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• W3190835082 abstract "Super Plastic Forming (SPF) is a well-known manufacturing process in the transportation industry in which a superplastic thin sheet metal is extended to very large strains and deformed to complex shapes. In this method, with applying gas pressure, the thin sheet material is shaped into the SPF die. This technique is mostly used in the aerospace and automotive industries. One of the basic disadvantages of this method is the high production cycle time, that is a constraint for the development of the method in mass production scale like automotive industry. In recent years, there have been many efforts to overcome the above problem. High Speed Blow Forming (HSBF) process, also known as Quick Plastic Forming (QPF) as an advanced method based on the SPF has been newly introduced and is characterized by higher production rates. In both methods, there are similar technical challenges that need to be deeply investigated. Distortion in the final product is one of the most important technical issues in this manufacturing technique. During the SPF/HSBF process temperature variations is a critical parameter that could affect the distortion in the completed product.Verbom Inc. is a Canadian base company located in Sherbrook, Quebec that utilizes both SPF and HSBF methods in the production of electrical car and train body panels. The company uses thin sheet aluminum alloy (5083) in their productions. However, the company is faced with undesirable distortion levels in some parts that could not be resolved using conventional trial and error practice. The present project was defined in this context and has objective to experimentally and numerically investigate the temperature variations and distortion phenomenon during the entire SPF/HSBF process, based on scientific methods. This project has resulted in the publication of three papers that will be explained in the following:In the first paper, the temperature evolution in a HSBF tool during the offline heating process was numerically and experimentally investigated. As the HSBF process is carried out at high temperatures (0.4 – 0.6 of melting point of the part), before installing the HSBF tool on the press, the tool is heated by several heating elements until reaching to the target temperature (≈470 oC in this case). This process is performed out of the press which is called offline heating. The temperature distribution on the HSBF die at the end of the offline heating process is important because the initial temperature distribution on the part after ejecting the part for the cooling purpose, follows the temperature distribution on the die. Due to the fact that the temperature discrepancy on the part during the cooling process could affect the distortion, then this study tried to simulate and investigate the temperature evolution during the offline heating process with the view of obtaining the most uniform temperature distribution on the HSBF die at the end of the process. As the offline heating in the SPF/HSBF process is a long process (≈30 hours in this case), the view of minimizing the duration of the process was also considered. In this regard, testing and modelling the offline heating process of the HSBF tool was considered. The dies of the HSBF tool (i.e. upper and lower dies) were instrumented by 14 K type thermocouples (TCs) 2 mm under the surface of the dies. The temperature of the TCs during the entire offline heating process was recorded. The process was also simulated by the commercial finite element software ABAQUS and a good conformity between the numerical and experimental results was found. Based on the valid numerical model, a new approach in the heating manner of the HSBF tool with the view of minimizing the duration of the process and improving the uniformity of the temperature distribution on the dies was proposed.In the second paper, the temperature evolution of a SPF part during the cooling step of the SPF process was numerically and experimentally investigated. In this work, for the numerical simulation of the process, the initial temperature distribution of the part was required. Normally this initial temperature distribution is the same as the SPF die at the time of the ejecting. Hence FE simulation of the SPF tool was needed to obtain the temperature distribution of the die which is a time consuming process as it was shown in the first paper. In this regard, a new approach as local temperature variation was proposed and practically the surface of a large SPF part was divided to 9 equal zones and a K type TC was attached on the center of each zone. The cooling process which starts after ejecting the part from the SPF die was tested. For the cooling purpose, during the cooling process several cooling fans after the ejecting process vertically blew on the top side of the part until the part reached to the ambient temperature. The temperature evolution of each TC during the entire process was recorded. The recorded temperature of the TC of each zone was considered as the temperature of the whole zone. The Heat Transfer Coefficient (HTC) of each zone based on the new approach as local temperature variation, was directly calculated from the experimental cooling curves. The cooling process was successfully simulated by ABAQUS and a good agreement between the experimental and numerical results was found. The results in the paper confirmed that the proposed approached was reasonable and therefore the numerical modelling of the SPF tool for determination of the initial temperature distribution of the part, is no longer required and the determined HTC values with this method could be considered for any thermal investigation in the SPF process. However the obtained initial temperature distribution of the part from the numerical modelling of the tool is a continuous value over the surface of the part. In other word, each point of the part has its own specific temperature and practically the calculation of the HTC value for each point form the cooling curves is not possible. Hence, the new proposed approach gave this possibility to calculate the HTC value for the numerical simulation purpose. However in the paper the contribution of the radiation term in the HTC value was investigated and the results showed that the radiation effect during the air cooling process is a negligible phenomenon.In the third paper, experimental investigation of the distortion issue in the same SPF part was considered. In this work, the SPF part was divided to 9 equal zones and a K type TC was assigned for each zone. The TCs were attached at the center of each zone and the temperature evolution of each zone during the cooling process was recorded. In this study, four cooling tests with different thermal conditions was defined and conducted. In each test, the conditions were changed to see the effect of the important parameters as initial temperature distribution and HTC value distribution. The four defined tests were successfully performed and the tested parts were scanned by a 3D scanner camera for comparison with the CAD model of the SPF part. The model of each part was built and compared with the CAD model in the metrology software PolyWorks. The observations showed that more uniformity in the initial temperature distribution within the part could improve the distortion while more uniformity in the HTC distribution did not show considerable effect on the distortion. Hence, the study concluded that the initial temperature distribution is more important and effective parameter in comparison with more uniformity in HTC value over the surface of the part." @default.
• W3190835082 created "2021-08-16" @default.
• W3190835082 creator A5040257594 @default.
• W3190835082 date "2020-10-30" @default.
• W3190835082 modified "2023-09-23" @default.
• W3190835082 title "Experimental and numerical investigation of temperature evolution during super plastic forming of an aluminum alloy sheet and its influence on distortion" @default.
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