1、1DiedesignforstampinganotebookcasewithmagnesiumalloysheetsContentSummaryInthepresentstudy，thestampingprocessformanufacturinganotebooktopcovercasewithLZ91magnesiumlithiumalloysheetatroomtemperaturewasexaminedusingboththeexperimentalapproachandthefiniteelementanalysis/Afour-operationstampingprocesswas
2、developedtoeliminateboththefractureandwrinkledefectsoccurredinthestampingprocessofthetopcovercase/Inordertovalidatethefiniteelementanalysis，anactuafour-operationstampingprocesswasconductedwiththeuseof0/6mmthickLZ91sheetastheblank/Agoodagreementinthethicknessdistributionatvariouslocationsbetweentheex
3、perimentaldataandthefiniteelementresultsconfirmedconfirmedtheaccuracyandefficiencyoftheementanalysis/ThesuperorformabilityofLZ91sheetatroomtemperaturewasalsodemonstratedinthepresentstudybysuccessfulmanufacturingofthenotebooktopcovercase/Theproposedfouroperationprocesslendsitselftoanefficientapproach
4、toformthehingeinthenotebookwithlessnumberofoperationalproceduresthanthatrequiredinthecurrentpractice/ItalsoconfirmsthatthenotebookcovercasescanbeproducedwithLZ91magnesiumalloysheetbythestampingprocess/Itprovidesanalternativetotheelectronicsindustryintheapplicationofmagnesiumalloys/Keywords/Notebookc
5、ase；LZ91magnesiumlithiumalloysheet；stamping；Multi-operation；Formability21/IntroductionDuetoItslightweightandgoodperformanceinEMIresistance/magnesiumalloyhasbeenwidelyusedforstructuralcomponentsintheelectronicsindustry/suchascellularphonesandnotebookcases/Althoughtheprevailingmanufacturingprocessofma
6、gnesiumalloyproductshasbeendiecasting，thest-ampingofmagnesiumallsheethasdrawninterestsfromindustrybecauseofitscompetitiveproductivityandperformanceintheeffectiveproductionofthin-walledstructuralcomponents/Asforstampingprocess，AZ31magnesiumalloy(aluminum3%/zinc1%)sheethasbeencommonlyusedfortheforming
7、processatthepresenttime/eventhoughitneedstobeformedatelevatedtemperatureduetoitshexagonalclosedpacked(HCP)crystalstructureRecently/themagnesiumlithium(LZ)alloyhasalsobeensuccessfullydeve-lopedtoimprovetheformabilityofmagnesiumalloyatroomtemperature/Theductilityofmagnesiumalloycanbeimprovedwiththeadd
8、itionoflithiumthatdevelopstheformationofbodycentered-cubic(BCC)crystalstructure(Takudaetal//1999a/b；Drozdetal/2004)/Inthepresentstudy/thestampingprocessofanotebooktopcovercasewiththeuseofLZsheetwasexamined/Theformingofthetwohingesinthetopcoverofanotebook/asshowninFig/1(aandb)/isthemostdifficultopera
9、tioninthestampingprocessduetothesmalldistancebetweentheflangesandthesmallcornerradiiattheflanges/asdisplayedinFig/1(c)/Thisgeometricomplexitywascausedbyadramaticchangeinthecornerradiuswhentheflangeofgetstooclosetthenotebook/whichwouldeasilycausefracturedefectaroundtheflangeofhingeandrequireamulti-op
10、erationstampingprocesstoovercomethisproblem/Inthepresentstudy/theformabilityofLZmagnesiumalloysheetswasinvest-igatedandanoptimummulti-operationstampingprocesswasdevelopedtoreducethenumberofoperationallprocedusingboththeexperimentapproachandthefiniteelementanalysis/3Fig/1Flangeofhingesatnotebooktopco
11、vercase/(a)Hinge/(b)topcovercaseand(c)flangesofhinge/2/Mechanicalpropertiesofmagnesiumcontentoflithiumincreases/ItisalsoobservfromFig/2(a)thatthecurvesofLZ91sheetatroomtemperatureandAZ31sheetat200/Careclosetoeachother/LZ101sheetatroomtemperatureexhibitsevenbetterductilitythanLZ91andAZ31doat200/C/Sin
12、cethecostoflithiumisveryexpensive/LZ91sheet/insteadofLZ101sheet/canbeconsideredasasuitableLZmagnesiumalloysheettorenderfavorableformabilityatroomtemperature/Forthisreason/thepresentstudyadoptedLZ91sheetastheblankforthenotebooktopcovercaseandattemptedtoexaminetheformabilityofLZ91atroomtemperature/Ino
13、rdertodetermineifthefracturewouldoccurinthefiniteelementanalysis/theforminglimitdiagramforthe0/6mmthickLZ91sheetwasalsoestablishedasshowninFig/2(b)/alloysheetsThetensiletestswereperformedformagnesiumlithiumalloysheetsofLZ61(lithium6%/zinc1%)/LZ91/andLZ101atroomtemperaturetocomparetheirmechanicalprop
14、ertiestothoseofAZ31sheetsatelevatedtemperatures/Fig/2(a)showsthestressstrainrelationsofLZsheetsatroomtemperatureandthoseofAZ31sheetsatbothroomtemperatureand200?C/Itisnotedthatthestressstraincurvetendstobelower/4Fig/2Mechanicalpropertiesofmagnesiumalloy/(a)Thestressstrainrelationsofmagnesiumalloy；(b)
15、forminglimitdiagram(FLD)ofLZ91sheet/3/ThefiniteelementmodelThetoolinggeometrieswereconstructedbyaCADsoftware/PRO/E/andwereconvertedintothefiniteelementmesh/asshowninFig/3(a)/usingthesoftwareDELTAMESH/Thetoolingwastreatedasrigidbodies/andthefour-nodeshellelementwasadoptedtoconstructthemeshforblank/Th
16、emateriallpropertiesandforminglimitdiagramsobtainedfromtheexperimentswereusedinthefiniteelementsimulations/Theothersimulationparametersusedintheinitialrunwere/punchvelocityof5mm/s/blank-holderforceof3kN/andCoulombfrictioncoefficientof0/1/ThefiniteelementsoftwarePAMSTAMPwasemployedtoperformtheanalysis/andthesimulationswereperformedonadesktopPC/Afiniteelementmodelwasfirstconstructedtoexaminetheoneoperationformingprocessofthehinge/Duetosymmetry/onlyonehalfofthetopcover
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