Spring Back Investigations in Aluminium and Stainless-Steel Sheets Sudhy S. Panicker, K. Jithesh, P.V. Sivaprasad, Priyaranjan Sharma, Vinay Varghese International Journal of Vehicle Structures and Systems, 2023 Sheet metal forming is a process where pieces of sheet metal are modified to their geometry rather than removing any materials. Major problems in sheet metal forming operations are the spring back effect and the deformation errors. Spring back is a very complicated behaviour and is not easy to predict through the mathematical models. It can only be controlled and minimised but quite difficult to be eliminated. Different types of materials used for sheet metal forming are aluminium and mild steel for its deformation capabilities and other properties. In this work, an experimental investigation of spring back of aluminium and stainless-steel sheets with two different thicknesses is carried out using V bending machine under dry and wet environment. The grid analysis method will be used for stress-strain deformation analysis and a stress vs strain graph will be plotted. A Taguchi based optimization technique is carried out to find optimum parameter combination and analysis of variance (ANOVA) to find the most significant factor.
Experimental and numerical studies on the formability of AA5754 and AA6082 thin sheets in nonisothermal warm redrawing process Sudhy S Panicker, Sushanta Kumar Panda Proceedings of the Institution of Mechanical Engineers Part L Journal of Materials Design and Applications, 2022 The present work demonstrates a comparative investigation of the nonisothermal warm forward redrawing behavior of AA5754-H22 and AA6082-O sheets. The design and development of a new warm forward redrawing process was demonstrated. The complete redrawing was obtained by keeping the redrawing die and binder at 200 °C and cooling punch near to room temperature using water circulation. This process improved the thickness and surface strain distribution in redrawn cups without the onset of strain localization at the bottom corner. A thermomechanical finite element (FE) model of the nonisothermal warm redrawing process was developed applying the temperature-dependent Barlat-89 yield criterion and the Cowper–Symonds strain rate sensitive hardening model. The FE model reasonably predicted the part depth, earing development, thickness distribution, and surface strain evolution of the redrawn cups. The evolution of temperature distribution within the redrawing cup during the process was captured from FE simulations, and its role in the improvement in redrawing depth was demonstrated. Furthermore, the post-forming characterization of redrawn cup wall was also evaluated by microhardness and ring hoop tensile tests. It was found that the hardness, hoop tensile strength, and energy absorption capacity of AA5754-H22 cups were better than AA6082-O cups.
Mechanical properties, springback, and formability of W-temper and peak aged 7075 aluminum alloy sheets: Experiments and modeling Yumi Choi, Jinwoo Lee, Sudhy S. Panicker, Hong-Kyo Jin, Sushanta Kumar Panda, Myoung-Gyu Lee International Journal of Mechanical Sciences, 2020 High strength aluminum alloys have drawn much attention as the requirement for lightweight vehicle design increases in the automotive industry. However, inferior formability due to higher strength poses a technical hurdle against successful application of high strength aluminum sheets in automotive components. In this study, the mechanical properties of 7075 aluminum alloy sheet after W-temper heat treatment, which consists of solution heat treatment and subsequent quenching, are investigated. Detailed experimental and numerical studies are conducted on the anisotropy, non-proportional deformation behavior, and corresponding constitutive modeling in comparison with the corresponding characteristics of peak aged T6 heat-treated as-received alloy sheets. Based on the experimentally characterized mechanical properties and associated constitutive laws, the formability and springback of the W-tempered sheet are analyzed using the Marciniak–Kuczyinski forming limit diagram and U-draw bending springback simulations, respectively, by employing the Yld2000-2d anisotropic yield function and distortional hardening-based homogeneous anisotropic hardening model. Additionally, the improved constitutive modeling of the W-tempered 7075 aluminum sheets due to the effect of serrated flow characteristics on the hardening and frictional behaviors is discussed.
Warm redrawing of AA6082 sheets and investigations into the effect of aging heat treatment on cup wall strength S.S. Panicker, K.S. Prasad, G. Sawale, S. Hazra, B. Shollock, S.K. Panda Materials Science and Engineering A, 2019 In this work, novel warm deep drawing and redrawing test setups were designed and developed, and a process sequence was proposed to enhance the forming depth of AA6082 sheet. The complete redrawing of the cup was ensured by maintaining the temperature of redrawing die and binder at 200 °C and water-circulated cooling punch near to room temperature. The warm redrawing negated the sudden thinning and strain localization at cup corner, producing an overall draw ratio of 3.38. Further, the fully redrawn cups were subjected to solution heat treatment (SHT) and subsequent different artificial aging cycle to evaluate the impact on post-forming strength. The post-forming cup wall strength was characterized using Vickers microhardness test and ring hoop tensile test (RHTT). Approximately 30% improvement in microhardness of redrawn cup wall was obtained as compared to that of the undeformed sheet, and it was due to the significant grain refinement occurred during the warm deep drawing and subsequent redrawing process as characterized by SEM and EBSD techniques. Moreover, it was observed that the heat treatment had a pronounced effect on both the hardness and ultimate hoop tensile strength of the cup wall, and the peak aged cup wall hardness and tensile strength were 119 VHN and 316.8 MPa, respectively. As verified by TEM micrographs, the precipitation of coherent large needle-shaped β′′ precipitate was responsible for the significant improvement in the strength during the aging treatment. However, the presence of plate-shaped incoherent β-Mg2Si precipitate marginally decreased the total elongation at peak aged condition. Finally, the fractographs of redrawn and different artificially aged RHTT samples were analyzed to comprehend the nature of failure.
Investigations into Improvement in Formability of AA5754 and AA6082 Sheets at Elevated Temperatures Sudhy S. Panicker, Sushanta Kumar Panda Journal of Materials Engineering and Performance, 2019 Warm forming is an attractive formability improvement technique which can be utilized to intensify the usage of aluminum alloy sheets in autobody constructions. In the present work, laboratory-scale stretch forming and deep drawing experiments were performed to demonstrate the comparative formability improvement in AA6082-O and AA5754-H22 aluminum alloy sheets at elevated temperatures. Significant enhancement of limiting dome height and forming limit diagram (FLD) was observed when stretch forming was performed at 200 °C. Warm deep drawing under both isothermal and nonisothermal conditions was carried out, and drastic improvement in drawability was found only under nonisothermal condition with an initial temperature gradient of 93 °C across the blank. Thermomechanical finite element (FE) models of the warm forming processes were developed using temperature-dependent Barlat-89 yield model coupled with Cowper–Symonds strain rate sensitivity model. The limiting dome heights, failure locations and strain distributions were well predicted by implementing experimental FLD as the failure criterion. Further, the effect of evolution of nonisothermal temperature gradient on the improvement in drawability of both the materials was analyzed in terms of cup height, earing profile, thickness distribution and surface strain evolution.
Effect of W-Tempering on the Formability of Dissimilar Friction Stir Tailor-Welded AA7075/AA5083 Sheets AE Alex, RR Rao, BS Katiyar, SS Panicker Transactions of the Indian Institute of Metals 79 (6), 100 , 2026 2026
Effect of Material Modeling on Prediction of Isothermal Formability of AA6082-O Sheet at Elevated Temperature SS Panicker, S Basak Applied Mechanics and Materials 925, 51-57 , 2025 2025
Crushing performance of AA5754 and AA6082 shells fabricated by warm redrawing process BS Katiyar, SS Panicker, SK Panda Journal of materials engineering and performance 33 (17), 9244-9254 , 2024 2024 Citations: 3
Spring Back Investigations in Aluminium and Stainless-Steel Sheets. SS Panicker, K Jithesh, PV Sivaprasad, P Sharma, V Varghese International Journal of Vehicle Structures & Systems (IJVSS) 15 (6) , 2023 2023 Citations: 1
Springback in Tailor Welded Blanks Using a Heuristic Approach SS Panicker, H Krishnaswamy, N Chakraborti Springback Assessment and Compensation of Tailor Welded Blanks, 93-140 , 2022 2022
Study of Dual Pulse Gas Metal Arc Welding Process Characteristics on IS 2062 Steel M Arunkumar, PA Kumar, S Sampreeth, SS Panicker Materials Today: Proceedings , 2022 2022 Citations: 13
Experimental and numerical studies on the formability of AA5754 and AA6082 thin sheets in nonisothermal warm redrawing process SS Panicker, SK Panda Proceedings of the Institution of Mechanical Engineers, Part L: Journal of … , 2022 2022 Citations: 4
Nonisothermal Warm Deep Drawing Behavior of Automotive Grade Aluminum Alloy Sheets SS Panicker, SK Panda IOP Conference Series: Materials Science and Engineering 1132 (1), 012006 , 2021 2021
Investigations on Joining of High Density Poly Ethylene Sheets using Resistance Welding Technique K Pradeep, SS Panicker, K Panneerselvam, P Asokan IOP Conference Series: Materials Science and Engineering 1132 (1), 012001 , 2021 2021
Mechanical, Metallurgical and Corrosion Properties of Dual Pulsed, Pulsed Gas and Shielded Metal Arc Welded AISI 310 Austenitic Stainless Steel M Arunkumar, SS Panicker, P Aneesh Kumar, K Devakumaran IOP Conference Series: Materials Science and Engineering 1132 (1), 012028 , 2021 2021 Citations: 2
Mechanical properties, springback, and formability of W-temper and peak aged 7075 aluminum alloy sheets: Experiments and modeling Y Choi, J Lee, SS Panicker, HK Jin, SK Panda, MG Lee International Journal of Mechanical Sciences 170, 105344 , 2020 2020 Citations: 157
Warm redrawing of AA6082 sheets and investigations into the effect of aging heat treatment on cup wall strength SS Panicker, KS Prasad, G Sawale, S Hazra, B Shollock, SK Panda Materials Science and Engineering: A 768, 138445 , 2019 2019 Citations: 21
Investigations into improvement in formability of AA5754 and AA6082 sheets at elevated temperatures SS Panicker, SK Panda Journal of Materials Engineering and Performance 28 (5), 2967-2982 , 2019 2019 Citations: 23
Warm Forming of Aluminium Alloy Sheets and Formability Improvement in Nonisothermal Redrawing Process SS Panicker IIT Kharagpur , 2019 2019
Failure Prediction and Forming Behavior of AA5754 Sheets at Warm Temperature SS Panicker, K Bandyopadhyay, SK Panda All India Manufacturing Technology, Design and Research conference, 53-65 , 2018 2018 Citations: 1
Constitutive Behavior and Deep Drawability of Three Aluminum Alloys Under Different Temperatures and Deformation Speeds SS Panicker, KS Prasad, S Basak, SK Panda Journal of Materials Engineering and Performance , 2017 2017 Citations: 32
Improvement in Material Flow During Nonisothermal Warm Deep Drawing of Nonheat Treatable Aluminum Alloy Sheets SS Panicker, SK Panda ASME Journal of Manufacturing Science and Engineering 139 (3), 031013-031013-8 , 2017 2017 Citations: 20
Improvement in Material Flow During Non-Isothermal Warm Deep Drawing of Non-Heat Treatable Aluminum Alloy Sheets SS Panicker, SK Panda International Manufacturing Science and Engineering Conference 49897 … , 2016 2016 Citations: 2
Characterization of tensile properties, limiting strains, and deep drawing behavior of AA5754-H22 sheet at elevated temperature SS Panicker, HG Singh, SK Panda, R Dashwood Journal of Materials Engineering and Performance 24 (11), 4267-4282 , 2015 2015 Citations: 49
Formability analysis of AA5754 alloy at warm condition: appraisal of strain rate sensitive index SS Panicker, SK Panda Materials Today: Proceedings 2 (4-5), 1996-2004 , 2015 2015 Citations: 15
MOST CITED SCHOLAR PUBLICATIONS
Mechanical properties, springback, and formability of W-temper and peak aged 7075 aluminum alloy sheets: Experiments and modeling Y Choi, J Lee, SS Panicker, HK Jin, SK Panda, MG Lee International Journal of Mechanical Sciences 170, 105344 , 2020 2020 Citations: 157
Characterization of tensile properties, limiting strains, and deep drawing behavior of AA5754-H22 sheet at elevated temperature SS Panicker, HG Singh, SK Panda, R Dashwood Journal of Materials Engineering and Performance 24 (11), 4267-4282 , 2015 2015 Citations: 49
Constitutive Behavior and Deep Drawability of Three Aluminum Alloys Under Different Temperatures and Deformation Speeds SS Panicker, KS Prasad, S Basak, SK Panda Journal of Materials Engineering and Performance , 2017 2017 Citations: 32
Investigations into improvement in formability of AA5754 and AA6082 sheets at elevated temperatures SS Panicker, SK Panda Journal of Materials Engineering and Performance 28 (5), 2967-2982 , 2019 2019 Citations: 23
Warm redrawing of AA6082 sheets and investigations into the effect of aging heat treatment on cup wall strength SS Panicker, KS Prasad, G Sawale, S Hazra, B Shollock, SK Panda Materials Science and Engineering: A 768, 138445 , 2019 2019 Citations: 21
Improvement in Material Flow During Nonisothermal Warm Deep Drawing of Nonheat Treatable Aluminum Alloy Sheets SS Panicker, SK Panda ASME Journal of Manufacturing Science and Engineering 139 (3), 031013-031013-8 , 2017 2017 Citations: 20
Formability analysis of AA5754 alloy at warm condition: appraisal of strain rate sensitive index SS Panicker, SK Panda Materials Today: Proceedings 2 (4-5), 1996-2004 , 2015 2015 Citations: 15
Study of Dual Pulse Gas Metal Arc Welding Process Characteristics on IS 2062 Steel M Arunkumar, PA Kumar, S Sampreeth, SS Panicker Materials Today: Proceedings , 2022 2022 Citations: 13
Experimental and numerical studies on the formability of AA5754 and AA6082 thin sheets in nonisothermal warm redrawing process SS Panicker, SK Panda Proceedings of the Institution of Mechanical Engineers, Part L: Journal of … , 2022 2022 Citations: 4
Crushing performance of AA5754 and AA6082 shells fabricated by warm redrawing process BS Katiyar, SS Panicker, SK Panda Journal of materials engineering and performance 33 (17), 9244-9254 , 2024 2024 Citations: 3
Mechanical, Metallurgical and Corrosion Properties of Dual Pulsed, Pulsed Gas and Shielded Metal Arc Welded AISI 310 Austenitic Stainless Steel M Arunkumar, SS Panicker, P Aneesh Kumar, K Devakumaran IOP Conference Series: Materials Science and Engineering 1132 (1), 012028 , 2021 2021 Citations: 2
Improvement in Material Flow During Non-Isothermal Warm Deep Drawing of Non-Heat Treatable Aluminum Alloy Sheets SS Panicker, SK Panda International Manufacturing Science and Engineering Conference 49897 … , 2016 2016 Citations: 2
Spring Back Investigations in Aluminium and Stainless-Steel Sheets. SS Panicker, K Jithesh, PV Sivaprasad, P Sharma, V Varghese International Journal of Vehicle Structures & Systems (IJVSS) 15 (6) , 2023 2023 Citations: 1
Failure Prediction and Forming Behavior of AA5754 Sheets at Warm Temperature SS Panicker, K Bandyopadhyay, SK Panda All India Manufacturing Technology, Design and Research conference, 53-65 , 2018 2018 Citations: 1
Effect of W-Tempering on the Formability of Dissimilar Friction Stir Tailor-Welded AA7075/AA5083 Sheets AE Alex, RR Rao, BS Katiyar, SS Panicker Transactions of the Indian Institute of Metals 79 (6), 100 , 2026 2026
Effect of Material Modeling on Prediction of Isothermal Formability of AA6082-O Sheet at Elevated Temperature SS Panicker, S Basak Applied Mechanics and Materials 925, 51-57 , 2025 2025
Springback in Tailor Welded Blanks Using a Heuristic Approach SS Panicker, H Krishnaswamy, N Chakraborti Springback Assessment and Compensation of Tailor Welded Blanks, 93-140 , 2022 2022
Nonisothermal Warm Deep Drawing Behavior of Automotive Grade Aluminum Alloy Sheets SS Panicker, SK Panda IOP Conference Series: Materials Science and Engineering 1132 (1), 012006 , 2021 2021
Investigations on Joining of High Density Poly Ethylene Sheets using Resistance Welding Technique K Pradeep, SS Panicker, K Panneerselvam, P Asokan IOP Conference Series: Materials Science and Engineering 1132 (1), 012001 , 2021 2021
Warm Forming of Aluminium Alloy Sheets and Formability Improvement in Nonisothermal Redrawing Process SS Panicker IIT Kharagpur , 2019 2019
