiency and reducing carbon emission in the automotive sector.
Improving the Room Temperature Formability of Magnesium AZ31B Alloy Sheets during the Incremental Sheet Forming Process
https://orcid.org/https://orcid.org/0000-0003-3622-2329
Incremental sheet forming (ISF) uses a simple CNC milling machine to produce 3D geometries at very low cost and time using the CAD geometry of the parts. Due to the localised plastic deformation of the process, it can be used to make it easier to shape materials that are hard to shape, such as magnesium and titanium. Magnesium AZ31B alloy sheets of 1.5 mm thickness were formed at room temperature using the conventional Erichsen cupping and ISF process to quantify the maximum room temperature formability of the alloy. Using the conventional Erichsen cupping test, a maximum forming depth of 2.88 mm was obtained. ISF was performed using the helical toolpath strategy up to fracture for three different feed rates (F) (50, 1000, and 2500 mm/min), spindle speeds (S) (50, 500, and 3000 rpm), and pitch sizes (P) (0.1, 0.5, and 2.5 mm). A maximum forming depth of 8.86 mm was obtained for the process parameter condition—F50S3000P0.5 during the ISF process. It was observed that the formability of the alloy was reduced with increasing feed rate and pitch size, whereas it was enhanced while increasing the spindle speed. The starting material possessed a strong basal texture, which does not favour the activation of (10–12) tension twins during the uniaxial stretching of the conventional process. In contrary, the enormous frictional heat generated at high spindle speed (3000 RPM) and the plane strain and biaxial stretching nature of the ISF process resulted in the activation of newer twins during the ISF process, thereby improving the formability of the alloy sheets up to 8.86 mm. This shows that the ISF process is capable of forming hard-to-shape materials, like magnesium, at room temperature without compromising their excellent ambient temperature mechanical properties. It is also imperative that the ISF process can be used as a substitute to the conventional forming process and form Mg AZ31 sheets at room temperature at very low cost and lead time, thereby widening its usage in the automotive sectors. The higher formability of AZ31B sheets at room temperature imparted by the ISF process will be useful to down-gauge the input sheet metal thickness, thereby improving the fuel efficiency and reducing carbon emission in the automotive sector.
Improving the Room Temperature Formability of Magnesium AZ31B Alloy Sheets during the Incremental Sheet Forming Process
Int J Interact Des Manuf
Karthikeyan, G. (author) / Nagarajan, D. (author)
2024-08-01
16 pages
Article (Journal)
Electronic Resource
English
Incremental sheet forming , Erichsen Cupping test , Magnesium AZ31B alloy , Helical toolpath , Frictional heating , Dynamic recrystallization Engineering , Engineering, general , Engineering Design , Mechanical Engineering , Computer-Aided Engineering (CAD, CAE) and Design , Electronics and Microelectronics, Instrumentation , Industrial Design
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