Study of single point incremental forming limits of Al 1050/Mg-AZ31B two-layer sheets fabricated by roll bonding technique: Finite element simulation and experiment

In this work, for the first time, the two-layer Aluminum (Al 1050) and magnesium (AZ31B) sheet were used in the single point incremental forming (SPIF) process. Due to the high strength-to-weight ratio of the Al 1050/MgAZ31B sample, today it is used in significant industries such as automotive and aerospace. The finite element simulation process was carried out using the Abaqus Software considering five approaches to determine forming limits. These approaches were forming limit diagram criterion (FLDcrt), effective strain rate (ESR), second derivation of thinning (SDT), Major strain rate (MSR) and Thickness strain rate (TSR) methods. The results showed that the failure prediction in the FLDcrt method was more accurate than other methods. The thickness distribution process was carried out both by simulation and experiment to validate the simulation results. The results show a good agreement between simulation and experimental results. Finally, the results obtained from the SPIF process were compared with the FLD results of the conventional hemispherical punch test, and it was observed that the FLD was higher in the SPIF process. Moreover, the layer arrangement, which affects formability, was investigated. The results showed that the FLD with Mg-AZ31B/Al 1050 arrangement fails in higher strains compared to Al 1050/Mg-AZ31B. After validating the simulation results, the parameter effect of the stepdown and tool diameter on the two-layer formability was investigated by the design of experiment. Considering the greater importance of the step-down and tool diameter effect on the created stresses and forming time compared to other parameters, their effect will be investigated. The results showed an optimal condition for the tool diameter, but an opposite relationship with formability was obtained for the step-down.