Experimental and Simulation Investigation on the Ultrasonic-Assisted Bending of Annealed and Aged AA6061 Aluminum Alloy
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ORIGINAL ARTICLE
Experimental and Simulation Investigation on the UltrasonicAssisted Bending of Annealed and Aged AA6061 Aluminum Alloy Sheets F. Asadi1 • H. R. Rezaei Ashtiani1 • A. Pak2
Received: 5 July 2020 / Accepted: 2 September 2020 The Indian Institute of Metals - IIM 2020
Abstract This paper aims to investigate the influence of ultrasonic vibration on bending parameters of AA 6061 aluminum alloy sheet. Required setup involves generator, horn, load cell, and die. Four amplitudes of 0, 3.68, 9.2, and 14.72 lm with three different horn speeds of 20, 50, and 80 mm/min were considered. Moreover, two processes of heat treatments, namely annealing and aging, have been applied. It was found that application of ultrasonic vibration generally improved bending parameters. Ultrasonic vibration reduced required bending force and also springback angle; with increasing amplitude of vibration, more reduction in force and spring-back angle was seen. Furthermore, at lower horn speed, the required force to bend the sheet metal was less than the case with higher horn speed. In addition, due to the low strength of the annealed aluminum alloy sheet metals (AA6061-O) in comparison with aged ones (AA6061-T6), less spring-back was observed in annealed sheet metals. Keywords Bending Ultrasonic vibrations Bending force Spring-back AA6061
& H. R. Rezaei Ashtiani [email protected]; [email protected] 1
School of Mechanical Engineering, Arak University of Technology, Arak 38135-1177, Iran
2
Faculty of Engineering, Mechanical Engineering Department, Bu-Ali Sina University, Hamedan, Iran
1 Introduction Aluminum alloys have found spreading use in automotive and aerospace industries because of their superior structural performance and high strength to weight ratio. For instance, typical automobile body replacement of steel with aluminum alloys provides mass reduction up to 50% [1, 2]. AA6061 contains magnesium and silicon as its major elements. This alloy provides remarkable mechanical properties and displays good weldability. It is one of the most common aluminum alloys for general applications [3]. Metal forming is ubiquitous because of its high production output, decreased material removal operations, and preferable mechanical properties [4]. Metal forming is near net production, in a way that with plastic deformation, the surface roughness will decrease [5]. The application of ultrasonic waves in metal forming has been studied since the 1950s [6, 7, and 8]. Ultrasonic vibration affects material deformation by increasing their formability [4]. Highfrequency vibration was applied to various metal forming processes [9–13]. Effects of ultrasonic waves were studied in severe plastic deformation (SPD) processes, such as equal channel angular press (ECAP), high-pressure torsion (HPT), and tube spinning (TS). It was found that applying ultrasonic vibrations during the tube spinning process can intensify some advantages such as high surface quality and hardness and low forming forces. Many researchers discussed the inf
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