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

为了减轻乘用车的重量，越来越多的钣金件由铝制成。为了提高铝的可成形性，一些汽车板在高温（约450ºC）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量化汽车部件。虽然铝的超塑成形导致了显着的重量减轻，它仍然是一个缓慢的过程，本研究项目的目的是评估的潜力，改善超塑成形的alumautomotive面板上叠加的振动，而板材料正在变形。AEM PowerSystems Inc.，与温莎大学合作，将在超塑性温度下，在有和没有叠加振动的情况下，对铝板进行一些实验性拉伸测试，并记录在两种情况下可以实现的最大变形。基于振动在其他金属板成形工艺中的已知优点，预计将观察到可成形性的改善。在第二阶段，将改变叠加振动的振幅和频率，并将研究每个参数对所实现的最大变形的影响。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是开发一个不包括振动影响的超塑性成形过程的初步数值模型。包括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，但是，在未来将合作扩展到这个初步调查之外是很重要的，以便开发和验证一个可靠的有限元模型，用于模拟叠加振荡的工业超塑成形。知识和能力，以减少thecosts和周期时间与超塑性成型的铝汽车零件。

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.