CAREER: Integrated Materials-Mechanics-Manufacturing Approach to Hot Blank - Cold Die (HB-CD) Forming of Lightweight Alloy Sheets

职业：轻质合金板材热坯冷模 (HB-CD) 成形的集成材料-力学-制造方法

• 批准号: 1254670
• 负责人: Fadi Abu-Farha
• 金额: $ 40万
• 依托单位: Clemson University
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2013
• 资助国家: 美国
• 起止时间: 2013-03-01 至 2018-02-28
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1254670&HistoricalAwards=false
• 关键词: CAREER; Integrated; Materials; Mechanics; Manufacturing

This Faculty Early Career Development (CAREER) grant provides funding for advancing a new sheet metal forming process, referred to as "hot blank-cold die," which is particularly suited for manufacturing components out of lightweight materials, such as magnesium and aluminium alloys. A coupled thermo-mechanical numerical tool will be developed to simulate the process and capture the non-isothermal material deformation. The numerical tool will incorporate analytical material models that take both anisotropy and changes in the microstructure into account. Uniaxial and biaxial tensile tests will be carried out over a wide range of conditions (temperatures and strain rates), in order to fully characterize material behaviour and calibrate the material models. Overall validation of the numerical tool will be performed by comparing predictions to experimental hot blank-cold die forming runs under various process conditions. The latter will be performed progressively, starting from small-scale lab experiments, to full-scale forming runs of automotive components. Material properties in the formed parts will be evaluated and post-process maps will be constructed, paving the way for future process optimization work.If successful, the proposed process has the potential to enable the manufacture of these hard-to-form alloys at lower cost and higher throughput than is currently achieved with hot forming operations. The research outcomes could enable product design for these limited-use materials, especially for light weighting of automobiles. The project has educational and outreach components that will foster undergraduate research activities in a graduate-only institution, integrate education and research within a recently-established automotive engineering program, and will enrich educational and outreach activities at the only Children's Museum in the upstate region of South Carolina. The project will also contribute to developing an Educational Television Program that aims at promoting awareness of grand long-term issues (energy conservation, sustainability, etc.), and inspiring the younger generations on how engineering and innovation help tackle such issues.

该学院早期职业发展（CAREER）拨款为推进新的金属板材成形工艺提供资金，该工艺被称为“热坯料-冷模”，特别适用于用镁和铝合金等轻质材料制造部件。将开发一个热-力耦合数值工具来模拟该过程并捕捉非等温材料变形。数值工具将结合分析材料模型，考虑到各向异性和微观结构的变化。单轴和双轴拉伸试验将在广泛的条件（温度和应变率）下进行，以充分表征材料行为并校准材料模型。数值工具的总体验证将通过将预测结果与各种工艺条件下的实验性热坯料冷模成形运行进行比较来进行。后者将逐步进行，从小规模的实验室实验开始，到汽车零部件的全尺寸成型运行。成形零件的材料性能将被评估，后处理图将被构建，为未来的工艺优化工作铺平道路。如果成功，所提出的工艺有可能使这些难以成形的合金的制造成本更低，产量更高，比目前的热成形操作。研究结果可以使这些有限使用材料的产品设计，特别是汽车的轻量化。该项目有教育和推广的组成部分，将促进本科研究生的研究活动，在最近成立的汽车工程计划整合教育和研究，并将丰富在唯一的儿童博物馆在南卡罗来纳州北部地区的教育和推广活动。该项目还将有助于开发一个教育电视节目，旨在提高对重大长期问题（节能、可持续性等）的认识，并激励年轻一代了解工程和创新如何帮助解决这些问题。