Computational Technology Resources - CCC

A. Piccininni, I. Marchese, G. Palumbo, A. Lo Franco, G. Russello, "An emerging manufacturing route for the fabrication of Al-based complex railway interiors at room temperature", in J. Pombo, (Editor), "Proceedings of the Fifth International Conference on Railway Technology: Research, Development and Maintenance", Civil-Comp Press, Edinburgh, UK, Online volume: CCC 1, Paper 32.1, 2022, doi:10.4203/ccc.1.32.1

Keywords: aluminium, lightweighting, formability, locally annealed blanks, FEM, sheet metal forming.

Abstract

In the present work, an emerging manufacturing route to enhance the poor formability of Aluminium (Al) alloys at room temperature is investigated and applied to two different industrial sheet metal components, both made of AA5754 initially purchased in wrought conditions (H32). The approach was based on splitting the manufacturing processes into two separate moments: at first, the blank was subjected to local short-term heat treatments (to bring the material in the more formable annealed H111 condition) and, once cooled down, formed at room temperature. After the preliminary characterization of the alloy in both the conditions (H32 and H111), based on tensile tests and forming limit curves, the two abovementioned steps were numerically designed by means of the Finite Element (FE) commercial code Abaqus/CAE. In particular, the local heating step was simulated in order to define the best combination of time and temperature to bring locally the material in the annealed H111 state. The resulting distribution of properties was then imported in a second numerical model where the parameters of the forming operations were numerically set to avoid the blank rupture and obtain the two components, i.e. the window panel via sheet stamping and the bicycle rack via sheet bending. The numerical results, in terms of heating strategies and forming setup, were eventually validated by means of experimental trials and both the components were correctly manufactured.

download the full-text of this paper (PDF, 8 pages, 699 Kb)

go to the previous paper
go to the next paper
return to the table of contents
return to the volume description

	Computational & Technology Resources an online resource for computational, engineering & technology publications
	not logged in - login
Front Page Browse CCC CCP CSETS CTR IJRT Other Authors Search Purchase Guide FAQ Contact us	Civil-Comp Conferences ISSN 2753-3239 CCC: 1 PROCEEDINGS OF THE FIFTH INTERNATIONAL CONFERENCE ON RAILWAY TECHNOLOGY: RESEARCH, DEVELOPMENT AND MAINTENANCE Edited by: J. Pombo Paper 32.1 An emerging manufacturing route for the fabrication of Al-based complex railway interiors at room temperature A. Piccininni¹, I. Marchese², G. Palumbo¹, A. Lo Franco² and G. Russello² ¹Politecnico di Bari, Department of Mechanics, Mathematics and Management, Bari, Italy ²O.Me.R. s.p.a., Carini, Italy doi:10.4203/ccc.1.32.1 Full Bibliographic Reference for this paper A. Piccininni, I. Marchese, G. Palumbo, A. Lo Franco, G. Russello, "An emerging manufacturing route for the fabrication of Al-based complex railway interiors at room temperature", in J. Pombo, (Editor), "Proceedings of the Fifth International Conference on Railway Technology: Research, Development and Maintenance", Civil-Comp Press, Edinburgh, UK, Online volume: CCC 1, Paper 32.1, 2022, doi:10.4203/ccc.1.32.1 Keywords: aluminium, lightweighting, formability, locally annealed blanks, FEM, sheet metal forming. Abstract In the present work, an emerging manufacturing route to enhance the poor formability of Aluminium (Al) alloys at room temperature is investigated and applied to two different industrial sheet metal components, both made of AA5754 initially purchased in wrought conditions (H32). The approach was based on splitting the manufacturing processes into two separate moments: at first, the blank was subjected to local short-term heat treatments (to bring the material in the more formable annealed H111 condition) and, once cooled down, formed at room temperature. After the preliminary characterization of the alloy in both the conditions (H32 and H111), based on tensile tests and forming limit curves, the two abovementioned steps were numerically designed by means of the Finite Element (FE) commercial code Abaqus/CAE. In particular, the local heating step was simulated in order to define the best combination of time and temperature to bring locally the material in the annealed H111 state. The resulting distribution of properties was then imported in a second numerical model where the parameters of the forming operations were numerically set to avoid the blank rupture and obtain the two components, i.e. the window panel via sheet stamping and the bicycle rack via sheet bending. The numerical results, in terms of heating strategies and forming setup, were eventually validated by means of experimental trials and both the components were correctly manufactured. download the full-text of this paper (PDF, 8 pages, 699 Kb) go to the previous paper go to the next paper return to the table of contents return to the volume description
Back to top	©Civil-Comp Limited 2023 - terms & conditions