Viscous warm pressure bulging process of AZ31B magnesium alloy with different ellipticity dies

Based on the bulging principle of different ellipticity dies, the methyl vinyl silicone rubber with excellent thermal stability and heat transfer performance was chosen as the viscous medium. The finite element analysis and experiments of viscous warm pressure bulging （VWPB） of AZ31B magnesium alloy were conducted to analyze the influence of different ellipticity dies on the formability of AZ31B magnesium alloy. At the same time, based on the grid strain rule, the forming limit diagram （FLD） of VWPB of AZ31B magnesium alloy was obtained through measuring the strain of bulging specimens. The results showed that at the temperature range of viscous medium thermal stability, the viscous medium can fit the geometry variation of sheet and generate non-uniform pressure field, and as the die ellipticity increases, the difference value of non-uniform pressure reduces. Meanwhile, according to the FLD, the relationship between part complexity and ultimate deformation was investigated.

Fracture prediction in non-isothermal viscous pressure bulging of aluminum alloy sheet using ductile fracture criterion

The failure of AA3003 aluminum alloy sheet metal was predicted for non-isothermal viscous pressure bulging (VPB). Utilizing the coupled thermo-mechanical finite element method combined with ductile fracture criterion, the calculations were carried out for non-isotherm VPB at various temperatures and the influences of the initial temperature of viscous medium on failure mode of bulge specimens were investigated. The results show that the failure modes are different for the non-isothermal VPB with different initial temperatures of viscous medium. For the non-isothermal VPB of AA3003 aluminum alloy sheet with initial temperature of 250 ℃, when the initial temperature of viscous medium ranges from 150 to 180 ℃, the formability of sheet metal can be improved to a full extent. The validity of the predictions is examined by comparing with experimental results.

Finite Element Analysis and Experiment on Viscous Warm Pressure Bulging of AZ31B Magnesium Alloy

Aiming at overcoming the low plasticity of magnesium alloy at room temperature, we researched viscous warm pressure bulging（VWPB） of AZ31B magnesium alloy based on the excellent thermal stability of viscous medium under the warm forming condition. The potential improvements of plastic deformation ability and forming quality of AZ31B magnesium alloy are expected with the aid of thermal characteristics of viscous medium. During bulging process the velocity field variation and pressure stress field distribution of viscous medium are observed at different temperatures through which the effect of temperature on the mechanical property of viscous medium and AZ31B magnesium alloy are analyzed. The results show that the formability of AZ31B magnesium alloy increases first and then decreases as the temperature increases and it is the best at 200 ℃. On the other hand, the viscous medium which can build non-uniform pressure stress field also exhibits a good flow property at elevated temperature, and it is helpful to improving the formability of AZ31B magnesium alloy.

Influence of Transverse Normal Pressure on Deformation Behavior of Sheet Metal

To investigate the influence of magnitude and distribution of the transverse normal pressure on deformation behavior of sheet metal,viscous pressure bulge test (VPB) of overlapping sheet metals is proposed,where the overlapped sheet metal is deformed under the dual-sided normal pressure provided by viscous medium and the overlapping sheet.The transverse normal pressure loading features provided by overlapping sheet metals are first simulated by DEFORM-2D.It shows that the magnitude and space distribution of transverse normal pressure are dependent on strain hardening exponent n-,strength coefficient K-and thickness t-values of the overlapping sheet metal.Based on the stress,deviator stress and strain distribution resulted from the finite element simulation,it indicated that the uniform transverse normal pressure has no effect on deviator stress,the figure and strain distribution of bulge specimens have no change.The non-uniform transverse normal pressure can remarkably change the figure and metal flow of specimens,and the formability of sheet metal can be improved by controlling the transverse normal pressure distribution.

SIMUUTION OF ELECTROMAGNETIC TUBE BULGING BASED ON LOOSE COUPLING METHOD

A loose coupling method is used to solve the electromagnetic tube bulging. ANSYS/ EMAG is used to model the time varying electromagnetic field with the discharge current used as excitation, in order to obtain the radial and axial magnetic pressure acting on the tube, the magnetic pressure is then used as boundary conditions to model the high velocity deformation of tube with DYNAFORM, The radial magnetic pressure on the tube decreases from the center to the tube end, axial magnetic pressure is greater near the location equal to the coil height and slight in the other region. The radial displacement of deformed workpicces is distributed uniformly near the tube center and decreases from the center to the end; Deformation from the location equal to coil height to the tube end is little. This distribution is consistent with the distribution of radial pressure; Effect of the axial magnetic pressure on deformation can be ignored, The calculated results show well agreements with the experimental results.