Investigation of Punching Parameters Effect on Mechanical Properties of Al-1100-O in Incremental Sheet Metal Hammering Process
Процесс штамповки является быстрым и технологичным способом производства изделий из листовых материалов. Его инновационный вариант – последовательная штамповка листовых металлов – обеспечивает штамповку трехмерного изделия путем его последовательного выдавливания пуансоном из исходного листа без при...
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Інститут проблем міцності ім. Г.С. Писаренко НАН України
2015
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| Назва видання: | Проблемы прочности |
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irk-123456789-1734002020-12-04T01:26:28Z Investigation of Punching Parameters Effect on Mechanical Properties of Al-1100-O in Incremental Sheet Metal Hammering Process Asgari, A. Sedighi, M. Riahi, M. Научно-технический раздел Процесс штамповки является быстрым и технологичным способом производства изделий из листовых материалов. Его инновационный вариант – последовательная штамповка листовых металлов – обеспечивает штамповку трехмерного изделия путем его последовательного выдавливания пуансоном из исходного листа без применения ответной матрицы. Исследуется влияние диаметра пуансона и частоты его приложения на механические свойства листового сплава Al-1100-O (твердость, прочность при растяжении, размеры и ориентация зерен). Показано, что с уменьшением диаметра пуансона и повышением частоты его приложения увеличиваются твердость и прочность материала после штамповки. Для оценки его механических свойств указанным методом успешно применяются две статистические модели. Процес штампування є швидким і технологічним способом виготовлення виробів із листових матеріалів. Його інноваційний варіант – послідовне штампування листових металів – забезпечує штампування тривимірного виробу шляхом його послідовного видавлювання пуансоном із вихідного листа без застосування відповідної матриці. Досліджується вплив діаметра пуансона і частоти його прикладення на механічні властивості листового сплаву Al-1100-O (твердість, міцність при розтязі, розміри й орієнтація зерен). Показано, що зі зменшенням діаметру пуансона і підвищенням частоти його прикладання збільшуються твердість і міцність матеріалу після штампування. Для оцінки його механічних властивостей зазначеним методом успішно використовуються дві статистичні моделі. 2015 Article Investigation of Punching Parameters Effect on Mechanical Properties of Al-1100-O in Incremental Sheet Metal Hammering Process / A. Asgari, M. Sedighi, M. Riahi // Проблемы прочности. — 2015. — № 6. — С. 121-128. — Бібліогр.: 14 назв. — англ. 0556-171X http://dspace.nbuv.gov.ua/handle/123456789/173400 539.4 en Проблемы прочности Інститут проблем міцності ім. Г.С. Писаренко НАН України |
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Digital Library of Periodicals of National Academy of Sciences of Ukraine |
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Научно-технический раздел Научно-технический раздел |
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Научно-технический раздел Научно-технический раздел Asgari, A. Sedighi, M. Riahi, M. Investigation of Punching Parameters Effect on Mechanical Properties of Al-1100-O in Incremental Sheet Metal Hammering Process Проблемы прочности |
| description |
Процесс штамповки является быстрым и технологичным способом производства изделий из листовых материалов. Его инновационный вариант – последовательная штамповка листовых металлов – обеспечивает штамповку трехмерного изделия путем его последовательного выдавливания пуансоном из исходного листа без применения ответной матрицы. Исследуется влияние диаметра пуансона и частоты его приложения на механические свойства листового сплава Al-1100-O (твердость, прочность при растяжении, размеры и ориентация зерен). Показано, что с уменьшением диаметра пуансона и повышением частоты его приложения увеличиваются твердость и прочность материала после штамповки. Для оценки его механических свойств указанным методом успешно применяются две статистические модели. |
| format |
Article |
| author |
Asgari, A. Sedighi, M. Riahi, M. |
| author_facet |
Asgari, A. Sedighi, M. Riahi, M. |
| author_sort |
Asgari, A. |
| title |
Investigation of Punching Parameters Effect on Mechanical Properties of Al-1100-O in Incremental Sheet Metal Hammering Process |
| title_short |
Investigation of Punching Parameters Effect on Mechanical Properties of Al-1100-O in Incremental Sheet Metal Hammering Process |
| title_full |
Investigation of Punching Parameters Effect on Mechanical Properties of Al-1100-O in Incremental Sheet Metal Hammering Process |
| title_fullStr |
Investigation of Punching Parameters Effect on Mechanical Properties of Al-1100-O in Incremental Sheet Metal Hammering Process |
| title_full_unstemmed |
Investigation of Punching Parameters Effect on Mechanical Properties of Al-1100-O in Incremental Sheet Metal Hammering Process |
| title_sort |
investigation of punching parameters effect on mechanical properties of al-1100-o in incremental sheet metal hammering process |
| publisher |
Інститут проблем міцності ім. Г.С. Писаренко НАН України |
| publishDate |
2015 |
| topic_facet |
Научно-технический раздел |
| url |
http://dspace.nbuv.gov.ua/handle/123456789/173400 |
| citation_txt |
Investigation of Punching Parameters Effect on Mechanical Properties of Al-1100-O in Incremental Sheet Metal Hammering Process / A. Asgari, M. Sedighi, M. Riahi // Проблемы прочности. — 2015. — № 6. — С. 121-128. — Бібліогр.: 14 назв. — англ. |
| series |
Проблемы прочности |
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2025-07-15T10:03:54Z |
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2025-07-15T10:03:54Z |
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| fulltext |
UDC 539.4
Investigation of Punching Parameters Effect on Mechanical Properties of
Al-1100-O in Incremental Sheet Metal Hammering Process
A. Asgari, M. Sedighi,
1
and M. Riahi
School of Mechanical Engineering, Iran University of Science and Technology, Narmak, Tehran,
Iran
1 sedighi@iust.ac.ir
ÓÄÊ 539.4
Èññëåäîâàíèå âëèÿíèÿ ïàðàìåòðîâ ïóàíñîíà íà ìåõàíè÷åñêèå ñâîéñòâà
ëèñòîâîãî àëþìèíèåâîãî ñïëàâà Al-1100-O â ïðîöåññå åãî ïîñëåäîâàòåëü-
íîé øòàìïîâêè
À. Àñãàðè, Ì. Ñåäèãõè, Ì. Ðèàõè
Èðàíñêèé óíèâåðñèòåò íàóêè è òåõíîëîãèè, Íàðìàê, Òåãåðàí, Èðàí
Ïðîöåññ øòàìïîâêè ÿâëÿåòñÿ áûñòðûì è òåõíîëîãè÷íûì ñïîñîáîì ïðîèçâîäñòâà èçäåëèé èç
ëèñòîâûõ ìàòåðèàëîâ. Åãî èííîâàöèîííûé âàðèàíò – ïîñëåäîâàòåëüíàÿ øòàìïîâêà ëèñòîâûõ
ìåòàëëîâ – îáåñïå÷èâàåò øòàìïîâêó òðåõìåðíîãî èçäåëèÿ ïóòåì åãî ïîñëåäîâàòåëüíîãî
âûäàâëèâàíèÿ ïóàíñîíîì èç èñõîäíîãî ëèñòà áåç ïðèìåíåíèÿ îòâåòíîé ìàòðèöû. Èññëåäóåòñÿ
âëèÿíèå äèàìåòðà ïóàíñîíà è ÷àñòîòû åãî ïðèëîæåíèÿ íà ìåõàíè÷åñêèå ñâîéñòâà ëèñòîâîãî
ñïëàâà Al-1100-O (òâåðäîñòü, ïðî÷íîñòü ïðè ðàñòÿæåíèè, ðàçìåðû è îðèåíòàöèÿ çåðåí).
Ïîêàçàíî, ÷òî ñ óìåíüøåíèåì äèàìåòðà ïóàíñîíà è ïîâûøåíèåì ÷àñòîòû åãî ïðèëîæåíèÿ
óâåëè÷èâàþòñÿ òâåðäîñòü è ïðî÷íîñòü ìàòåðèàëà ïîñëå øòàìïîâêè. Äëÿ îöåíêè åãî ìåõàíè-
÷åñêèõ ñâîéñòâ óêàçàííûì ìåòîäîì óñïåøíî ïðèìåíÿþòñÿ äâå ñòàòèñòè÷åñêèå ìîäåëè.
Êëþ÷åâûå ñëîâà: ïîñëåäîâàòåëüíàÿ ëèñòîâàÿ øòàìïîâêà, ñïëàâ Al-1100-O, äèàìåòð
ïóàíñîíà, ÷àñòîòà.
Introduction. Incremental sheet metal forming (ISMF) process was introduced by
Leszak [1] for the first time about 45 years ago. This process was presented based on
industrial research for dieless sheet forming. Nakajima [2] developed the first concepts of
incremental forming process by numerical control machines to provide a flexible process.
These improvements continued eventually led to the incremental forming machines by
Allwood and Utsunomiya [3]. In recent years, assessment of the process parameters has
been considered. For example, the influence of parameters on the dimensional accuracy by
Ambrogio et al. [4] can be cited. Petek et al. [5] presented the effect of dependent variables
on the forces. Ben Hmida et al. [6] presented the effect of initial copper grain size on the
mechanical properties in incremental sheet metal forming.
In recent years, incremental sheet metal hammering (ISMH) process as a development
of ISMF process was introduced. This process is based on incremental punching where a
sheet metal is formed into the final shape by a series of punch impacts as shown in Fig. 1.
Available literature in this field is limited and there is still a gap toward its industrial
application. Puzik [7] studied on design and construction of several hammering tools. He
has investigated different aspect of this method such as tools and advantages of the process.
Tanaka et al. [8] studied a new method for rapid-prototyping with a mechanism that uses a
servo-motor. A new method has been presented by Luo et al. [9] based on hydraulic
© A. ASGARI, M. SEDIGHI, M. RIAHI, 2015
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2015, ¹ 6 121
mechanism, while the process has been analyzed in study [10] by simulation of incremental
sheet metal hammering process.
In the present work, the influence of diameter and frequency of punch on the
mechanical properties of the formed sheet is studied. In order to study these parameters,
aluminum sheet is clamped and successive blows of punch is applied by a hammering tool.
After preparation of the specimens the tensile and hardness tests have been carried out to
investigate the influence of forming parameters. In this paper, firstly the experimental
procedure is explained. Then, the results and discussion of the mechanical properties and
microstructure are presented.
1. Experimental Procedure. This section introduces the approach, materials and
methods for assessment of mechanical properties.
1.1. Process Approach. To remove the effects of rolling process, a number of blanks
of sheet is annealed for one hour at temperature 450�C. After that, sheet has been clamped
such that no material may flow into the forming area. Then, by applying the successive
blows of the punch on the clamped sheet, the ISMH process has been accomplished (Fig. 2a
and 2b). In this study, the process was done using different punch diameters (Fig. 2c).
The strategy of sheet forming includes two stages: decreasing cone radius and
increasing depth. The hammering frequency has three values of 13, 18, and 25 Hz, the cone
angle is 45� and hammering increment is equal to 0.1 mm. Forming strategy and definition
of the cone shape is shown in Fig 3.
After the forming process, the specimens have been cut out from the cone wall for
tensile test, hardness measurements and metallographic investigations.
1.2. Material. The material used in this study is an Al-1100-O blank with an initial
thickness t of 0.5 mm and 140 mm in diameter. In addition, the initial hardness of
annealed material is 25.7 HV.
1.3. Assessment of Mechanical Properties. This section includes the hardness
evaluation, strength of material and investigation of grain size.
A. Asgari, M. Sedighi, and M. Riahi
122 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2015, ¹ 6
Fig. 1 Fig. 2
Fig. 1. Schematic of incremental sheet metal hammering process: (1) clamp, (2) punch, (3) initial
shape, (4) final shape, and (5) support.
Fig. 2. Testing ring and tools: (a) hammering tools; (b) clamping system; (c) punches with different
diameter.
a b
Fig. 3. The forming strategy in ISMH process with forming parameters dx dy� � 0.1 mm/s (a) and
definition of the cone shape (b).
1.3.1. Hardness Evaluation. Aluminum sheet is formed by successive blows of punch
with diameter of 3, 5, and 10 mm and the frequency of 13, 18, and 25 Hz. The Vickers
microhardness measurements were carried out with 2 N load at the cross-sectional
thickness shown in Fig. 4.
1.3.2. Strength of Material. The uniaxial tensile tests of the specimens have been
carried out using a standard tensile testing machine. The crosshead velocity of the testing
machine was 0.0017 mm/s. The reaction force F is measured by the way of load cell with
a measurement range of 0–5 kN for all tests. The specimens were elongated up to fracture
and the true stress–true strain curves were obtained. The geometry and dimensions of the
tensile specimen are shown in Fig. 5 and Table 1.
Some technical problems were encountered in application of the conventional tensile
test technique to thin sheets: due to specimen small thickness of 0.5 mm, the buckling has
occurred at the first few of the tensile tests. To prevent buckling of a thin specimen, a tiny
fixture was designed and manufactured (Fig. 6). When the crosshead jaw moves to clamp
the specimen, the fixture bears the load of crosshead and clamping. Then, by rotating the
screw, fixture will be opened and the specimen will fully bear the load.
1.3.3. Investigation of Grain Size. After mounting the specimen, it was polished with
sandpaper of diminishing roughness to get a flat section. Hydrofluoric was used for etching
and grain boundary observation. The microstructure images will be shown in the results
and discussion section.
Investigation of Punching Parameters Effect on Mechanical Properties ...
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2015, ¹ 6 123
T a b l e 1
Specimen Dimensions
Lt , mm LG , mm LU , mm WG , mm WU , mm r, mm
30 5 12 5 3 4
Fig. 4 Fig. 5
Fig. 4. Schematic of the hardness measurements.
Fig. 5. The tensile test specimen after fracture (a) and its geometry (b).
Fig. 6. The schematic of the buckling-preventing fixture.
2. Results and Discussion. In this section, the results obtained for hardness behavior,
tensile strength and the grain size are presented. Also, two different statistical models were
suggested for prediction of mechanical properties after ISMH process.
2.1. Hardness Behavior. The effects of diameter and frequency of punch on hardness
are shown in Fig. 7. The hardness of the annealed specimen is 25.7 HV.
According to the plots presented in Fig. 7, the hardness after ISMH processes has
increased. The hardness in the areas close to the punched surface is higher than in other
points. This variation of hardness is related to the higher strain at the mentioned area.
Moreover, since grain size reduction was observed with punch diameter reduction, this fact
could also attribute for the increased hardness. The variation of hardness versus depth
indicates that the effect of punch impact is less pronounced in the areas located farther from
the punched surface. For example, the specimen hardness has increased about 37% for
punch diameter of 3 mm and frequency of 25 Hz.
2.2. Tensile Strength. To assess the effect of punch diameter and frequency, the
tensile test was used. The variations of stress–strain curves vs. different values of punch
diameter and frequency are illustrated in Fig. 8. As shown, the stress–strain curve of
annealed specimen is close to that implied by the elastic-perfectly plastic model.
By reducing the punch diameter, the trend of local strain increases and by increasing
punch frequency, the strain rate increases. This event leads to increasing of strain-hardening
rate. In literature, the strain-hardening phenomenon is attributed to:
(i) increased dislocation density at constant volume of microstructure leads to
intensifying of intersections between mobile dislocations and some microstructural
imperfections, such as, grain boundaries, Lomer–Cottrell barriers and forest dislocations;
124 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2015, ¹ 6
A. Asgari, M. Sedighi, and M. Riahi
a b
c
Fig. 7. Hardness vs. depth for different punch frequencies: 13 (a), 18 (b), and 25 Hz (c).
(ii) intersection of mobile dislocations leads to formation of pile-ups behind the
above imperfections. The dislocation pile-up is a completely different kind of dislocation
array that is formed during plastic deformation. In pile-ups, dislocations interact elastically,
so that dislocations of a pile-up apply a backward force to the other dislocations. This fact
leads to increased resistance to shear stress of the material structure (the so-called
Peierls–Nabarro stress) and results in the specimen strain-hardening [11, 12]. The yield
stress and the ultimate tensile stress at the maximum frequency and minimum diameter of
the punch are increased by 25 and 15%, respectively.
According to the above plots, the tensile strength was increased with reduction of the
punch diameter: it decreases the material elongation, which naturally causes a higher
tendency to the brittle failure. Also, the strength of the material was improved by increasing
the punch frequency.
2.3. Grain Size. The microstructure of the formed specimen after ISMH process is
shown in Fig. 9. As shown, the grains are more tangibly stretched and become smaller as
the punch diameter is decreased. The tendency to punch indentation (smaller punch
diameter) induces higher shear stresses in the sheet and, consequently, leads to further grain
refinement. In literature, this is related to the generation of sub-grains with a high density of
dislocations in the high-Gibbs energy areas in microstructure, such as grain boundaries and
twinning boundaries. The mechanism of growing of these subgrains is migration of
dislocations from regions of high-density dislocations to lower-density places [11, 12].
The grain sizes for various process parameters are given in Table 2, from which it is
evident that the stress applied to the sheet surface increases with punch diameter reduction.
The geometry of the formed grains indicates that stress execution occurs in this process: the
grains are elongated in the linear direction due to action of tensile stresses.
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2015, ¹ 6 125
Investigation of Punching Parameters Effect on Mechanical Properties ...
a b
c
Fig. 8. Stress–strain curves for different punch frequencies: 13 (a), 18 (b), and 25 Hz (c).
2.4. Modeling and Prediction. Due to the importance of the prediction of mechanical
properties after ISMH process, two models were suggested. These presented models are
based on the statistical analysis.
2.4.1. Hardness Variation Prediction. To predict the hardness variation of the surface
after ISMH process, a model was presented. This model is based on the curve-fitting of a
surface to the results using in Eq. (1):
H D f Df D f� � � � � �34 83 132 018 002 009 6942 2. . . . . . , (1)
where H , D, and f are hardness (HV), punch diameter, and punch frequency,
respectively. According to the above relation we can predict the hardness with adjusted
R-squared equal to 0.99. The statistical analysis indicates that the hardness is more strongly
affected by punch diameter than by punch frequency (see Fig. 10).
The above-mentioned prevalence of the punch diameter effect over frequency can be
due to the fact that the applied strain in the ISMH process is related to the punch diameter
while the frequency is related to the strain rate. In fact, due to the small strain-rate
sensitivity of the material at room temperature, the effect of punch frequency on the
hardness is lower than that of the punch diameter [13].
2.4.2. Material Strength Prediction. To assess the effect of punch diameter and
frequency on the strength of material, the tensile tests were performed. Since prediction of
the material strength after the forming process due to the applied loads is of interest, the
statistical analysis was used process the available test data and to achieve a smart model.
The obtained model is presented by Eq. (2):
S D f Df D f� � � � � �10868 274 038 357 016 2082 2. . . . . . , (2)
where S is the material ultimate strength. The presented correlation has adjusted as
R-squared of 0.95. For more illustrative presentation of the punching parameters’ effect on
the material strength, the respective plots in Fig. 11 were also constructed.
126 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2015, ¹ 6
A. Asgari, M. Sedighi, and M. Riahi
T a b l e 2
Variation of Grain Size for Different Diameters and Frequencies of the Punch
Frequency (Hz) Grain size (�m)
Annealed D �10 mm D � 5 mm D � 3 mm
13
18
25
57
57
57
55
50
48
52
44
39
43
39
34
Fig. 9. Variation of shape and grain size in annealed specimens (a) and specimens produced with
different punch diameters: 10 (b), 5 (c), and 3 mm (d).
As shown in Fig 11, the maximum strength was attained for lower punch diameter
(3 mm) and higher frequency (25 Hz). Also, the effect of frequency on the material
strength has approximately a linear pattern, while the punch diameter has nonlinear effects
on the ultimate tensile strength.
According to the literature, due to the punch diameter increase, the pressure required
for the forming process is also increased [14]. In fact, the forming process is completed by
one increment (impact) in case of a small punch diameter. As a result, the applied strain is
increased by using a small punch diameter, whereas the material strength is also increased.
Conclusions. In this paper, the effects of diameter and frequency of punch on the
mechanical properties of Al-1100-O aluminum alloy sheet in incremental sheet metal
hammering process were analyzed. To investigate these effects, the hardness and tensile
tests were carried out. Also, the effect of the tool parameters on the grain size was studied.
Based on the results obtained, the following conclusions can be drawn:
1. The hardness of formed aluminum sheet is increased by reduction of punch
diameter and increase in the frequency. The maximum variation of the hardness is about
37%.
2. By reducing the punch diameter from 10 to 3 mm, the yield stress and the ultimate
tensile stress are increased about 24 and 7%, respectively.
3. The strength of formed sheet is improved by increasing the punch frequency, which
also decreases the elongation values.
4. By decreasing the punch diameter and increasing the frequency, the grain size can
be reduced.
5. Two different statistical models are proposed for prediction of the hardness and
strength of the material under study after the forming process.
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2015, ¹ 6 127
Investigation of Punching Parameters Effect on Mechanical Properties ...
Fig. 10. Variation of hardness versus the punch diameter and frequency.
Fig 11. Variation of the material strength versus punch diameter and frequency.
Ð å ç þ ì å
Ïðîöåñ øòàìïóâàííÿ º øâèäêèì ³ òåõíîëîã³÷íèì ñïîñîáîì âèãîòîâëåííÿ âèðîá³â ³ç
ëèñòîâèõ ìàòåð³àë³â. Éîãî ³ííîâàö³éíèé âàð³àíò – ïîñë³äîâíå øòàìïóâàííÿ ëèñòîâèõ
ìåòàë³â – çàáåçïå÷óº øòàìïóâàííÿ òðèâèì³ðíîãî âèðîáó øëÿõîì éîãî ïîñë³äîâíîãî
âèäàâëþâàííÿ ïóàíñîíîì ³ç âèõ³äíîãî ëèñòà áåç çàñòîñóâàííÿ â³äïîâ³äíî¿ ìàòðèö³.
Äîñë³äæóºòüñÿ âïëèâ ä³àìåòðà ïóàíñîíà ³ ÷àñòîòè éîãî ïðèêëàäåííÿ íà ìåõàí³÷í³
âëàñòèâîñò³ ëèñòîâîãî ñïëàâó Al-1100-O (òâåðä³ñòü, ì³öí³ñòü ïðè ðîçòÿç³, ðîçì³ðè é
îð³ºíòàö³ÿ çåðåí). Ïîêàçàíî, ùî ç³ çìåíøåííÿì ä³àìåòðó ïóàíñîíà ³ ï³äâèùåííÿì
÷àñòîòè éîãî ïðèêëàäàííÿ çá³ëüøóþòüñÿ òâåðä³ñòü ³ ì³öí³ñòü ìàòåð³àëó ï³ñëÿ øòàìïó-
âàííÿ. Äëÿ îö³íêè éîãî ìåõàí³÷íèõ âëàñòèâîñòåé çàçíà÷åíèì ìåòîäîì óñï³øíî âèêî-
ðèñòîâóþòüñÿ äâ³ ñòàòèñòè÷í³ ìîäåë³.
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Received 01. 10. 2014
128 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2015, ¹ 6
A. Asgari, M. Sedighi, and M. Riahi
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