Influence of process parameters on the cup drawing of aluminium 7075 sheet

AA7075 is one of the most important structural materials extensively used in automobile and aerospace industries. Extensive research on its formability aspects is required to develop useful components of complex shapes out of this material. One of the ways to measure the formability is to find its deep drawability characteristics. In this study, the significance of three important deep drawing process parameters namely blank temperature, die arc radius and punch velocity on the deep drawing characteristics of aluminium 7075 sheet was determined. The combination of finite element method and Taguchi analysis was used to determine the influence of process parameters. Simulations were carried out as per orthogonal array using DEFORM 2D software. Based on the predicted deformation of deep drawn cup and analysis of variance test (Anova), it was observed that blank temperature has greatest influence on the formability of aluminium material followed by punch velocity and die arc radius. Multiple regression analysis techniques were applied in modelling the behaviour of AA 7075 aluminium alloy under multistep deformation conditions.

[1]  Saurav Datta,et al.  Parametric optimization of CNC end milling using entropy measurement technique combined with grey-Taguchi method , 2010 .

[2]  R. Retoux,et al.  TEM study of dislocation patterns in near-surface and core regions of deformed nickel polycrystals with few grains across the cross section , 2010 .

[3]  M. Davidson,et al.  Surface roughness prediction of flow-formed AA6061 alloy by design of experiments , 2008 .

[4]  M. Finn,et al.  Numerical prediction of the limiting draw ratio for aluminum alloy sheet , 2000 .

[5]  Madhan Shridhar Phadke,et al.  Quality Engineering Using Robust Design , 1989 .

[6]  Saurav Datta,et al.  Optimization of CNC end milling process parameters using PCA-based Taguchi method , 2010 .

[7]  E. A. Starke,et al.  Progress in structural materials for aerospace systems , 2003 .

[8]  Ken-ichiro Mori,et al.  Finite element simulation of warm deep drawing of aluminium alloy sheet when accounting for heat conduction , 2002 .

[9]  You-Min Huang,et al.  Influence of the die arc on formability in cylindrical cup-drawing , 1995 .

[10]  Tetsuo Naka,et al.  Deep drawability of type 5083 aluminium–magnesium alloy sheet under various conditions of temperature and forming speed , 1999 .

[11]  D. Wilson.  Aluminium versus steel in the family car — the formability factor , 1988 .

[12]  Fahrettin Ozturk,et al.  Review of warm forming of aluminum-magnesium alloys , 2008 .

[13]  R. Pearce,et al.  Warm forming of aluminium/magnesium alloy sheet☆ , 1978 .

[14]  I. Dejmal,et al.  On the optimal die curvature in deep drawing processes , 2002 .

[15]  D Mathivanan,et al.  Minimization of sink mark defects in injection molding process - Taguchi approach , 2010 .

[16]  Bogdan Alexandreanu,et al.  The effect of grain boundary character distribution on the high temperature deformation behavior of Ni–16Cr–9Fe alloys , 2003 .

[17]  李劲风,et al.  Mechanical properties, corrosion behaviors and microstructures of 7075 aluminium alloy with various aging treatments , 2008 .

[18]  C. Narayanan,et al.  Application of Taguchi approach on investigation of formability for perforated Al 8011 sheets , 2010 .

[19]  W. S. Miller,et al.  Recent development in aluminium alloys for aerospace applications , 2000 .

[20]  M. Joseph Davidson,et al.  Experimental investigation on flow-forming of AA6061 alloy—A Taguchi approach , 2008 .