Deformation and fracture behavior of 5052 aluminum alloy by electromagnetic-driven stamping

The plastic deformation ability of aluminum alloys is poor and cracking can easily occur during traditional stamping. Electromagnetic forming is a high-speed forming method that can increase the forming limits of aluminum alloys. However, shape deformation of the part is difficult to control owing to fast deformation speeds and uneven electromagnetic force distribution. In this paper, electromagnetic driven stamping (EMDS) is used that combines electromagnetic forming with traditional stamping is proposed. The deformation process of 5052 aluminum alloy sheets during static and dynamic stamping was analyzed through experimental investigations and numerical simulations. Under dynamic conditions, the forming height of 5052-O aluminum alloy increased by 11.4% compared with quasi-static stamping. The Gurson-Tvergaard-Needleman damage model was adopted to predict deformation and fracture behavior during the stamping process. During dynamic stamping, the strain rate reached 405 s(-1), which is much higher than that in quasi-static stamping. With EMDS, the void volume fraction in the cracked region decreased by 17.6% compared with quasi-static stamping. Under a high strain rate, the sheet forming height improved as void formation was inhibited and dimples were more evenly distributed.