Residual stresses in cold formed automotive grade aluminium alloys
Sheet metal forming is a widely used manufacturing process that converts thin, flat sheet into a desired part using a set of tooling. The plastic deformation that occurs during the process is commonly assumed to take place under plane stress conditions, where out-of-plane stresses are absent. However, it is common for tools to have features (eg. the die radius) with a radius to sheet thickness ratio of less than 20, so that the plane stress assumption becomes less valid. While this has been known for some time, recent work highlighted that out-of-plane contact stresses can exceed yield stress when the flat sheet first comes into contact with the tool radius, leading to defects in the part and high tool wear. The aim of this experiment will be to measure the stresses in the walls of two channel sections and to relate it to the critical conditions that exist during the forming process.
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HAZRA Sumit; HUGHES Darren J and PIRLING Thilo. (2013). Residual stresses in cold formed automotive grade aluminium alloys. Institut Laue-Langevin (ILL) doi:10.5291/ILL-DATA.1-02-117
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