7
Long Ju School of Mechanical Engineering, University of Science and Technology Beijing, 30 Xueyuan Road, Haidian, Beijing 100083, China e-mail: [email protected] Shrinivas Patil Aida-America Corporation, 7660 Center Point 70 Boulevard, Dayton, OH 45424 e-mail: [email protected] Jim Dykeman Honda R&D Americas, Inc., 21001 State Route 739, Raymond, OH 43067-9705 e-mail: [email protected] Taylan Altan 1 Center for Precision Forming, The Ohio State University, 339 Baker Systems, 1971 Neil Avenue, Columbus, OH 43210 e-mail: [email protected] Forming of Al 5182-O in a Servo Press at Room and Elevated Temperatures Aluminum alloys are increasingly used in automotive manufacturing to save weight. The drawability of Al 5182-O has been proven at room temperature (RT) and it is also shown that formability is further enhanced at elevated temperatures (ETs) in the range of 250–350 C. A cost effective application of ET forming of Al alloys can be achieved using heated blank and cold dies (HB–CD). In this study, the material behavior of Al 5182-O is characterized using tensile test and viscous bulge test at RT. The nonisothermal finite ele- ment model (FEM) of deep drawing is developed using the commercial software PAMSTAMP. Initially, deep drawing simulations and tests were carried out at RT using a 300 ton servo press, with a hydraulic cushion. The predictions with flow stress curves obtained from tensile and bulge tests were compared with experimental data. The effect of punch speed and temperature rise during forming at RT is investigated. The warm forming simulations were carried out by combining material data at ETs obtained from the literature. The coupled effects of sheet temperatures and punch speeds are investi- gated through the finite element analysis (FEA) to provide guidelines for ET stamping of Al 5182-O. [DOI: 10.1115/1.4030334] Keywords: warm forming, aluminum alloy, deep drawing, nonisothermal FEA 1 Introduction The use of aluminum alloys is increasing in automotive stamp- ing, because of aluminum’s low density and high strength to weight ratio. However, stamping of Al alloys presents new chal- lenges in obtaining good part definition and formability at RT. Recent studies have indicated the workability and formability can be increased considerably at ETs [1]. However, this process also has its own challenges, such as heating the blank, controlling the die temperature, lubrication, selection of the appropriate form- ing press, cycle time, and increased cost [2]. Considerable R&D has been conducted in North America in warm forming (around 250–400 C) of “soft” nonage hardenable 5xxx series alloys. Stud- ies covered: determination of material properties, lubrication, FEA, various forming methods such as super plastic forming, quick plastic forming (developed by GM), and development of warm forming cells [3,4]. In a major study conducted by USAMP (U.S. Automotive Materials Partnership), extensive investigations and prototype trials have been conducted in warm forming of Al 5xxx and 6xxx series alloys, mostly on 5754 and 5182. In all these studies, sheet material was formed at around 275 C while the dies were heated in some cases [5] and were kept at RT in most recent studies [4,6]. HB–CD stamping process, with blank heated only, can provide an efficient and economic approach to form Al alloys [7]. Servo presses, having the capability to enable infinitely variable and controllable ram speed and dwell at bottom dead center (BDC), offer a potential improvement in forming quality at both RT and ET [8]. The application of servo presses is continuously increasing in drawing, blanking, and warm forming processes [9]. By using servo presses, the drawability and productivity of deep drawn parts, such as door panels and fenders, were found to be improved with optimized punch speed profiles at RT [1012]. Regarding to warm drawing of Al–Mg alloys, with specially designed slide motions in a servo press, the blank holder pressure and punch speed were found to have significant effects on heat transfer between interfaces and thickness distribution of the formed part [13]. A number of previous studies have focused on FE simulations of warm forming process by using isothermal and nonisothermal models. Kaya et al. [13] conducted cup drawing simulation of Al sheet forming at ET (25–300 C). The warm forming process of Al 5754-O was simulated using a nonisothermal FEM to study the complex interactions between material properties, temperature, and punch velocity (strain rate). Kim et al. [14] investigated ther- momechanically coupled FEM, which was performed for forming of Al rectangular cups at ETs. The effects of some major factors (i.e., forming speed, blank holder pressure, and friction condition) on forming performance were reviewed and discussed. Abedrabbo et al. [15] developed a temperature-dependent anisotropic material model for use in a coupled thermomechanical FEA of the pure stretch forming of Al 5182 and Al 5754. The failure locations of simulation results at RT and ET matched well with the experiments. The major conclusions of these studies were that (a) due to increased formability Al 5182-O could be successfully warm formed at about 250 C, (b) the cycle time for the operation could be kept to less than 15 s per part, and (c) most importantly, to reduce production costs, it is preferred to use nonheated dies, and provide quick transport of the heated blank from heater into the press, in the forming cell [2]. In this paper, based on previous material characterization and lubricant study, forming of Al 5182-O at both RT and ET is dis- cussed. The nonisothermal FE simulations are carried out using commercial software PAMSTAMP. Deep drawing experiments were performed at RT in a 300 ton servo press. The effects of forming speed at RT were evaluated and presented in detail. HB–CD warm forming was simulated with different blank temperatures and forming speeds. The thickness distribution along critical sec- tions in the formed part was predicted and compared with results at RT. 1 Corresponding author. Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received January 8, 2015; final manuscript received March 26, 2015; published online September 4, 2015. Assoc. Editor: Yannis Korkolis. Journal of Manufacturing Science and Engineering OCTOBER 2015, Vol. 137 / 051009-1 Copyright V C 2015 by ASME Downloaded From: http://manufacturingscience.asmedigitalcollection.asme.org/ on 11/20/2015 Terms of Use: http://www.asme.org/about-asme/terms-of-use

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Page 1: Warm - Up - Germainium.netgermainium.net/wp-content/uploads/2010/06/Ch-6-2013.pdfNonmetals Sulphur, phosphorous, pure charcoal, radical muriatique, radical fluorique, radical boracique

Warm - Up

1. Write the electron configurations for F, Cl, and Br.

2. Draw the Lewis dot structure.

3. How many valence electrons in each?

4. If you were wondering if your favorite actor was in a new movie, how would you figure it out?

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Today’s Agenda

• QOTD: How is the periodic table organized?

• The scientists that developed the periodic table and how they did it!

• Types of elements

• Characterizations of elements by valence electrons

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History of the Periodic Table • Antoine Laviosier’s list of elements

• By 1870 there was 70 known elements

Simple Substances

Gases Light, heat, dephlogisticated air, phlogisticated gas, inflammable air

Metals Antimony, silver, arsenic, bismuth, cobalt, copper, tin, iron, manganese, mercury, molybdena, nickel, gold, platina, lead, tungsten, zinc

Nonmetals Sulphur, phosphorous, pure charcoal, radical muriatique, radical fluorique, radical boracique

Earths Chalk, magnesia, barote, clay, siliceous earth

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• Meyer and Medeleev

– Atomic mass is related to properties

– Mendeleev published the first periodic table.

Sc, Ga, Ge

predicted!

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Feuding Scientists (Table 6.2) • Arranging by MASS = problematic

• Moseley – 1913

– Stated atomic # as # of protons

– Arranging by atomic NUMBER solved problems.

• Periodic Law – ________ repetition of _______ and ______ properties of elements when they are arranged by increasing atomic number

Periodic

chemical physical

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Groups (families) = columns Periods = rows

Representative Elements Transition Elements

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Metals

• Shiny, smooth,

solid at room temp,

good conductors of

electricity, malleable

and ductile (can be

bent and reshaped).

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Forming Ions

• All representative elements want a _______ _______ Configuration.

• Elements will lose/gain electrons in order to have a full s and p shell and be in a stable electron configuration (8 valence) OCTET RULE!

• Metals LOSE / Nonmetals GAIN electrons

• What ion does Na form? – If Na loses 1 electron its got an NGC! Na is always a +1

cation.

Noble Gas

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Warm Up

• What is the octet rule?

• Where are the metals and where are the nonmetals on the periodic table?

• What do groups (or families) have in common?

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Today’s Agenda • QOTD: What are the groups and what are

their properties?

• Review

• Groups/properties

• Periodic Trends

• HW: pg 198 #’s 26,29,30-35,37,42, 45,46,48,51,54

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Review 1. Elements were initially arranged according to

their _______ _______. They were later reorganized by ______ ________ because their properties were consistent with their placement on the table.

2. Representative or transition element?? Iodine, Chromium, Uranium, Cesium

3. What are the names for group 1 and 2 metals?

4. What do atoms try to achieve when forming ions?

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Predict the Ions!

• Mg will form an ______ ion.

A) +1 C) +3

B) +2 D) -1

• Cl will form an _______ ion.

A) +1 C) -1

B) +2 D) -2

What about Oxygen? Al?

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Alkali and Alkaline Earth Metals • Alkali metals – group 1 except for H (very reactive)

• Alkaline earth metals – group 2 (also reactive)

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Transition Metals = d & f block

Can form ions of many charges and complex ions.

ALWAYS CATIONS!!!!

METALS ARE LOSERS!!

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Nonmetals

• Usually gases or dull brittle solids. Poor conductors of heat or electricity.

One of the only liquids at RT

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Halogens Also highly reactive Form ANIONS easily

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Noble Gases

UNreactive Don’t form IONS

Important when considering ions and how they form

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Metalloids

• Have properties of both metals and nonmetals.

• Silicon and germanium used extensively in ______ cells and computer ______ . solar chips

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Warm Up! • Sketch a periodic table. Identify:

Metals (all 3 types) Halogens

Nonmetals Noble gases

Metalloids

• What are some general characteristics of metals and nonmetals?

• Li, F, Se, Kr, predict the ions

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Today’s Agenda

• QOTD: How can we predict chemical behavior?

• Classification of elements by valence electrons

• Periodic Trends

• Atomic Radii

• HW due tomorrow

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Predicting Trends! (Copy down questions and wait for data)

• Make predictions about Fr!

1. From the data, devise a plan to predict mp, bp, and radius of Fr. Why can we do this?

2. Is Fr a solid, liquid, or gas at RT?

3. Which column do you think introduces the most error (mp, bp, or radius)?

These are called Periodic Trends and are seen all over the table!

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Classification of Elements

• Valence electrons - All electrons in the highest principle energy level (outermost electrons).

How many valence electrons in Na, Li, K, Rb?

All members in each GROUP have the same number of valence electrons.

Where the valence electrons are indicates the PERIOD.

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Valence Electrons and Groups

• Determine the valence electrons for groups 1, 2, 13-18.

• The group will indicate the number of valence electrons.

• ONE exception : He

– Helium is a noble gas but only has 2 valence electrons.

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Remember…

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Try these: • Without using the table, determine the group,

period, and block of these elements:

[Ne]3s2, [He]2s2, [Kr]5s24d105p5

• What are the symbols for the elements with the following valence electron configurations?

s2d1 s2p3 s2p6

• Write the electron configs:

group 2 element in 4th period

noble gas in 5th period

group 12 element in the fourth period

group 16 element in the second period

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Warm Up • Write the electron configs:

group 2 element in 4th period

noble gas in 5th period

Prefers -2 charge in the second period

• Name the atom

• Forms +3 ion Period 3

• Two valence electrons Period 2

• n = 4 with 6 valence electrons

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Warm Up – Welcome back • List the alkali metals in order of increasing

reactivity in water.

• Why do the alkali metals all react similarly?

• Name the element:

• An alkaline earth in period 5

• n = 4 in the group of the LEAST reactive elements

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Agenda

• What is Zeff? How does it affect all the other periodic trends?

• Zeff

• Atomic radii/Ionic radii

• Ionization energy

• HW: pg 199 # 56 – 59, 62-66, 69, 70

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Effective Nuclear Charge

e-

e-

• Electrons are pulled toward nucleus like a magnet. The stronger the force that the electrons feel the more the “rings” will contract.

• Z – S = Zeff

• Down a group – no change

• Across a period – Zeff stronger! (more “pull”)

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Trends - Atomic Radius

• Atomic radius – half the distance between adjacent nuclei in a crystal of the element.

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Periodic Trends– Atomic Radii

• Atomic Radii decreases across a period.

Add electrons to same

energy level more

attracted to the nucleus.

Electrons squeeze in and

radii get smaller.

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Periodic Trends– Atomic Radii

• Atomic radii increase down a group.

Add energy levels and

electrons, with more

“stuff” comes bigger

atoms.

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What about Ions?

• Ions have _______ or _______ charges.

• Cations have _______ charges and have a _________ atomic radii than their atoms.

– Lose electrons to form cations – less stuff = smaller radii

• Anions have ________ charges and have a _________ atomic radii than their atoms.

– Gain electrons to form anions – more stuff = larger radii

positive negative

positive

SMALLER

negative

LARGER

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Draw:

• A metal atom and it’s ion (consider relative sizes)

• A nonmetal atom and it’s ion (consider relative sizes)

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Circle the Largest atom or ion

a) Cl or Cl-

b) Mg or Sr

c) Mg or Si

d) Mg or Mg+

e) Se2- or Br-

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Warm - Up • What happens to atomic radii (size) across a

period? Why does this happen?

• What happens to atomic size down a group? Why does this happen

• Why are cations smaller than their atoms and anions larger?

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Today’s Agenda

• QOTD: How do periodic trends relate to the arrangement of electrons and ENERGY?

• Ionization energy – definition and trends

• Electronegativity – definition and trends

• HW due tomorrow, quiz Friday, lab due today!

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Ionization Energy

• The energy required to ________ an electron from an atom.

• How strongly an atom holds on to it’s valence electrons.

– Is it easier to remove an electron from a metal or a nonmetal?

• Metals have _____ ionization energy because they are LOSERS and give up electrons easily.

remove

LOW

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Trends in Ionization Energy

• Remember, across a period:

Zeff increases, size decreases… is it easy to remove an electron??

• Down a group, Zeff constant, size increases… is it easy to remove an electron??

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Trends in Ionization Energies

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Removing More than 1 Electron

• Second and Third ionization energies…

Get’s harder to remove as you remove more.

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Electronegativity

• Relative ability of an element to attract electrons in a chemical bond.

• Some elements are greedier than others with electrons! In a bond, they steal most of the electron density!

• Fluorine is small and selfish!

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Electronegativity Trends

• Electronegativity __________across a period.

and __________down a group!

INCREASES

DECREASES

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Periodic Trend Summary

Electronegativity

s p

d

BIG

Generous with electrons

Small

Selfish with electrons

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Identify

• Trends in atomic radii –

• Trends in ionic radii -

• Trends in ionization energy -

Sizes of atoms decrease across a period and increase down a group.

Sizes of cations are smaller than their atoms, sizes of anions are larger than their atoms

How much energy does it take to remove an electron? Metals require less ionization energy

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Identify

• Electronegativity –

• Noble gas configurations and octet rule-

In bonds, one element can pull all the electron cloud towards itself depending on how badly that atom wants an electron.

Lowest in energy! All elements want to be more stable and have lower energy, so they IONIZE to look like the noble gases. 8 valence electrons!

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Today’s Agenda

• QOTD: How do periodic trends relate to the arrangement of electrons and ENERGY?

• Review trends in radii and ionization energy

• Electronegativity – definition and trends

• Practice Worksheet

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Warm Up!

• Using the periodic table, rank each group in order of increasing size

– Calcium, magnesium, and strontium

– Oxygen, lithium, and fluorine

– Selenium, chlorine, and tellurium

• Write electron configs, draw Lewis diagrams and predict the ion

– F

– S

– Ba

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Warm Up!

• Using the periodic table, rank each group of in order of increasing size

– Calcium, magnesium, and strontium

– Oxygen, lithium, and fluorine

– Selenium, chlorine, and tellurium

• Write electron configs, draw Lewis diagrams and predict the ion

– F

– S

– Ba

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Warm Up 1. Rank these in order of increasing atomic size:

P, Al, Na, Ar, S

P, Bi, N, Sb

Justify your answer…(why is that the trend)

2. Rank the following in order of increasing ionization energy and justify your answer.

P, Al, Na, Ar, S

P, Bi, N, Sb

3. Define electronegativity. What is the most electronegative atom.

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Today’s Agenda

• QOTD: How does electronegativity affect bonding?

• Trends Practice

• Polar vs non-polar activity

• Review sheet

• Ch 6 Quiz on Friday! Review sheet due Friday.

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Practice • Why is it hard to remove a second electron

from Li?

• If the ionization energy increases drastically after you remove 2 electrons, in which group is the element most likely?

• Is it easier to remove an electron from Mg or from Cl? Why?

• Rate these with increasing IE then with increasing electronegativity

– Ca, Se, Ge, Kr

– Te, S, Se, O