Analysis of the forming behaviour of in-situ drawn sandwich sheets
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Analysis of the forming behaviour of in-situ drawn sandwich sheets. / Mennecart, Thomas; Hiegemann, Lars; Ben Khalifa, Noomane.
In: Procedia Engineering, Vol. 207, 01.01.2017, p. 890-895.Research output: Journal contributions › Conference article in journal › Research › peer-review
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TY - JOUR
T1 - Analysis of the forming behaviour of in-situ drawn sandwich sheets
AU - Mennecart, Thomas
AU - Hiegemann, Lars
AU - Ben Khalifa, Noomane
N1 - International Conference on the Technology of Plasticity, ICTP 2017; Hucisko; United Kingdom; 17 September 2017 through 22 September 2017; Code 137838
PY - 2017/1/1
Y1 - 2017/1/1
N2 - One way to produce metal fibre-reinforced plastic-metal sandwich parts is to inject the polymer between the sheets during deep drawing. A new process has been designed in which parts with an interlayer of glas fibres including a thermoplastic matrix and two metallic sheets can be produced by combining deep drawing and thermoplastic-resin transfer moulding (T-RTM). With the possibility of forming sandwich sheets with a wide range of states of the interlayers' viscosity and due to the polymerisation of the monomers between the sheets, the process combines a lot of advantages but also faces challenges due to the viscous fluid interlayer being hindered from squeezing out. This contribution analyses the dependency of the interlayer on the forming behaviour of the sheets in this process. When forming circular cups with aluminium (AA5182) sheets and a viscous interlayer of different heights, the effect of bulging could be observed which affects a free formed shape during forming. The viscous interlayer does not remain at the same position during forming which leads to an inhomogeneous total blank thickness of the part. In experiments and FE simulations a shape with bulged zones could be observed. An analytical approach for the prediction of these bulge heights has been developed so that both bulge dome heights could be predicted analytically. This approach is verified by experiments and numerical simulations. The results serve to set the process window for the in-situ hybridisation method in which the starting point of injection, volume fraction of the thermoplastic matrix in the fibres, mechanical properties of the materials, and geometrical parameters can be adjusted so that this effect is reduced.
AB - One way to produce metal fibre-reinforced plastic-metal sandwich parts is to inject the polymer between the sheets during deep drawing. A new process has been designed in which parts with an interlayer of glas fibres including a thermoplastic matrix and two metallic sheets can be produced by combining deep drawing and thermoplastic-resin transfer moulding (T-RTM). With the possibility of forming sandwich sheets with a wide range of states of the interlayers' viscosity and due to the polymerisation of the monomers between the sheets, the process combines a lot of advantages but also faces challenges due to the viscous fluid interlayer being hindered from squeezing out. This contribution analyses the dependency of the interlayer on the forming behaviour of the sheets in this process. When forming circular cups with aluminium (AA5182) sheets and a viscous interlayer of different heights, the effect of bulging could be observed which affects a free formed shape during forming. The viscous interlayer does not remain at the same position during forming which leads to an inhomogeneous total blank thickness of the part. In experiments and FE simulations a shape with bulged zones could be observed. An analytical approach for the prediction of these bulge heights has been developed so that both bulge dome heights could be predicted analytically. This approach is verified by experiments and numerical simulations. The results serve to set the process window for the in-situ hybridisation method in which the starting point of injection, volume fraction of the thermoplastic matrix in the fibres, mechanical properties of the materials, and geometrical parameters can be adjusted so that this effect is reduced.
KW - Engineering
KW - Deep drawing
KW - Hybridisation
KW - Sandwich-sheets
UR - http://www.scopus.com/inward/record.url?scp=85036630522&partnerID=8YFLogxK
U2 - 10.1016/j.proeng.2017.10.847
DO - 10.1016/j.proeng.2017.10.847
M3 - Conference article in journal
AN - SCOPUS:85036630522
VL - 207
SP - 890
EP - 895
JO - Procedia Engineering
JF - Procedia Engineering
SN - 1877-7058
ER -