Modelling of springback in creep forming thick aluminum sheets

Abstract Integrated numerical techniques have been developed to predict springback in creep forming thick aluminum sheet components using physically-based unified creep constitutive equations, which model the primary hardening, ageing, creep constrained damage and their effects on creep deformation of an aluminum alloy. Springback effects have been studied for two aluminum shapes. One is a single curvature cylindrical component and the other is a doubly curved spherical component. Stress relaxation and creep deformation of the aluminum sheet under different forming conditions are studied. The effects of forming processes and the thickness of the material sheet on springback of formed parts are investigated. The amount of springback on forming doubly curved and single curvature sheet components is predicted and compared for different forming conditions.

[1]  Han-Chin Wu,et al.  Anisotropic plasticity for sheet metals using the concept of combined isotropic-kinematic hardening , 2002 .

[2]  John Peddieson,et al.  A simple unified age forming model , 2000 .

[3]  Tongxi Yu,et al.  An energy approach for predicting springback of metal sheets after double-curvature forming. Part II : Unequal double-curvature forming , 2001 .

[4]  Liangchi Zhang,et al.  An analytical solution to springback of sheet metals stamped by a rigid punch and an elastic die , 1997 .

[5]  Nader Asnafi.  On Springback of Double-Curved Autobody Panels , 1998 .

[6]  J. K. Lee,et al.  Modeling the Bauschinger effect for sheet metals, part I: theory , 2002 .

[7]  Mitchell C. Holman,et al.  Autoclave age forming large aluminum aircraft panels , 1989 .

[8]  Jian Cao,et al.  Prediction of forming limit curves using an anisotropic yield function with prestrain induced backstress , 2002 .

[9]  Fabrice Morestin,et al.  Elasto plastic formulation using a kinematic hardening model for springback analysis in sheet metal forming , 1996 .

[10]  R. H. Wagoner,et al.  Measurement of springback , 2002 .

[11]  Erhard Krempl,et al.  Relaxation behavior and modeling , 2001 .

[12]  Lembit M. Kutt,et al.  Non‐linear finite element analysis of springback , 1999 .

[13]  Yukio Takahashi,et al.  A viscoplastic constitutive model incorporating dynamic strain aging effect during cyclic deformation conditions , 2000 .

[14]  Payam Matin,et al.  Influence of transverse normal stress on sheet metal formability , 2003 .

[15]  John Peddieson,et al.  Mathematical modeling of an age-forming process , 1990 .

[16]  G. Pasquinelli.  Simulation of metal-forming processes by the finite element method , 1995 .

[17]  A. Makinouchi,et al.  Sheet metal forming simulation in industry , 1996 .

[18]  Thomas B. Stoughton,et al.  A non-associated flow rule for sheet metal forming , 2002 .

[19]  A. Ghosh,et al.  Inelastic effects on springback in metals , 2002 .

[20]  Tongxi Yu,et al.  An energy approach for predicting springback of metal sheets after double-curvature forming, Part I: axisymmetric stamping , 2001 .

[21]  P.D. Pitcher,et al.  Creep Age Forming of 2024A, 8090 and 7449 Alloys , 2000 .

[22]  J. K. Lee,et al.  Modeling the Bauschinger effect for sheet metals, part II: applications , 2002 .

[23]  Mary C. Boyce,et al.  Tooling and binder design for sheet metal forming processes compensating springback error , 1996 .

[24]  K. Kaneko,et al.  A viscoplastic constitutive model with effect of aging , 2000 .

[25]  Claes Magnusson,et al.  Finite-element simulation of V-die bending: a comparison with experimental results , 1997 .

[26]  Georges Cailletaud,et al.  Study of plastic/viscoplastic models with various inelastic mechanisms , 1995 .

[27]  Frédéric Barlat,et al.  A general elasto-plastic finite element formulation based on incremental deformation theory for planar anisotropy and its application to sheet metal forming , 1999 .

[28]  John Peddieson,et al.  A Simulation Procedure for Panel Age Forming , 1998 .

[29]  Dong-Yol Yang,et al.  An assessment of numerical parameters influencing springback in explicit finite element analysis of sheet metal forming process , 1998 .

[30]  B. Bès,et al.  Improving the Forming Characteristics of Aluminium Sheets for Aerospace Applications , 2000 .

[31]  Investigation of a high accuracy uni-axial creep testpiece with slit extensometer ridges , 1995 .

[32]  E. Nakamachi,et al.  Formability assessment of FCC aluminum alloy sheet by using elastic/crystalline viscoplastic finite element analysis , 2002 .

[33]  Mai Huang,et al.  Springback of Doubly Curved Developable Sheet Metal Surface - An Overview , 1994 .

[34]  Luc Papeleux,et al.  Finite element simulation of springback in sheet metal forming , 2002 .

[35]  Mary C. Boyce,et al.  Tooling design in sheet metal forming using springback calculations , 1992 .