The simulation study of preheating temperature and blank thickness on hot press forming of aluminium alloy 6061
The need for affordable, lightweight materials rises in industrial applications. The problems of forming lightweight material are low formability and springback failure at room temperature. High-strength aluminium alloys offer lightweight properties due to their excellent formability at elevat...
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| Format: | Thesis |
| Language: | English English English |
| Published: |
2022
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| Subjects: | |
| Online Access: | http://eprints.uthm.edu.my/8270/1/24p%20LAI%20CHEE%20FUNG.pdf http://eprints.uthm.edu.my/8270/2/LAI%20CHEE%20FUNG%20COPYRIGHT%20DECLARATION.pdf http://eprints.uthm.edu.my/8270/3/LAI%20CHEE%20FUNG%20WATERMARK.pdf |
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| Summary: | The need for affordable, lightweight materials rises in industrial applications. The
problems of forming lightweight material are low formability and springback failure
at room temperature. High-strength aluminium alloys offer lightweight properties due
to their excellent formability at elevated temperatures and strength restoration after
heat treatment. This numerical simulation study aims to develop a hot press forming
(HPF) process model compared with the experimental result. The effect of preheating
temperature and blank thickness on state variables was investigated based on the model
constructed. Lastly, the grain transformation of the blank in the HPF was studied.
DEFORM-3D simulation was used within this research to investigate the application
of AA6061 on the HPF. Initially, a geometry model was constructed. The model has
varied based on different preheating temperatures and blank thickness. The desired
parameters were chosen for the subsequent grain analysis and blank temperature
behaviour study. The results stated that 550 °C preheating temperature and 3 mm blank
thickness were selected as the optimum process parameter to produce an ideal blank.
The comparison was made between the simulation and experimental results; the
maximum error obtained was 5.17%, considering the model chosen was valid. The
grain study has found that as the quenching process took place, the grain amount and
size would reduce. In conclusion, the findings have shown that the deformed blank
quality was dependent on preheating temperature and blank thickness. The HPF
process could alter and improve the grain distribution of the blank. DEFORM-3D can
reveal the hidden phenomena and behaviours of forming AA6061 using the HPF
process, which is challenging to identify by the experiments. |
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