Warm Air Bending of AZ31B Sheets Based on an Online Local Contact Heating Method

Warm forming holds significant potential in shaping challenging materials due to its comprehensive advantages compared to cold and hot forming. Effective heating is crucial for precise warm forming processes. This study explored an innovative warm air bending technique employing an online local contact heating method. Heat transfer during the preheating stage and the air bending of AZ31B sheets were investigated through experiments and finite element analysis at temperatures ranging from room temperature (24 °C) to 250 °C, considering the thermomechanical coupling effect. The results indicate a significant increase in the bending center angle, advancing from 69.8 deg to more than 119 deg as the heating temperature rises from room temperature to 250 °C. Fractures were effectively eliminated when the sheet heating temperatures exceeded 150 °C. Simultaneously, as the localized heating temperature increases, a corresponding decrease in the rebound angle is observed, reducing from 10.6 deg to 2.3 deg. The findings validate the feasibility of warm air bending using online local contact heating in industrial applications, with regard to forming quality and production efficiency.