U-channel forming of an 7075-T6 in warm conditions

Abstract

Abstract The use of high mechanical strength aluminum coupled with the warm forming process makes it possible to replace certain steel parts in vehicles, thus reducing its mass and consequently greenhouse gas emissions. Warm forming of aluminum alloys requires heating the part between 150°C and 250°C to increase formability and reduce springback. In this study, a 7075-T6 alloy U-channel part was warm formed at 200°C in a short enough time to maintain the T6 state of the material. The process consisted of successively performing the heating by contact and stamping steps on the same mechanical press. From a thermomechanical characterization of the alloy in the temperature range between RT and 200°C and several strain rates, numerical simulations of the forming of the U-channel part were carried out using Abaqus. The experimental springbacks reduced with temperature were in agreement with the numerical simulations. An analysis of the conductivity and hardness of the material showed also that the 7075 keeps its T6 state until 10 s of warm forming.