Ural Federal University named after the First President of Russia B. N. Yeltsin, Yekaterinburg, Russia¹ ; M. N. Mikheev Institute of Metal Physics at the Ural Branch of the Russian Academy of Sciences, Yekaterinburg, Russia²:

Yu. N. Loginov, Professor¹, Lead Researcher at the Department of Structural and Functional Alloys and Intermetallics at the Laboratory of Structural and Functional Materials², Doctor of Technical Science, e-mail: j.n.loginov@urfu.ru

Kamensk-Uralsky Metallurgical Works OJSC, Kamensk-Uralsky, Russia:
I. V. Snegirev, Process Person, e-mail: igor_snegirev@mail.ru

This paper considers some features related to the filling of a die bed contour when making embossed surface strips, with the opposite side of the parent sheet remaining flat. Such sheets are often used for interior and exterior design purposes. When the die bed contour is not filled up, it results in a misshaped final product. The finite element technique was used for the modelling purposes. The input data included the real mechanical properties of aluminium alloy AlMg3, which is frequently used for making embossed sheets. Relevant initial and boundary conditions were preset. The authors determined the strain degree distribution as the plastic layer is pressed into the die bed, with the die moving 1 and 2 mm. The plastic strain zones concentrated at the die bed corners may reach the value of 1.5 leading to an increased strength of the material. The paper shows the distribution of the displacement vector components. It is highlighted that the horizontal component has a local maximum located opposite to the point in which the horizontal surface of the die goes into the slope. The vertical stress was estimated that should be created at this process stage. It was found that a 200 MPa stress needs to be created to fill the die bed contour 1 mm (the height of the relief), and it needs to be 400 MPa for a 2 mm level. Explaining the above phenomenon contributes to the practical relevance of this research. The finite element modelling of the die bed contour being filled with metal indicates a nonuniform stress-strain state scenario that is realized in this case.

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