Finite Element Modeling and Process Optimization for Preform Anneal Forming
Background
- To meet fuel efficiency standards, aluminum alloys are more and more used in automobile manufacturing to substitute conventional steel alloys. The obstacle for aluminum sheet forming is its poor formability.
- The preform anneal forming method developed by GM is a promising technology to improve the formability of aluminum alloys.
Problem Statement
- Currently, the cycle time is long because the process has to be stopped after preform to take the part out of the die for annealing.
- There is a lack of good knowledge of the preform-anneal-induced changes of the flow behavior and forming limit for the aluminum, which makes it difficult for accurate FE analysis.
Objective
- To develop a procedure to determine the optimal localized heating scheme.
- To get a better understanding how preform-annealing process effects the mechanical behaviors and forming limit of aluminum alloys.
Approach
- Study mechanical properties and microstructures of aluminum alloys after 3 stages: preform, anneal and final forming
- Develop finite element models to simulate preform anneal stamping process.
- Verify and improve the FE modeling with experiment.
- Use nonlinear programming/statistic method to develop a procedure for best localized annealing.
Researchers
