Development of model materials for physical forming simulation of metals and alloys

Abstract

In conjunction with experimental simulation of metal forming, the development of model materials, by which forming simulation can be carried out at a low stress level at room temperature, was performed. The model materials are mixtures of microcrystalline wax, rosin, mineral oil and powder. The flow curves of the model materials show three typical configurations, i.e., work-softening type, steady state deformation type and work-hardening type, which are observed in metals and alloys. The above configurations of the flow curves of the model materials could be changed and controlled by adjusting powder content. The flow curves of the model material could be predicted accurately using the work-hardening rate equation determined in this work. As an application example, experiments on and visio-plasticity analyses of the plane strain backward extrusion of magnesium alloy and its model material, which represent the deformation property of work-softening type materials, were carried out. We confirmed that the material flow and strain conditions in both materials correspond to each other with sufficient accuracy for engineering purpose. © 2011 The Japan Society for Technology of Plasticity.