STUDY OF TRIMMING BEHAVIOR OF AUTOMOTIVE MAGNESIUM SHEET MATERIALS

Abstract

Sheet trimming is an important forming operation in stamping industry. However, trimming of automotive magnesium sheet materials is not well understood. The objective of present study was to investigate the trimming behavior of AZ31 and ZEK100 automotive magnesium sheet materials using a laboratory-based experimental set-up and complementary finite element (FE) simulations of the lab-based experiments. The effects of the trimming process parameters that included tool setup configuration, punch speed, clearance, sheet thickness and sheet orientation (rolling and transverse directions) on the quality of trimmed edge were analyzed. Experimental results indicated that the trimmed edge quality depended strongly on the trimming conditions. The optimal trimming parameters for AZ31 and ZEK100 sheets were experimentally obtained. Interrupted trimming experiments were conducted to examine crack initiation and development, the mechanism of fracture, and the generation of the fracture profile of the trimmed edges. The R-value as a measure of material anisotropy and fracture strain of both materials were measured using uniaxial tension and plane strain tests and incorporated in the FE model. General purpose Finite Element software ABAQUS/Explicit was employed to simulate the trimming process where five different fracture criteria and element deletion method were used to predict profile of trimmed edge and the fracture initiation and development during the trimming process. Good general agreement was observed between experiments and FE simulations. However, some discrepancies were also observed. These are presented and discussed in the thesis.