The influence of different compositions of fiber metal laminates on the fracture in the semi-solidified stamping forming

2020 ◽  
pp. 105678952095447
Author(s):  
Lei Li ◽  
Lihui Lang ◽  
Blala Hamza ◽  
Sergei Alexandrov ◽  
Shiyue Li
Keyword(s):  
Thickness Distribution ◽  
Process Condition ◽  
Middle Layer ◽  
Forming Limit ◽  
Fiber Metal Laminates ◽  
Specific Strength ◽  
Bonding Performance ◽  
Fiber Deformation ◽  
Fiber Metal ◽  
Small Parts

Fiber metal laminates (FMLs) are widely used in manufacturing due to the high specific strength, fatigue resistance, and lightweight. However, because of the deformation coordination of different layers of FMLs, challenges have been faced in rapid and small part forming. To research the feasibility of the fast forming of small parts using the FMLs, the influence of different compositions of FMLs on the stamping performance under the semi-solidified process condition was investigated, including the outer aluminum layer, the fiber lay-up direction in the middle layer, and the various states of the resin. Based on the results of Finite-element simulation and experiments, the semi-solidified process can improve the forming performance of FMLs by making the thickness distribution of the outer aluminum layers more uniform and preventing excessive fiber deformation. The coordination of fiber lay-up direction and interlayer forces can improve the forming limit height of semi-solidified FMLs. Besides, the fracture position of the cup part is related to the fiber lay-up direction and interfacial bonding performance in FMLs. This study provides necessary guidance for the rapid stamp forming of small parts using FMLs.

Formability Analysis of Fiber Metal Laminates with Different Core and Skin Layers by Stamping Process

2020 ◽  
Vol 982 ◽  
pp. 85-91
Author(s):  
Lei Li ◽  
Li Hui Lang ◽  
Blala Hamza ◽  
Sergei Alexandrov
Keyword(s):  
Complex Shape ◽  
Aerospace Industry ◽  
Skin Layer ◽  
Raw Material ◽  
Forming Limit ◽  
Fiber Metal Laminates ◽  
Specific Strength ◽  
Large Size ◽  
High Specific Strength ◽  
Fiber Metal

Fiber metal laminates (FMLs) are widely used in aerospace industry due to their unique high specific strength, fatigue resistance, corrosion resistance and other excellent characteristics. Thermosetting FMLs is generally used for forming large size parts and rarely used as raw material for producing small size and complex shape parts. This study attempts a methodology that stamping thermosetting FMLs to form cylinder shape parts before the curing process. The forming limit height of FMLs were analyzed by choosing different core materials, layup direction and skin layer thickness. And through the optimization of these variables, a better-quality part has been formed.

Multilayer and Fiber Metal Laminate Materials Hydro-Bulging

2018 ◽  
Vol 941 ◽  
pp. 1996-2005
Author(s):  
Ehsan Sherkatghanad ◽  
Li Hui Lang ◽  
Shi Chen Liu
Keyword(s):  
Thickness Distribution ◽  
Single Layer ◽  
Experimental Tests ◽  
Middle Layer ◽  
Composite Fiber ◽  
Advanced Materials ◽  
Carbon Cloth ◽  
Stress Strain ◽  
Aluminum Composite ◽  
Fiber Metal

Advanced materials such as aluminum alloys and composites offer great potential for weight reduction applications in automotive and aerospace vehicles construction. In order to investigate the feasibility of using such materials in the form of laminates, sheet bulging with single-layer aluminum and the aluminum/Composite laminate with the carbon cloth as the middle layer is investigated under uniform liquid pressure conditions. The aluminum sheet stress-strain, wall thickness distribution, carbon fiber radius stress-strain distribution and the effect of die entrance radius etc. are discussed and compared in details. FE results validate that the numerical method can predict the same fracture regions for bulging-blank as observed in experimental tests. Furthermore, the study validates that multi-layer sheet hydro-bulging process with composite fiber as a middle layer is not feasible to form laminates due to rupture of composite fibers near edge regions. Further study is needed to improve the methodology.

Influencing Factors of AZ31B Sheet Deep Drawing

2011 ◽  
Vol 189-193 ◽  
pp. 88-91
Author(s):  
Jun Gao ◽  
Zhen Ming Yue ◽  
Shu Xia Lin
Keyword(s):  
Numerical Simulation ◽  
Deep Drawing ◽  
Experimental Approach ◽  
Elevated Temperatures ◽  
Heating Temperature ◽  
Thickness Distribution ◽  
Simulation Software ◽  
Forming Limit ◽  
Forming Process ◽  
Specific Strength

Magnesium alloys have been attracting much more attentions due to its low density, high specific strength and its lightweight during the past 30 years. In this paper, the deep drawing performance of AZ31B magnisium alloy sheets at elevated temperature was studied by the experimental approach. The results indicated that the formability of the AZ31B sheets at elevated temperatures could be improved significantly. The best external forming parameters can be obtained such as heating temperature of sheet, die-punch clearance, punch fillet radius, etc. Simulating the forming process by using the numerical simulation software, we investigated the stress-strain distribution, thickness distribution and forming limit, etc. The thickness distribution by the numerical simulation agrees well with the experimental results.

scholarly journals Formability study and metallurgical properties analysis of FSWed AA 6061 blank by the SPIF process

2021 ◽  
Vol 3 (3) ◽  
Author(s):  
Payam Tayebi ◽  
Ali Fazli ◽  
Parviz Asadi ◽  
Mahdi Soltanpour
Keyword(s):  
Base Metal ◽  
Strain Distribution ◽  
Thickness Distribution ◽  
Experimental Studies ◽  
Welding Process ◽  
Forming Limit ◽  
Forming Process ◽  
Friction Stir ◽  
Numerical Process ◽  
Tailor Welded Blank

AbstractIn this study, in order to obtain the maximum possible formability in tailor-welded blank AA6061 sheets connected by the friction stir welding (FSW) procedure, the incremental sheet forming process has been utilized. The results are presented both numerically and experimentally. To obtain the forming limit angle, the base and FSWed sheets were formed in different angles with conical geometry, and ultimately, the forming limit angle for the base metal and FSWed sheet is estimated to be 60° and 57.5°, respectively. To explore the effects of welding and forming procedures on AA6061 sheets, experimental studies such as mechanical properties, microstructure and fracture analysis are carried out on the samples. Also, the thickness distribution of the samples is studied to investigate the effect of the welding process on the thickness distribution. Then, the numerical process was simulated by the ABAQUS commercial software to study the causes of the FSWed samples failure through analyzing the thickness distribution parameter, and major and minor strains and the strain distribution. Causes of failure in FSWed samples include increased minor strain, strain distribution and thickness distribution in welded areas, especially in the proximity of the base metal area.

Optimization of Tube Hydroforming Process Using Probabilistic Constraints on Failure Modes

2011 ◽  
Vol 62 ◽  
pp. 21-35 ◽  
Author(s):  
Anis Ben Abdessalem ◽  
A. El Hami
Keyword(s):  
Failure Modes ◽  
High Reliability ◽  
Thickness Distribution ◽  
Tube Hydroforming ◽  
Forming Limit Diagram ◽  
Plastic Instability ◽  
Probabilistic Constraints ◽  
Forming Limit ◽  
Reliability Based Design ◽  
Hydroforming Process

In metal forming processes, different parameters (Material constants, geometric dimensions, loads …) exhibits unavoidable scatter that lead the process unreliable and unstable. In this paper, we interest particularly in tube hydroforming process (THP). This process consists to apply an inner pressure combined to an axial displacement to manufacture the part. During the manufacturing phase, inappropriate choice of the loading paths can lead to failure. Deterministic approaches are unable to optimize the process with taking into account to the uncertainty. In this work, we introduce the Reliability-Based Design Optimization (RBDO) to optimize the process under probabilistic considerations to ensure a high reliability level and stability during the manufacturing phase and avoid the occurrence of such plastic instability. Taking account of the uncertainty offer to the process a high stability associated with a low probability of failure. The definition of the objective function and the probabilistic constraints takes advantages from the Forming Limit Diagram (FLD) and the Forming Limit Stress Diagram (FLSD) used as a failure criterion to detect the occurrence of wrinkling, severe thinning, and necking. A THP is then introduced as an example to illustrate the proposed approach. The results show the robustness and efficiency of RBDO to improve thickness distribution and minimize the risk of potential failure modes.

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