SPIF Manufacture of a Dome Part Made of AA1060-H14 Aluminum Alloy Using CNC Lathe Machine: Numerical and Experimental Investigations

The present paper presents a comprehensive study based on numerical and experimental investigations testing the use of NC lathe machine in SPIF process of a dome part made of AA1060-H14 aluminum alloy. The main idea is to check the viability of NC turning machine in SPIF process of axisymmetric parts usually manufactured using 3-axis milling machines. For this purpose, aluminum thin sheet is firstly characterized and the right material behavior is identified. A VUMAT subroutine is used to implement this material behavior in ABAQUS/explicit FE used to simulate the SPIF-Turning operation. A comparison between experimental and numerical results showed the efficiency of this FE model to simulate a 2-axis SPIF strategy. Results, covering forming effort, thinning, the strain state distribution, fracture occurrence, and surface finish proved that NC turning machines could manufacture rapidly and with more accuracy, revolved components usually formed by a 3-axis NC milling machine.