In warm forming of aluminum sheet materials, determination, realization, and maintenance of optimal temperature gradient is a key process parameter for increased formability. In this study, a two-phase procedure for efficient and accurate determination of proper temperature condition for warm forming of aluminum sheet metal blanks is presented using a hybrid 3D isothermal/non-isothermal finite element analysis (FEA) and design of experiments (DOE) approach. First, the relative trend, priority and overall temperature ranges of aluminum sheet metal blank regions are obtained using isothermal FE modeling and DOE techniques to reduce the analysis time significantly. In this phase, different temperature levels were assigned onto different regions of the deforming blank material (i.e., holding region, corner region, etc.). Heat transfer with the tooling and environment during the deformation process is ignored in order to achieve rapid predictions. Second, few additional non-isothermal FEAs, taking heat transfer into account, are conducted to validate and to refine the warm forming conditions based on the results from the isothermal FEA/DOE analysis. The proposed hybrid methodology offers rapid and relatively accurate design of warm forming process, especially for large parts that require 3D FE analysis. In addition, effects of forming speed , friction , and blank holder pressure on formability are investigated. Increasing part formability is observed with decreasing punch speed and blank holder pressure while an optimal process window is found in case of varying friction coefficients.
Skip Nav Destination
e-mail: mkoc@umich.edu
Article navigation
August 2006
Technical Papers
Determination of Proper Temperature Distribution for Warm Forming of Aluminum Sheet Materials
Hong Seok Kim,
Hong Seok Kim
S. M. Wu Manufacturing Research Center, College of Engineering,
University of Michigan
, 2250 G. G. Brown Building, 2350 Hayward Street, Ann Arbor, MI 48109
Search for other works by this author on:
Muammer Koc,
Muammer Koc
S. M. Wu Manufacturing Research Center, College of Engineering,
e-mail: mkoc@umich.edu
University of Michigan
, 2250 G. G. Brown Building, 2350 Hayward Street, Ann Arbor, MI 48109
Search for other works by this author on:
Jun Ni
Jun Ni
S. M. Wu Manufacturing Research Center, College of Engineering,
University of Michigan
, 2250 G. G. Brown Building, 2350 Hayward Street, Ann Arbor, MI 48109
Search for other works by this author on:
Hong Seok Kim
S. M. Wu Manufacturing Research Center, College of Engineering,
University of Michigan
, 2250 G. G. Brown Building, 2350 Hayward Street, Ann Arbor, MI 48109
Muammer Koc
S. M. Wu Manufacturing Research Center, College of Engineering,
University of Michigan
, 2250 G. G. Brown Building, 2350 Hayward Street, Ann Arbor, MI 48109e-mail: mkoc@umich.edu
Jun Ni
S. M. Wu Manufacturing Research Center, College of Engineering,
University of Michigan
, 2250 G. G. Brown Building, 2350 Hayward Street, Ann Arbor, MI 48109J. Manuf. Sci. Eng. Aug 2006, 128(3): 622-633 (12 pages)
Published Online: November 9, 2005
Article history
Received:
December 16, 2004
Revised:
November 9, 2005
Citation
Kim, H. S., Koc, M., and Ni, J. (November 9, 2005). "Determination of Proper Temperature Distribution for Warm Forming of Aluminum Sheet Materials." ASME. J. Manuf. Sci. Eng. August 2006; 128(3): 622–633. https://doi.org/10.1115/1.2162913
Download citation file:
Get Email Alerts
Special Issue on the State-of-the-Art in Japanese Manufacturing Research
J. Manuf. Sci. Eng
A Review of Advanced Roll-to-Roll Manufacturing: System Modeling and Control
J. Manuf. Sci. Eng (April 2025)
Related Articles
Failure Analysis of Rapid Prototyped Tooling in Sheet Metal Forming—Cylindrical Cup Drawing
J. Manuf. Sci. Eng (February,2005)
A Study on Warm Hydroforming of Al and Mg Sheet Materials: Mechanism and Proper Temperature Conditions
J. Manuf. Sci. Eng (August,2008)
Using Servo-Drive Presses to Determine the Effect of Blank Holder Pressure on Temperature Change in Warm Forming of Sheet
J. Manuf. Sci. Eng (December,2011)
Related Chapters
STRUCTURAL RELIABILITY ASSESSMENT OF PIPELINE GIRTH WELDS USING GAUSSIAN PROCESS REGRESSION
Pipeline Integrity Management Under Geohazard Conditions (PIMG)
Study on Weld-Line Movement of TWBs with Different Thickness in Hydro-Forming Deep Drawing of Square Cup
International Conference on Mechanical Engineering and Technology (ICMET-London 2011)
Data Tabulations
Structural Shear Joints: Analyses, Properties and Design for Repeat Loading