Optimization of Superplastic Forming Process of AA7075 Alloy for the Best Wall Thickness Distribution
This work aims to optimize the process parameters for improving the wall thickness distribution of the sheet superplastic forming process of AA7075 alloy. The considered factors include forming pressure p (MPa), deformation temperature T (°C), and forming time t (minutes), while the responses are the thinning degree of the wall thickness ε (%) and the relative height of the product h*. First, a series of experiments are conducted in conjunction with response surface method (RSM) to render the relationship between inputs and outputs. Subsequently, an analysis of variance (ANOVA) is conducted to verify the response significance and parameter effects. Finally, a numerical optimization algorithm is used to determine the best forming conditions. The results indicate that the thinning degree of 13.121% is achieved at the forming pressure of 0.7 MPa, the deformation temperature of 500°C, and the forming time of 31 minutes.
N. E. Prasad, A. A. Gokhale, and R. J. H. Wanhill, Aluminum-Lithium Alloys: Processing, Properties, and Applications, Oxford: Elsevier, 2014.
E. A. Starke and J. T. Staley, “Application of Modern Aluminum Alloys to Aircraft,” Progress in Aerospace Sciences, vol. 32, no. 2-3, pp. 131-172, 1996.
R. J. Bhatt, “Advanced Approaches in Superplastic Forming—A Case Study,” Journal of Basic and Applied Engineering Research, vol. 1, pp. 57- 64, October 2014.
I. Charit, R. S. Mishra, and M. W. Mahoney, “Multi-Sheet Structures in 7475 Aluminum by Friction Stir Welding in Concert with Post-Weld Superplastic Forming,” Scripta Materialia, vol. 47, no. 9, pp. 631-636, November 2002.
S. X. McFadden, R. S. Mishra, R. Z. Valiev, A. P. Zhilyaev, and A. K. Mukherjee, “Low-Temperature Superplasticity in Nanostructured Nickel and Metal Alloys,” Nature, vol. 398, no. 6729, pp. 684-686, April 1999.
Y. Wang and R. S. Mishra, “Finite Element Simulation of Selective Superplastic Forming of Friction Stir Processed 7075 Al Alloy,” Materials Science and Engineering: A, vol. 463, no. 1-2, pp. 245-248, August 2007.
G. Giuliano, Superplastic Forming of Advanced Metallic Materials: Methods and Applications, Cambridge: Woodhead, 2011.
C. H. Hamilton and N. E. Paton, Superplasticity and Superplastic Forming: Proceedings of an International Conference on Superplasticity and Superplastic Forming, Warrendale: The Minerals, Metals, and Materials Society,1989.
C. K. Syn, M. J. O’Brien, D. R. Lesuer, and O. D. Sherby, “An Analysis of Gas Pressure Forming of Superplastic Al 5083 Alloy,” International Conference on Light Materials for Transportation Systems, May 2001, pp. 1-8.
M. Alirezaiee, R. J. Nedoushan, and D. Banabic, “Improvement of Product Thickness Distribution in Gas Pressure Forming of a Hemispherical Part,” Proceedings of the Romanian Academy, vol. 17, no. 3, pp. 245-252, July-September 2016.
T. G. Nieh, J. Wadsworh, and O. D. Sherby, Superplasticity in Metals and Ceramics, Cambridge: Cambridge University Press, 2005.
A. O. Caballero, O. A. Ruano, E. F. Rauch, and F. Carreño, “Severe Friction Stir Processing of an Al-Zn-Mg-Cu Alloy: Misorientation and Its Influence on Superplasticity,” Materials and Design, vol. 137, pp. 128-139, October 2017.
J. R. Groza, J. F. Shackelford, M. T. Lavernia, and M. T. Powers, Materials Processing Handbook, Boca Raton: CRC Press, 2007.
A. D. Jose and J. Babu, “Experimental Studies on Thinning Characteristics of Superplastic Hemi-Spherical Forming,” International Journal of Emerging Technology and Advanced Engineering, vol. 5, no. 1, pp. 104-109, January 2015.
A. Smolej, B. Skaza, and M. Fazarinc, “Determination of the Strain-Rate Sensitivity and the Activation Energy of Deformation in the Superplastic Aluminum Alloy Al-Mg-Mn-Sc,” Materials and Geoenvironment, vol. 56, no. 4, pp. 389-399, December 2009.
M. H. Shojaeefard, A. Khalkhali, and E. Miandoabchi, “Effects of Process Parameters on Superplastic Forming of a License Plate Pocket Panel,” Advanced Design and Manufacturing Technology, vol. 7, no. 2, pp. 25-33, June 2014.
F. Jarrar, “Designing Gas Pressure Profiles for AA5083 Superplastic Forming,” Procedia Engineering, vol. 81, pp. 1084-1089, October 2014.
G. Kumaresan and A. Jothilingam, “Experimental and FE Simulation Validation of Sheet Thickness Optimization in Superplastic Forming of Al Alloy,” Journal of Mechanical Science and Technology, vol. 30, no. 7, pp. 3295-3300, September 2016.
M. Balasubramanian, P. Ganesh, K. Ramanathan, and V. S. S. Kumar, “Superplastic Forming of a Three-Stage Hemispherical 5083 Aluminium Profile,” Journal of Mechanical Engineering, vol. 61, no. 6, pp. 365-373, Arpil 2015.
D. Harwani, V. Badheka, V. Patel, and J. Andersson, “Developing Superplasticity in Magnesium Alloys with the Help of Friction Stir Processing and Its Variants—A Review,” Journal of Materials Research and Technology, vol. 12, pp. 2055-2075, May-June 2021.
V. Patel, V. Badheka, W. Li, and S. Akkireddy, “Hybrid Friction Stir Processing with Active Cooling Approach to Enhance Superplastic Behavior of AA7075 Aluminum Alloy,” Archives of Civil and Mechanical Engineering, vol. 19, no. 4, pp. 1368-1380, August 2019.
V. Patel, W. Li, A. Vairis, and V. Badheka, “Recent Development in Friction Stir Processing as a Solid-State Grain Refinement Technique: Microstructural Evolution and Property Enhancement,” Critical Reviews in Solid State and Materials Sciences, vol. 44, no. 5, pp. 378-426, July 2019.
V. V. Patel, V. Badheka, and A. Kumar, “Friction Stir Processing as a Novel Technique to Achieve Superplasticity in Aluminum Alloys: Process Variables, Variants, and Applications,” Metallography, Microstructure, and Analysis, vol. 5, no. 4, pp. 278-293, August 2016.
N. M. Tien, N. T. An, T. D. Hoan, L. D. Giang, and L. T. Tan, “Experimental Study on Effects of Process Parameters on Superplastic Deformation Ability of 7075 Aluminium Alloy Using Taguchi Method,” International Conference on Engineering Research and Applications, December 2019, pp. 328-334.
C. F. Wu and M. Hamada, Experiments: Planning, Analysis, and Optimization, Hoboken: Wiley, 2009.
S. Gopalakannan, T. Senthilvelan, and S. Ranganathan, “Modeling and Optimization of EDM Process Parameters on Machining of Al 7075-B4C MMC Using RSM,” Procedia Engineering, vol. 38, pp. 685-690, 2012.
R. Kumar and S. Chauhan, “Study on Surface Roughness Measurement for Turning of Al 7075/10/SiCp and Al 7075 Hybrid Composites by Using Response Surface Methodology (RSM) and Artificial Neural Networking (ANN),” Measurement, vol. 65, pp. 166-180, April 2015.
E. Salur, A. Aslan, M. Kuntoglu, A. Gunes, and O. S. Sahin, “Experimental Study and Analysis of Machinability Characteristics of Metal Matrix Composites During Drilling,” Composites Part B: Engineering, vol. 166, pp. 401-413, June 2019.
S. A. Sonawane and M. L. Kulkarni, “Multi-Response Optimization of Wire Electrical Discharge Machining for Titanium Grade-5 by Weighted Principal Component Analysis,” International Journal of Engineering and Technology Innovation, vol. 8, no. 2, pp. 133-145, March 2018.
C. S. Syan and G. Ramsoobag, “A Differential Evolution Optimization Approach for Parameters Estimation of Truncated and Censored Failure Time Data,” Advances in Technology Innovation, vol. 3, no. 4, pp. 185-194, October 2018.
Copyright (c) 2021 Manh Tien Nguyen, Truong An Nguyen, Duc Hoan Tran, Van Thao Le
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.
Submission of a manuscript implies: that the work described has not been published before that it is not under consideration for publication elsewhere; that if and when the manuscript is accepted for publication. Authors can retain copyright in their articles with no restrictions. is accepted for publication. Authors can retain copyright of their article with no restrictions.
Since Jan. 01, 2019, AITI will publish new articles with Creative Commons Attribution Non-Commercial License, under The Creative Commons Attribution Non-Commercial 4.0 International (CC BY-NC 4.0) License.
The Creative Commons Attribution Non-Commercial (CC-BY-NC) License permits use, distribution and reproduction in any medium, provided the original work is properly cited and is not used for commercial purposes.