Parametric analysis of warm forming of aluminum blanks with FEA and DOE

The effect of temperature distribution on warm forming performance was investigated for 5083-O (Al-Mg) sheet metal blanks. Combined isothermal/non-isothermal FEA with design of experiments tools were used to predict appropriate warm forming temperature conditions for deep drawing and two-dimensional stamping cases. In the investigated temperature range of 25°C-250°C, the formability of Al-5083 alloy is found to be greatly dependent on the temperature distribution of the die and punch. To achieve increased degrees of forming, different temperature levels should be assigned to the corner and body of the die and punch. And the optimal temperature distributions for warm deep drawing and warm two-dimensional stamping are not identical.