In this article, biaxial superplastic forming was conducted after the rolling process on. Thus, the whole forming time is divided into subintervals in which the displacement speed is considered to be changeless. Superplasticity article about superplasticity by the free. Superplastic forming of magnesium alloys sciencedirect.
Superplastic forming is a unique, hightemperature forming process, characterized by extreme formability at very low flow stresses and strain rates. Babeau 3 1esi group, the magdalen center, the oxford science park, oxford. New challenges and requirements in sheet metal stamping. Superplastic forming spf of an aluminum sheet trough with a large depth to width ratio is challenging because of the difficulties in obtaining a. Pdf towards a superplastic forming of femnal alloys. The alloys in which it was observed zk60a and hm21a had not been specially processed giving, perhaps, an early. Spf, qpf, forming, al alloys, mg alloys, deformation mechanisms, fracture mechanisms 1 introduction superplastic forming spf of light alloys has been successfully used in aeronautics since more than 30 years.
The result is less waste, lower weight and manufacturing costs, high precision and lack of residual stress associated with welding which makes components ideal for aerospace, automotive and other applications. In the case of aluminium alloys, various alloys 2004, 5083 or 7475 have been formed with this technique. The automotive, aerospace, and appliance industries use sheet metal forming processes that deform an initially flat sheet of. The automotive, aerospace, and appliance industries use sheet metal forming processes that deform an initially flat sheet of metal into a final threedimensional shape. Construction of nextgeneration superplastic forming using. Superplasticity and superplastic forming article pdf available in materials science and technology 111. The box is formed by means of a uniform fluid pressure. Superplastic forming 40 years and still growing springerlink. The process uses high temperature and gas pressure to form material at the desired deformation rates. Hot forming hf 8 superplastic forming spf 9 linear friction welding lfw 10 process automation turnkey workshop 11 customer support metal forming solutions for the aerospace industry aries alliance shaping a better future 3. Microstructure of sheet for superplastic forming british standard this standard contains pictures of the microstructure of. To have this capability, a computer controlled pneumatic operated bulge forming setup was designed and fabricated.
Construction of nextgeneration superplastic forming using additive. An experimental investigation and numerical simulation in. Our angle on this is to minimize unproductive times, thereby increasing oee. They are not necessarily new but can be regarded as emerging technologies with respect to their application to aluminum alloys. It is generally used for aerospace applications, and due to its remarkable abilities, it is crucial to improve the tool manufacturing leadtime and lifetime to make the spf applicable for further. Spfdb is the combination of any superplastic forming spf technique and diffusion bonding db. The deformation process is slow enough to be considered as quasistatic. Superplastic forming spf technology along with alloy improvements has potential at making this process more cost effective. Stretching of the sheet during superplastic forming is much higher than with rolling and sheet fo.
The alloy is optimized for the process by rigorous control of composition, melt practice and rolling conditions. Superplastic forming of a threestage hemispherical 5083. The superplastic forming spf process is used in a wide range of high. Selection of material models for predicting necking in superplastic forming article in international journal of plasticity 194. Superplasticity, first observed some seventy years ago, remained a scientific curiosity until about twenty years ago. This chapter deals with the application of spf and spfdb to aerospace component manufacture and as such relates to the use of superplastic alloys in thin sheet. In order to develop a material model which can be used in superplastic forming simulations, uniaxial and biaxial experiments are necessary. Stretch forming automotive stamping processes stretch forming vs. Due to the metastable nature of the amorphous structure, bmgs.
Superplastic forming and diffusion bonding of titanium alloys. Sheet metal forming massachusetts institute of technology. Forming hf superplastic forming spf hot forming is a forming technique with a short cycle time using mediumhigh temperature to increase the formability of the material being formed. In the superplastic forming process sfp, exceptional formability can be achieved. The superplastic forming of bulk metallic glasses article pdf available in jom. Forming studies were pursued to evaluate the process parameters of superplastic forming and to extend the process to forming aircraft structural components. A detailed study was carried out on the effect of forming parameter variations with the two titanium alloys and two configurations. Construction of nextgeneration superplastic forming using additive manufacturing and numerical techniques proceedings of the institution of mechanical engineers, part b. Material model calibration for superplastic forming. Stretching of the sheet during superplastic forming is much higher than with rolling and sheet forming. Elastomer matrix forming press emc high productivity multi reference forming quick and easy tool change equipped with standard elastomer pads.
The large tensile elongations and typically low flow stresses associated with a superplastic metal permit the forming of complex parts using methods andfbrming pressures not previously possible. Forming elastoforming is a drawing technique which only involves a half tool and a flexible matrix matching the contour of the tool under the effect of high pressure of the elastomer. The comprehensive directory provides access to full contact and ability information for sourcing professionals, engineers and researchers wishing to get information on metal forming services. This process has evolved as a natural combination of the spf and db process because the temperature requirements for both processes are similar. The superplastic forming of bulk metallic glasses jan schroers crystalline liquid 2 amorphous t l t x t g t t 1 processing of metals, is subject to several limitations when used for the production of bmgs. An experimental investigation and numerical simulation in spf of. Titanium and titanium alloys forming and formability of titanium and titanium alloys spf is a hot metal operation capable of making intricate parts in a single operation. Superplastic forming is already being used industrially. Superplastic forming spf is an advanced sheet manufacturing process designed to form complex and large workpieces. Superplastic forming is a specialist process used for deforming metal sheet to extremely large plastic strains to produce thinwalled components to the nearnet shape. Bachelor of engineering mechanical engineering toggle navigation. The objective of this paper is a superplastic forming spf technologies design and optimization. Titanium and titanium alloys superplastic forming of.
The outboard light housing on the boeing 737 next generation aircraft was initially designed and manufactured as a cast aluminum part. These slow rates of forming necessarily restrict the commercial applications of superplastic forming to a limited range of lowvolume highvalue components, primarily for use in the aerospace industry and building design, and they prevent, on economic grounds, an expansion of superplastic forming. Superplastic forming is a process by which extremely complex parts are produced from a single sheet of superplastic material. Mar 25, 20 comparisonexplosive forming superplastic forming in explosive forming an in super plastic forming explosive charge is used punch or press is used to instead of a punch or press. Superplastic forming of a threestage hemispherical5083 aluminium profile 367 for threestage superplastic forming, pressure was varied from 0. The superplastic forming process is used in a wide range of. Advances in material use and tooling were necessary to successfully transition the part to the spf form. Experimental investigation on biaxial superplastic. With its distinguished editor and international team of contributors, superplastic forming of advanced metallic materials is a valuable reference for metallurgists and engineers in such sectors as aerospace and automotive engineering. The superplastic forming process requires careful control of strain rates in order to avoid strain localizations. In such situations, prior knowledge of multidimensional profile forming operations will be highly relevant and useful. Superplastic forming of advanced metallic materials summarises key recent research on this important process. Superplasticity is the ability of material to undergo extreme elongation allowing for deep drawn, intricate shapes. Forming spf superplastic forming is a forming technique using material heated to the super plastic state to increase its formability allowing high elongation ratio for forming complex parts and deep shapes.
The example treated here corresponds to superplastic forming of a rectangular box whose final dimensions are 1524 mm 60 in long by 1016 mm 40 in wide by 508 mm 20 in deep with a 50. Superplastic forming is an important technique that can be found in the aerospace industry, automobile exterior components and turbine blades, where various dimensions have to be created in a single blowforming operation. Formability studies conventional processes h e r f techniques superplastic forming techniques hydro forming stretch forming water hammer forming principles and process parameters advantage, limitations and application. Often the sheets being formed in spf are very thin such that less expensive membrane elements can be. Super plastic forming spf superplastic forming is a forming technique using material heated to the super plastic state to increase its formability allowing high elongation ratio for forming complex parts and deep shapes. Superplastic forming involves stretching the material at least 200% beyond its original size, although the deformation can. Developing a superplastic forming application using aluminum. The current method to manufacture double wall stainless steel exhaust components is to use a lowcost alloy with good forming properties and extensively form, cut, assemble, and weld the pieces. The material forming in superplastic state takes place at a low strain rates. Superplastic forming of advanced metallic materials 1st edition. The forming time can be minimized by optimizing the pressure profile applied to the forming sheet. Using spf, complex shapes may be fabricated using significantly fewer steps than traditional manufacturing more economical process. Orbital forming is an incremental bulk forming operation to decrease the forming zone extension and consequently the required process force.
The concept of using a dispersion of two nanoscale phases to enhance superplasticity in ceramics is currently being tested. Superplastic forming spf process automation turnkey workshop 14 customer support aerospace metal forming technologies aries alliance shaping a better future 3. Customer support metal forming solutions for the aerospace industry aries alliance shaping a better future 3. The mechanics of superplastic forming university of strathclyde. Nikabdullahc a department of mechanical engineering, national university of singapore, singapore 117576, singapore bdepartment of materials science, national university of singapore, singapore 117576, singapore. Recommended citation deshmukh, pushkarraj vasant, study of superplastic forming process using finite element. Langdon2 1department of materials science and engineering faculty of engineering, kyushu university. The multiaxial deformation behavior of bulk metallic glasses at high homologous temperatures r. Superplastic forming an overview sciencedirect topics. Pdf superplasticity and superplastic forming an introduction. Forming of aluminum alloy sheet at high temperature produce a product has a different microstructure and mechanical properties than the original sheet or it may remove any heat treatment has been done to the sheet. Due to the metastable nature of the amorphous structure, bmgs must be cooled quickly to avoid crystallization.
Process modeling the superplastic forming behavior of. Formability studies sheet metal basics sheet metal forming involves a wide range of processes. Superplastic forming of advanced metallic materials by g. Superplastic forming has seen an increase in popularity within the automotive industry over. It can be use for large size of it can be only used for metal sheets. Forming and joining of lightweight and multimaterial systems with this special issue of the journal of manufacturing science and engineering jmse our objective is to collect papers which enhance the understanding of material deformation processes. Influence of rolling on the superplastic behavior of an almg. In the aircraft industry the term superplastic forming, or spf, generally denotes a sheet forming process. The optimization of the superplastic forming pressure is usually done such that a target strain rate at a high strain rate sensitivity is maintained. Superplastic forming is a process dedicated to sheet material allowing elongation of several. A load scheduler was developed and implemented into the nonlinear finite element code nike3d to provide strain rate control during forming simulation and process schedule output. Superplastic forming process engineers frequently evaluate the superplastic forming applicability of a given set of process conditions to produce a part on the basis of the m values likely to be encountered during fabrication, where m is defined as.
The forming rates are slow and the cost of producing fine grained. For specific product areas the formatted data could be. Pdf the superplastic forming of bulk metallic glasses. Institute of precision engineering huytuan pham 1 manual superplastic forming simulation with abaqus 6. To begin with there is the ability to form components with double curvature and smooth contours from single sheet in one operation, with exceptional dimensional accuracy and surface finish, and none of the spring back associated with cold forming techniques. The multiaxial deformation behavior of bulk metallic.
Feasibility study of nearnet shape superplastic forging arun mohan student. Effect of sheet thickness during superplastic forming of az31b. Delays in delivery and other quality problems resulted in the part being redesigned as an aluminum superplastically formed spf part. Outreach and highlights of research for nontechnical. Sheet stretch forming sheet stretch forming is a fast, economical, and. Selection of material models for predicting necking in. Superplastic manufacturers, service companies and distributors are listed in this trusted and comprehensive vertical portal. Nearnet shape superplastic forging of al7075 component. Superplastic forming spf is receiving increasing interest as a process capable of radically extending the limitations associated with the more conventional processes.
New challenges and requirements in sheet metal stamping and forming simulation d. The formability in sfp is far superior when compared to traditional methods. The conditions of superplasticity are very sensitive to strain. Medraj mech 4216511 lecture 102 stretch forming sheet metal is stretched and simultaneously bent to achieve shape change 1 start of. Superplastic forming is an industrial process used for creating precise and complex components out of superplastic materials. Langdon2 1department of materials science and engineering faculty of engineering, kyushu university, fukuoka 8128581, japan2departments of aerospace and mechanical engineering and materials science, university of. Process modeling the superplastic forming behavior of inconel. Rapid freeform sheet metal forming technology development and system verification of innovative forming process for rapid prototyping. Pdf components of design for the superplastic forming process. Under the correct combination of temperature, strain rate and. Superplastic forming spf is an advanced manufacturing process, typically restricted to low volume and.
The process offers a range of important benefits, from both the design and production aspects. It is now recognized as a property which can be utilized in forming processes. Process adapted semifinished products, containing a defined sheet thickness characteristic, are formed in the presented work by the technologies upsetting and orbital forming. Applying superplastic forming principles to titanium sheet.
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