Temperature-Controlled Forming of 7075-T6 Aluminum Using Linearly Decaying Direct Electric Current

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Journal of Manufacturing Science and Engineering




7075-T6 aluminum suffers from limited elongation during tensile forming; electrically assisted forming (EAF), which uses direct current to improve formability, is a viable candidate process to improve this effect. In past electrical tension testing by various authors, two types of waveforms have been examined: continuous current and square waveforms. For tension, it was shown that the applying current using square waveforms was able to extend formability beyond what continuous current could do, due to reducing the overheating in the necking region. The goal of this paper is to model the temperature and flow stress effects of saw tooth waves by modifying an existing square wave temperature prediction model and combining it with a theoretical flow stress model. Nondecaying and linearly globally decaying saw tooth waveforms are used in an attempt to control the temperature of the necking zone to allow for increased strain at fracture. Comparisons between saw tooth waveforms and square waveforms are exhibited, and it is found that the saw tooth waveforms are inferior to square waves for increasing strain at fracture for 7075-T6.