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<p>Bending operations hold significant prominence in the realm of sheet metal forming. Within this process, various challenges are encountered, with springback emerging as a particularly critical defect. Springback is responsible for dimensional inaccuracy and distortion of geometry. In this research paper, springback of Al-Fly ash green composite has been determined experimentally and numerically in the V-bending operations. The numerical and experimental investigation of residual stresses was also done for AA1050 and its ash composite. A good agreement has been seen between experimental and simulation results for both springback and residual stress. An attempt has been made to fabricate AA1050-Fly ash green composite, using stir casting route, and a comparative study of mechanical properties has been done between the composite and its parent aluminum AA1050. To achieve this goal, fly ash particles less than 90&#xa0;µm size were added 8 weight percentage of aluminum, in molten aluminum and mixed using mechanical stirrer. The incorporation of fly ash induces notable alterations in key properties such as hardness, density, stiffness, strength, and wear resistance. The blending of fly ash with aluminum castings contributes to a reduction in energy content, metal content, and overall cost of aluminum products.</p>

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Experimental and Numerical Analysis of Springback of AA1050-Fly Ash Green Composite Produced by Stir Casting Technique

  • 期刊论文

  • 发表日期：

    2025年6月9日

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  • Pankaj Kumar Sharma,
  • Vijay Gautam,
  • Subhajit Konar,
  • Vinita Bhardwaj,
  • Amit Kumar Sharma,
  • Shashi Prakash Dwivedi

摘要

Bending operations hold significant prominence in the realm of sheet metal forming. Within this process, various challenges are encountered, with springback emerging as a particularly critical defect. Springback is responsible for dimensional inaccuracy and distortion of geometry. In this research paper, springback of Al-Fly ash green composite has been determined experimentally and numerically in the V-bending operations. The numerical and experimental investigation of residual stresses was also done for AA1050 and its ash composite. A good agreement has been seen between experimental and simulation results for both springback and residual stress. An attempt has been made to fabricate AA1050-Fly ash green composite, using stir casting route, and a comparative study of mechanical properties has been done between the composite and its parent aluminum AA1050. To achieve this goal, fly ash particles less than 90 µm size were added 8 weight percentage of aluminum, in molten aluminum and mixed using mechanical stirrer. The incorporation of fly ash induces notable alterations in key properties such as hardness, density, stiffness, strength, and wear resistance. The blending of fly ash with aluminum castings contributes to a reduction in energy content, metal content, and overall cost of aluminum products.