Damage prediction in roll forming of the high strength aluminum alloy AA7075

Damage prediction in roll forming of the high strength aluminum alloy AA7075

SUCKOW Timon, GROCHE Peter

Abstract. The high-strength AA7075 alloy offers great potential for lightweight construction thanks to its high specific strength. However, high strength and low ductility are challenging for forming the material in the peak-aged T6-condition in terms of material failure and springback. Therefore, this alloy is usually formed in temperature-supported process routes, which poses major challenges for process design. For cold forming of the alloy in the T6-condition, a reliable prediction of material failure is required in terms of process design. Within this study, this is achieved by applying the modified Mohr-Coulomb (MMC) criterion and an increment based damage evolution rule to the FE-model. To validate the failure prediction and verify the general applicability to different profile geometries, two U-profiles and a V-profile are roll formed. Failure occurs during forming for all profile geometries and the experimental results show a good agreement with the failure prediction. The quality of the damage prediction strongly depends on the calibration for the MMC criterion and the setup of the FE-model, depending on the mesh size and the element type used.

Keywords
Roll Forming, Aluminum, 7075, Material Failure, Damage, FEM

Published online 4/19/2023, 12 pages
Copyright © 2023 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: SUCKOW Timon, GROCHE Peter, Damage prediction in roll forming of the high strength aluminum alloy AA7075, Materials Research Proceedings, Vol. 28, pp 787-798, 2023

DOI: https://doi.org/10.21741/9781644902479-86

The article was published as article 86 of the book Material Forming

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

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