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    Design, Fabrication, and Experimental Validation of a Warm Hydroforming Test System
    (ASME, 2016) Turkoz, Mevlut; Halkacr, Huseyin Selcuk; Halkaci, Mehmet; Dilmec, Murat; Avci, Semih; Koc, Muammer
    In this study, a hydroforming system was designed, built, and experimentally validated to perform lab-scale warm hydromechanical deep drawing (WHDD) tests and small-scale industrial production with all necessary heating, cooling, control and sealing systems. This manuscript describes the detailed design and fabrication stages of a warm hydroforming test and production system for the first time. In addition, performance of each subsystem is validated through repeated production and/or test runs as well as through part quality measurements. The sealing at high temperatures, the proper insulation and isolation of the press frame from the tooling and synchronized control had to be overcome. Furthermore, in the designed system, the flange area can be heated up to 400 degrees C using induction heaters in the die and blank holders (BH), whereas the punch can be cooled down to temperatures of around 10 degrees C. Validation and performance tests were performed to characterize the capacity and limits of the system. As a result of these tests, the fluid pressure, the blank holder force (BHF), the punch position and speed were fine-tuned independent of each other and the desired temperature distribution on the sheet metal was obtained by the heating and cooling systems. Thus, an expanded optimal process window was obtained to enable all or either of increased production/test speed, reduced energy usage and time. Consequently, this study is expected to provide other researchers and manufacturers with a set of design and process guidelines to develop similar systems.
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    Determination of optimal loading profiles in hydromechanical deep drawing process using integrated adaptive finite element analysis and fuzzy control approach
    (SPRINGER LONDON LTD, 2017) Ozturk, Ekrem; Turkoz, Mevlut; Halkaci, H. Selcuk; Koc, Muammer
    In this paper, an improved approach is proposed to determine the optimal profiles of two controllable process parameters (hydraulic pressure and blank holder force), which improve the forming condition and/or make better use of forming limits in hydromechanical deep drawing (HMD) process. A method based on adaptive finite element analysis coupled with fuzzy control algorithm (aFEA-FCA) was developed using LS-DYNA to determine the optimal loading profiles and thus to maximize the limiting drawing ratio (LDR). Maximum thickness reduction, maximum wrinkle height in the flange region of the sheet metal blank, and position of the nodes in the unsupported portion of the sheet metal blank between punch and die were used as criteria in the fuzzy control algorithm. Different rule-based matrices were compared by considering the maximum thinning occurred in the sheet metal blank, and thus, the most accurate matrices were determined for the control algorithm. The optimal loading profiles could be determined in a single FEA, thus reducing the computation time. The proposed approach enables determining the optimal loading profiles and also could be applied to complex parts easily. In addition, effects of initial blank diameter and coefficient of friction between the sheet-blank holder and sheet-die on the optimal loading profiles were investigated. An attainable LDR of 2.75 for AA 5754-O sheet material in hydromechanical deep drawing process was proven experimentally using the optimal loading profiles determined by adaptive FEA.
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    The Effect of Temperature and Strain-Rate Sensitivity on Formability of AA 5754
    (TRANS TECH PUBLICATIONS LTD, 2012) Turkoz, Mevlut; Halkaci, H. Selcuk; Koc, Muammer
    Aluminum alloys have limited usage because of their limited formability at room temperatures. In order to design and develop more parts made of aluminum, new forming techniques such as hydroforming, warm forming and warm hydroforming have been researched to overcome the low formability issues. This, in turn, necessitates understanding and modeling the behavior of aluminum alloys at different temperatures and strain rates. This paper deals with the investigation of the effect of temperature and strain rate sensitivity on the formability of AA 5754 aluminum alloy. Tensile tests were carried out at temperatures of 20,100,180 and 260 degrees C and forming rates of 25, 100 and 250 mm/min. The mechanical properties and flow curves were obtained and the strain rate sensitivities were calculated at different strains and temperatures. The effects of temperature and strain rate sensitivity on the formability were introduced.