Investigation of the effects of oscillations on the superplastic forming of aluminum sheets

为了减轻乘用车的重量，越来越多的金属薄板零件由铝制成。为了改善铝的成形性，一些汽车覆盖件正在高温(约450°C)下缓慢成形：这种超塑性成形工艺允许制造具有复杂特征的大型、轻质汽车零部件。虽然铝的超塑成形可以显著减轻重量，但它仍然是一个缓慢的过程。本研究项目的目的是评估通过在板材变形时在其上叠加振动来改善铝汽车覆盖件超塑成形的可能性。AEM PowerSystems Inc.将与温莎大学合作，在有和没有叠加振动的超塑性温度下对铝板进行一些实验拉伸测试，并记录在这两种情况下可以实现的最大变形。基于振动在其他板材成形过程中的已知好处，预计成形性能将得到改善。在第二阶段，叠加振动的幅度和频率将改变，并将研究每个参数对所获得的最大变形的影响。最后，对实验数据的分析将有助于确定振幅和频率的最佳组合。该项目的第三阶段将开发一个初步的超塑性成形过程的数值模型，该模型不包括振动的影响。包含振动影响的数值模型的开发超出了这个为期6个月的项目的范围，然而，未来重要的是将合作扩展到这个初步调查之外，以便开发和验证一个可靠的有限元模型，用于模拟工业超塑成形叠加振动。预计这项研究将为AEM Power Systems Inc.提供减少与铝合金汽车零件超塑成形相关的成本和周期时间的知识和能力。

In order to reduce the weight of passenger vehicles, more and more sheet metal parts are being made fromaluminum. And in order to improve the formability of aluminum, some automotive panels are being formedslowly at high temperatures (around 450ºC): this superplastic forming process allows large, lightweightautomotive parts with complex features to be manufactured. While superplastic forming of aluminum isleading to significant weight savings, it remains a slow process.The aim of this research project is to evaluate the potential for improving the superplastic forming of aluminumautomotive panels by superimposing a vibration on the sheet material while it is being deformed. AEM PowerSystems Inc., in collaboration with the University of Windsor will carry out some experimental tensile testingof aluminum sheets at superplastic temperatures with and without superimposed vibrations, and the maximumdeformations that can be achieved will be recorded in both cases. Based on the known benefits of vibrations inother sheet metal forming processes, it is anticipated that an improvement in formability will be observed.In a second phase the amplitude and frequency of the superimposed vibration will be varied, and the influenceof each parameter on the maximum deformation achieved will be investigated. Finally, the analysis of theexperimental data will help to identify the optimum combination of amplitude and frequency.The third phase of this project will be to develop a preliminary numerical model of this superplastic formingprocess that does not include the effect of the vibrations. The development of the numerical model to includethe effects of vibration are beyond the scope of this 6-month project, however, it will be important in the futureto extend the collaboration beyond this preliminary investigation so as to develop & validate a reliable finiteelement model for the simulation of industrial superplastic forming with superimposed oscillations.It is anticipated that this research will give AEM Power Systems Inc. the knowledge and ability to reduce thecosts and the cycle time associated with the superplastic forming of aluminum automotive parts.