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Ductile fracture behavior in micro-scaled progressive forming of magnesium-lithium alloy sheet

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Abstract

Micro-scaled progressive sheet metal forming is a promising process for producing bulk microparts, given its advantages of high efficiency and low cost. To enhance forming quality and efficiency, it is important to have an in-depth understanding of the forming mechanism and model the forming process and fracture behavior accurately. However, the prediction of fracture formation in sheet materials at the micro-scale has not yet been well explored, and thus current knowledge is not sufficient to support the continued development and application of microforming technology. This study investigated progressive sheet forming of magnesium-lithium alloy sheets of different grain sizes to produce bulk microparts directly from sheet metal via shearing, extruding, piercing, and blanking. Using the Gurson–Tvergaard–Needleman (GTN) damage model, the effects of the size factor on the formation and evolution of voids were considered, and the shear-modified GTN model was established by combining Thomason’s and Lemaitre’s damage mechanics models. The modified model could predict not only the ductile fracture behavior dominated by tension under high-stress triaxiality at the micro-scale, but also the damage behavior controlled by shear deformation under low-stress triaxiality. The progressive forming process was simulated using the modified model, which was verified by experimentation and simulation. Comparisons of the experiments and simulations revealed the size effects on the forming defects and fracture behaviors of microparts during progressive sheet forming. The results show that the stress during deformation is mainly concentrated at the edge of microparts, and irregular geometric defects including burr, rollover, incline, and bulge become deteriorated with the increase of the initial grain size. This study enhances the understanding and prediction of ductile fracture in the micro-scaled progressive forming of sheet metals.

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Funding

This work was supported by the Young Scholars Program of Shandong University, Undergraduate Education Teaching Reform and Research Programs of Shandong University [Grant number 2021Y220], and the Shandong Provincial Natural Science Foundation [Grant number ZR2019BEE062].

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Authors and Affiliations

  1. Key Laboratory of High Efficiency and Clean Mechanical Manufacture of Ministry of Education, School of Mechanical Engineering, Shandong University, Jinan, 250061, Shandong, China

    Jilai Wang, Zhifei Xiao & Xin Wang

  2. National Demonstration Center for Experimental Mechanical Engineering Education, Shandong University, Jinan, 250061, Shandong, China

    Jilai Wang, Zhifei Xiao & Xin Wang

  3. Institute of Laser & Optoelectronics, School of Precision Instruments and Opto-Electronics Engineering, Tianjin University, Tianjin, 300072, China

    Yan Sun

  4. Shandong Nonmetallic Materials Institute, Jinan, 250031, Shandong, China

    Yan Sun

  5. Beijing Key Laboratory of Lightweight Metal Forming, School of Mechanical Engineering, University of Science and Technology Beijing, Beijing, People’s Republic of China

    Chaoyang Sun

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  1. Jilai Wang
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All authors contributed to the study conception and design. Material preparation, data collection, and analysis were performed by Jilai Wang, Zhifei Xiao, and Xin Wang. The first draft of the manuscript was written by Jilai Wang and Zhifei Xiao, and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Jilai Wang.

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Wang, J., Xiao, Z., Wang, X. et al. Ductile fracture behavior in micro-scaled progressive forming of magnesium-lithium alloy sheet. Int J Adv Manuf Technol 121, 967–980 (2022). https://doi.org/10.1007/s00170-022-09370-2

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