Evaluation of Forming Limit Diagram of Aluminum alloy 6061-T6 at Ambient Temperature

Abstract

Forming is a compression-tension process involving a wide spectrum of operations and flow conditions. The result of the process depends on various parameters and their interdependence. The selection of these parameters is still based on trial and error methods. In the present communication a new approach to optimize the geometrical parameters of components and process parameters such as blank holder pressure and coefficient of friction etc. is introduced. The optimization problem has been used with the objective of optimizing the maximum forming load required for the forming. A Genetic Algorithm is also used as a tool for the optimization of drawing load and process parameters. Presently, automobile industries, mainly focus on light weight and fuel efficient vehicles. Their main challenges are to reduce the energy consumption and air pollution. Aluminum alloys have excellent strength, corrosion resistance, recyclability, durability, resistance, ductility and formability etc. Such unique combination of properties makes aluminum the best metal to use in automotive and aerospace industries. One automotive grade Aluminum alloy 6061-T6 is selected for this study. Most of the material properties for both the usage and formability requirements are determined by the tensile test. The tensile test can measure not only elastic properties, but also plastic properties, especially the strain hardening coefficient and plastic strain ratio, which are very important for formability analyses. One of the major formability engineering analyses is to measure strains and strain distributions regarding different stamping quality concerns. In the present work Digital Image Correlation (DIC) technique is used. The Forming Limit Diagram is the primary form of representing formability in the case of sheet metal and it is analyzed in this research.