Skip to content
Licensed Unlicensed Requires Authentication Published by De Gruyter November 21, 2017

Comparison of deep drawability of AA5754-H22 and AA6061-T6 aluminum alloys for automotive applications

Vergleich der Tiefziehbarkeit der Aluminiumlegierungen AA5754-H22 und AA6061-T6 für den Fahrzeugbau
Mehmet Ipekoglu, Onur Erbas and Hamad Ul Hassan
From the journal Materials Testing

Abstract

Being one of the most commonly applied sheet metal forming processes in automotive industry, deep drawing technologies are challenged by the concerns of global warming for higher fuel economy requirements in the recent years. To reduce the weight of the vehicles in order to obtain fuel economy, lighter and safer materials are used in automotive industry. Aluminum alloys, due to their low density compared to steels, are an important group of materials, in particular for lightweight construction of vehicles. In this study, two different aluminum alloys, namely AA5754-H22 and AA6061-T6, are evaluated for their potential use in nonload bearing applications in commercial vehicles by comparing their deep drawability characteristics. For this purpose, they are characterized by uniaxial tensile and Nakajima tests. In the next step, the deep drawing experiments are performed under different levels of blankholder force. The distance of the cup center to the edge of the die is also evaluated to investigate the formability of the designed cup for commercial use and to obtain the required product quality.

Kurzfassung

Als einer der am häufigsten angewandten Metallblechumformprozesse im Fahrzeugbau bestehen bei den Tiefziehtechniken Herausforderungen bezüglich des Klimawandels in Bezug auf höhere Treibstoffwirtschaftlichkeitsanforderungen in den letzten Jahren. Um das Gewicht der Fahrzeuge für eine bessere Treibstoffwirtschaftlichkeit zu reduzieren, werden leichtere und sichere Werkstoffe in der Automobilindustrie verwendet. Aufgrund ihrer geringeren Dichte im Vergleich zu Stählen stellen Aluminiumlegierungen eine wichtige Werkstoffgruppe dar, insbesondere für den Fahrzeugleichtbau. In der diesem Beitrag zugrunde liegenden Studie wurden zwei verschiedene Aluminiumlegierungen, und zwar AA5754-H22 und AA6061-T6, bezüglich ihres potentiellen Gebrauchs für nicht lasttragende Anwendungen in kommerziellen Fahrzeugen evaluiert, indem ihre Tiefzieheigenschaften verglichen wurden. Zu diesem Zweck wurden sie mittels einachsiger Zugversuche und sogenannter Nakajima-Tests charakterisiert. Im nächsten Schritt wurden die Tiefziehexperimente unter verschiedenen Niveaus der Niederhaltekraft durchgeführt. Der Abstand des Zentrums zur Kante der Form wurde ebenfalls herangezogen, um die Formbarkeit der designten Tiefziehform für die kommerzielle Anwendung zu untersuchen und um die erforderliche Produktqualität zu erreichen.


*Correspondence Address, Assist. Prof. Dr. Mehmet Ipekoglu, Department of Mechatronic Systems Engineering, Faculty of Engineering, Turkish-German University, Şahinkaya Caddesi No:86 Beykoz, 34820 Istanbul, Turkey, E-mail:

Assist. Prof. Dr. Mehmet Ipekoglu, born in 1978, graduated with a BSc, MSc and Phd in Mechanical Engineering from Bogazici University, Istanbul, Turkey, in 2001, 2004 and 2011, respectively. Since 2012, he has been working as an Assistant Professor in the Department of Mechatronic Systems Engineering of the Turkish-German University, Istanbul, Turkey.

Onur Erbas, born in 1988, graduated with a BSc in Manufacturing Engineering fromIstanbul Technical University, Turkey, in 2012 and a MSc in Manufacturing Technology from the Turkish-German University, Istanbul, Turkey, in 2014.

Dr.-Ing. Hamad Ul Hassan graduated with a BSc in Mechanical Engineering from University of Engineering and Technology, Taxila, Pakistan, in 2007 and a MSc in Computational Engineering from Ruhr-Universität Bochum, Germany, in 2011. He obtained his PhD in Mechanical Engineering from Technical University Dortmund, Germany in 2016. Since March 2016, he has been working as a group leader in the Department of Micromechanical and Macroscopic Modeling, ICAMS, Ruhr-Universität Bochum, Germany.


References

1 K.Lange: Handbook of Metal Forming, Society of Manufacturing Engineers, Michigan, USA (2006)Search in Google Scholar

2 T.Küçükömeroğlu, H.Yılmaz, M. S.Aktarer: The effect of tool press force to weldability of AA5754 and AA6061 alloys with friction stir welding method, Pamukkale University Journal of Engineering Sciences19 (2013), No. 7, pp. 28128610.5505/pajes.2013.92408Search in Google Scholar

3 M.Kleiner, M.Geiger, A.Klaus: Manufacturing of lightweight components by metal forming, Manufacturing Technology52 (2003), No. 2, pp. 52154210.1016/S0007-8506(07)60202-9Search in Google Scholar

4 W. S.Miller, L.Zhuang, J.Bottema, A. J.Wittebrood, P.De Smet, A.Haszler, A.Vieregge: Recent development in aluminium alloys for the automotive industry, Materials Science and EngineeringA280 (2000), pp. 374910.1016/S0921-5093(99)00653-XSearch in Google Scholar

5 N. L.Sukiman, X.Zhou, N.Birbilis, A. E.Hughes, J. M. C.Mol, S. J.Garcia, X.Zhou, G. E.Thompson: Durability and corrosion of aluminium and its alloys: Overview, property space, techniques and development, Z.Ahmad (Ed.): Aluminium Alloys – New Trends in Fabrication and Applications (2012), pp. 479710.5772/53752Search in Google Scholar

6 P. A.Friedman, S. G.Luckey, W. B.Copple, R.Allor, C. E.Miller, C.Young: Overview of superplastic forming research at Ford motor company, Journal of Materials Engineering and Performance13 (2004), No. 6, pp. 67067710.1361/10599490421277Search in Google Scholar

7 D. R.Kumar: Formability analysis of extra-deep drawing steel, Journal Materials Processing Technology130 (2002), pp. 314110.1016/S0924-0136(02)00789-6Search in Google Scholar

8 C.Girjob, G.Racz, O.Bologa: The determination of forming limit curve using a modular device, Academic Journal of Manufacturing8 (2010), pp. 3944Search in Google Scholar

9 T. B.Stoughton, X.Zhu: Review of theoretical models of the strain-based FLD and their relevance to the stress-based FLD, International Journal of Plasticity20 (2004), pp. 1463148610.1016/j.ijplas.2003.11.004Search in Google Scholar

10 S.Ahmadi, A. R.Eivani, A.Akbarzadeh: Experimental and analytical studies on the prediction of forming limit diagrams, Computational Materials Science44 (2009), pp. 1252125710.1016/j.commatsci.2008.08.008Search in Google Scholar

11 R.Narayanasamy, C. SathiyaNarayanan: Forming, fracture and wrinkling limit diagram for if steel sheets of different thickness, Materials Design29 (2008), pp. 1467147510.1016/j.matdes.2006.09.017Search in Google Scholar

12 D. W. A.Rees: Sheet orientation and forming limits under diffuse necking, Applied Mathematical Modelling20 (1996), No. 8, pp. 62463510.1016/0307-904X(96)00010-8Search in Google Scholar

13 S. P.Keeler: Determination of forming limits in automotive stampings, Sheet Metal Industry42 (1965), pp. 68369110.4271/650535Search in Google Scholar

14 K.Nakajima, T.Kikuma, K.Hasuka: Study on the formability of steel sheets, Yawata Technical Report, Tokyo, Japan, 284 (1971), pp. 678680Search in Google Scholar

15 T.Altan, A. E.Tekkaya: Sheet Metal Forming Fundamentals, ASM International, Materials Park, Ohio, USA (2012)10.31399/asm.tb.smff.9781627083164Search in Google Scholar

16 G.Ramesh, G. C. M.Reddy: Analysis of optimization of blank holding force in deep drawing by using LS DYNA, International Journal of Engineering Research and Applications3 (2013), No. 4, pp. 1975199510.1.1.377.8221Search in Google Scholar

17 H. I.Demirci, C.Esner, M.Yasar: Effect of the blank holder force on drawing of aluminium alloy square cup: Theoretical and experimental investigation, Journal of Materials Processing Technology206 (2008), pp. 15216010.1016/j.jmatprotec.2007.12.010Search in Google Scholar

18 S.Raju, G.Ganesan, R.Karthikeyan: Influence of variables in deep drawing of AA 6061 sheet, Transactions of Nonferrous Metals Society20 (2010), pp. 1856186210.1016/S1003-6326(09)60386-1Search in Google Scholar

19 H.Herdawandi, D. S.Wilkinson, M.Niewczas: The Portevin-Le Chatelier (PLC) effect and shear band formation in an AA5754-H22 alloy, Acta Materialia55 (2007), pp. 4151416010.1016/j.actamat.2007.03.007Search in Google Scholar

20 S.Aleksandrović, M.Stefanović, D.Adamović, V.Lazić: Variation of normal anisotropy ratio “r” during plastic forming, Journal of Mechanical Engineering55 (2009), No. 6, pp. 392399Search in Google Scholar

21 F.Ozturk, E.Esener, S.Toros, R. C.Picu: Effects of aging parameters on formability of 6061-O alloy, Materials Design31 (2010), pp. 4847485210.1016/j.matdes.2010.05.050Search in Google Scholar

22 H.Zein, M.El-Sherbiny, M.Abd-Rabou, M.El Shazly: Effect of die design parameters on thinning of sheet metal in the deep drawing process, American Journal of Mechanical Engineering1 (2013), No. 2, pp. 202910.12691/ajme-1-2-1Search in Google Scholar

Published Online: 2017-11-21
Published in Print: 2017-11-15

© 2017, Carl Hanser Verlag, München