Warm Forming Process for an AA5754 Train Window Panel

A warm forming process is designed for AA5754 to overcome low room temperature formability. The solution includes increased working temperature and is demonstrated with a railway vehicle component. A finite element (FE)-based methodology was adopted to design the process taking into account also the starting condition of the alloy. In fact, the component's dent resistance can be enhanced if the yield point is increased accordingly: the stamping process was thus designed considering the blank in both the H111 (annealed and slightly hardened) and H32 (strain-hardened and stabilized) conditions that were preliminarily characterized. Tensile and formability tests were carried out at different temperature and strain rate levels, thus providing the data to be implemented within the FE model (ABAQUS/CAE): the stamping was at first simulated at room temperature to evaluate the blank critical regions. Subsequently, the warm forming process was designed by means of an uncoupled thermo-mechanical approach. Thermal simulations were run to properly design the heating strategy and achieve an optimal temperature distribution over the blank deformation zone (according to the results of the material characterization). Such a distribution was then imported as a boundary condition into the mechanical step (ABAQUS/Explicit) to determine the optimal process parameters and obtain a sound component (strain severity was monitored implementing a forming limit diagram (FLD))-based damage criterion). The simulation model was validated experimentally with stamping trials to fabricate a sound component using the optimized heating strategy and punch stroke profile.