Grants and Contributions:

Grant or Award spanning more than one fiscal year (2017-2018 to 2018-2019).

In order to reduce the weight of passenger vehicles, more and more sheet metal parts are being made fromx000D
aluminum. And in order to improve the formability of aluminum, some automotive panels are being formedx000D
slowly at high temperatures (around 450ºC): this superplastic forming process allows large, lightweightx000D
automotive parts with complex features to be manufactured. While superplastic forming of aluminum isx000D
leading to significant weight savings, it remains a slow process.x000D
The aim of this research project is to evaluate the potential for improving the superplastic forming of aluminumx000D
automotive panels by superimposing a vibration on the sheet material while it is being deformed. AEM Powerx000D
Systems Inc., in collaboration with the University of Windsor will carry out some experimental tensile testingx000D
of aluminum sheets at superplastic temperatures with and without superimposed vibrations, and the maximumx000D
deformations that can be achieved will be recorded in both cases. Based on the known benefits of vibrations inx000D
other sheet metal forming processes, it is anticipated that an improvement in formability will be observed.x000D
In a second phase the amplitude and frequency of the superimposed vibration will be varied, and the influencex000D
of each parameter on the maximum deformation achieved will be investigated. Finally, the analysis of thex000D
experimental data will help to identify the optimum combination of amplitude and frequency.x000D
The third phase of this project will be to develop a preliminary numerical model of this superplastic formingx000D
process that does not include the effect of the vibrations. The development of the numerical model to includex000D
the effects of vibration are beyond the scope of this 6-month project, however, it will be important in the futurex000D
to extend the collaboration beyond this preliminary investigation so as to develop & validate a reliable finitex000D
element model for the simulation of industrial superplastic forming with superimposed oscillations.x000D
It is anticipated that this research will give AEM Power Systems Inc. the knowledge and ability to reduce thex000D
costs and the cycle time associated with the superplastic forming of aluminum automotive parts.