1、 FORD LABORATORY TEST METHOD BB 118-01 Date Action Revisions Rev. 0 2014 11 12 Released C. Mracna,NA Controlled document at www.MATS Copyright 2014, Ford Global Technologies, LLC Page 1 of 9 FLANGING TEST PROCEDURE FOR ALUMINUM ALLOY SHEET Application Scope This document covers the operation of a fl
2、anging die set for testing the 90 degree flanging performance of aluminum sheet for body exterior applications. Significance and Use This procedure shall be used to establish the maximum pre-strain for which an aluminum alloy sheet can be flanged. Flange acceptability is based on the visual inspecti
3、on and rating of the flange surface appearance. Applicable materials This test applies to aluminum alloy sheet used in body exterior applications. Applicable Documents ASTM Standard E290-97a Test Methods for the Bend Testing of Material for Ductility ISO 7438 Metallic Materials Bend Test Conflicts I
4、n the event of a conflict between the text of this procedure and the references cited herein, the text of this procedure shall take precedence. Definitions Orange Peel - A pebble-grained surface that develops in forming coarse-grained aluminum sheet. Orange peel roughening is linked with the less co
5、nstrained deformation of individual grains, with different orientations, at a free surface. It is related to grain size and is not noticeable on fine-grained material, since the individual crystals produce only extremely fine slip lines1. Quality Assurance Requirements Unless otherwise specified, th
6、e users of this procedure are responsible for all inspection and the test requirements specified herein, and may use internal testing facilities as long as they meet the requirements of this procedure and any other test agencies acceptable to Ford Motor Company. Sampling Samples shall be prepared fr
7、om a single production lot of alloy. The test report shall contain as a minimum, the following information. (a) Generic and specific product description of each alloy including lot number and date alloy was made. (b) Baseline material properties for each aluminum alloy. (c) Material processing infor
8、mation. (d) Flange test ratings for each specimen tested. Replicates At least four (4) sample replicates are required per test condition. FORD LABORATORY TEST METHOD BB 118-01 Copyright 2014, Ford Global Technologies, LLC Page 2 of 9 Data Reporting All physical and mechanical data shall be submitted
9、 using the Supplemental Data Reporting Package (SDRP) in Table 1, which is comprised of the form in the reporting section. The SDRP serves as the required reporting format for submitting material data. All material data requested herein shall be manually recorded onto the reporting forms. Graphs and
10、 other requested materials shall be packaged and sent with the SDRP. Apparatus Required Flanging Die A flanging die is described below and shown in Figures 1 and 2. The die is designed to function within a single action press or load frame. An air spring within the die set provides a second action h
11、olding the specimen prior to and during the forming operation of each station. The station creates a 900 bend in the sheet of the specimen (Fig. 2a, 2b) by flanging over a radius block. Alternatively this test method may be done using the first (flanging) station of the three station hemming die des
12、cribed in FLTM BB 115-01. Maintenance The die faces should be cleaned with acetone periodically to remove oil and residue from test specimens. All threads, sliding blocks, and bearings must be kept clean and lightly lubricated. (a) (b) Figure 1. (a) Die set within a manual hydraulic press. (b) Flang
13、ing station lineup within die. Hydraulic Press Die Set Station 1 90 flange FORD LABORATORY TEST METHOD BB 118-01 Copyright 2014, Ford Global Technologies, LLC Page 3 of 9 (a) Station 1, 90 flanging, Open (b) Station 1, 90 flanging, Closed Figure 2. Open and close positions for flanging station. Test
14、 Specimen Dimensions Each flange specimen shall have dimensions of 73.5 0.5 mm long by 25.5 0.5 mm wide. Mark the rolling direction on each sheet in the flange. Longitudinal specimens are defined as having the length of the sheet parallel to the rolling direction (the bend line is perpendicular to t
15、he rolling direction). Transverse specimens are defined as having the length of the sheet perpendicular to the rolling direction (the bend line is parallel to the rolling direction). All specimens shall be flanged with the production intent lubricant and coating weight. Dummy Specimen Dimensions Thi
16、s test method may be done using the first (flanging) station of the three station hemming die described in FLTM BB 115-01. When flanging a coupon in the first station the tool may be balanced by placing a dummy specimen (or shim) in the third (flat hem) station. The thickness of the dummy specimen (
17、or shim) shall be equal to twice the thickness sheet being flanged. Test Specimen Preparation The sheet for each specimen may be fabricated with a shear or by electrical discharge machining (EDM). The shear may cause a burr to form on the edge of the specimen that shall be filed down with medium gri
18、t sand paper for a smoother more uniform edge. Cracks observed within one thickness of the edge of the specimen are to be neglected in the bend surface rating analysis for both fabrication methods (shear or EDM). Number of Test Specimens No fewer than four (4) bend specimens per alloy be tested for
19、each test condition. Flanging Procedure Test Conditions: Laboratory ambient conditions are assumed to be 23 2C and 50 5 % Relative Humidity. Exceptions should be noted and reported. 1. Pre-strain sheet materials according following procedure in Appendix B. FORD LABORATORY TEST METHOD BB 118-01 Copyr
20、ight 2014, Ford Global Technologies, LLC Page 4 of 9 2. Trim sheet specimens to proper dimensions. 3. Ensure press / die set open height is sufficient for proper loading of specimens. 4. Check setup of bend radius block in station 1 (see Fig. 3). The radius shall be equal to the thickness of the she
21、et of the test specimen. The block shall be shimmed such that the flanging gap between wipe and bend radius block is equal to sheet thickness. 5. Insert the proper dummy specimen into the third station of the die. Align this specimen flush with the back, left corner of the station. Figure 3: Sheet s
22、pecimen in first station. 6. Place sheet in the first station of the press. Align the sheet flush with the back, right corner of the station. 7. Close press loading die set to a force of 5 +/- 0.25 tons (50 +/- 2.5 kN). 8. Open press. 9. Remove the sheet with 90 flange from the die for post-flange a
23、nalysis. Radius Block Sheet Specimen FORD LABORATORY TEST METHOD BB 118-01 Copyright 2014, Ford Global Technologies, LLC Page 5 of 9 Analysis Flange Test Rating Standard The flange radius surface shall be rated by visual inspection according to the acceptability and severity scales listed below. Any
24、 cracks within one thickness of the edge of the specimen are not considered in the rating process. Acceptable square4 1: No cracking, no to mild orange peel square4 2: No cracking, mild to heavy orange peel. Not acceptable square4 3: Crack initiation lines (i.e. lines of localized thinning or crazin
25、g) parallel to the flange bend line or discontinuous cracks parallel to flange bend line. square4 4: Continuous cracks or complete, through-thickness fracture. *Picture examples of each flange rating are available in appendix A. The maximum pre-strain is determined by finding the highest level of pr
26、e-strain where all four specimens demonstrate acceptable flanges having a rating of 1 or 2. Reporting 1. Complete identification of the material(s) tested, including alloy, manufacturer, lot / coil number, production data, gauge, and test date. 2. Complete identification of specimen test condition (
27、i.e. fabrication method, flange orientation, pre-flange procedure, and treatments performed on test specimens). 3. The individual flange rating of each specimen is to be recorded noting any unique or out of the ordinary observances. Each specimen should be marked for independent identification for f
28、uture examination. FORD LABORATORY TEST METHOD BB 118-01 Copyright 2014, Ford Global Technologies, LLC Page 6 of 9 Table 1 - Supplemental Data Reporting Package (SDRP) for Pre-Strain Example ID# Manufacturer: External - 2.9 1.0 inches (64 x 25 mm) Internal - 2.25 1.0 inches (57 x 25 mm) Ford Spec No
29、.: Lot/Coil: Alloy: External Gauge: Manuf. Location: Internal Gauge: Recd date: Test date: Test Lab: Specimen Orientation Pre-strain (%) Test 1 Test 2 Test 3 Test 4 Max Acceptable Pre-Strain Notes: Rating Guidelines: 1: No cracking, no to mild orange peel 2: No cracking, mild to heavy orange peel. 3
30、: Crack initiation lines (i.e. lines of localized thinning or crazing) parallel to the flange bend line or any discontinuous cracks parallel to flange bend line. 4: Continuous cracks or complete, through-thickness fracture. References 1. Altenpohl, D.G., Aluminum: Technology, Application, and Enviro
31、nment, The Aluminum Association and The Minerals, Metals, and Material Society, pp. 438, 1998 FORD LABORATORY TEST METHOD BB 118-01 Copyright 2014, Ford Global Technologies, LLC Page 7 of 9 Appendix A Flange Sample Ratings Figure 6. Rating scale from 4 to 1. Figure 7. Rating 1 vs. rating 2 4 3 3 3 2
32、 1 1 2 FORD LABORATORY TEST METHOD BB 118-01 Copyright 2014, Ford Global Technologies, LLC Page 8 of 9 Figure 8. Rating 3 Figure 9. Rating 4 FORD LABORATORY TEST METHOD BB 118-01 Copyright 2014, Ford Global Technologies, LLC Page 9 of 9 Appendix B Method for Applying Nominal Pre-Strain 1. Find the i
33、nitial length, g1838g2868, to cut the specimen to using formula 1, which is derived from the basic strain formula and accounts for added length to be gripped by the tensile machine. g1838g2868 = g1838g30331 + % g1871g1872g1870g1853g1861g1866100%+ 50.8 g1865g1865 (1) For the flanging die, g1838g3033
34、is taken to be 2.9 inches (64 mm). % strain is the prescribed pre-strain defined in the Material Specification. 2. Cut specimen to length g1838g2868 and a width of 1 inch. 3. Use calipers to create a line 1.0 inch (25 mm) from each edge of the initial specimen to guide placement of the tensile machi
35、ne grips. 4. Secure the specimen in the tensile machine grips. The specimen should be centered in the grips and they should reach from the ends of the specimen to the 1.0 inch (25 mm) lines. It is important that the grips do not reach beyond the 1.0 inch (25 mm) lines, as this would cause a lack of
36、pre-strained material in the specimen. However, it is acceptable for the grips to come slightly short of the line, as this will merely cause an excess of pre-strained material that can be discarded later. 5. Pre-strain sheet within tensile machine using an axial extensometer. 6. Following pre-strain
37、 remove the specimen from tensile machine and trim it to 2.9 inches (64 mm) in length. To ensure uniformity among the pre-strained specimens, this is a four step process when using a hand shear. 6.1. Cut off one end of the specimen approximately 0.13 inches (3.2 mm) away from the 1.0 inch (25 mm) li
38、ne. 6.2. Cut off opposite end directly on 1.0 inch (25 mm) line. 6.3. Use calipers to mark a line exactly 2.9 inches (64 mm) from the end in step 6.2. 6.4. Cut directly on the line created in step 6.3. Note: The reason for the first cut being offset from the line is due to deformation in the specimen causing alignment problems while attempting to make right angle cuts. Summary of Revisions
