In mould decoration (IMD) is attractive because a fully, or partially, decorated component is produced directly from the moulding process, with reduced emissions at lower process costs when compared to traditional techniques. A new IMD process has been developed to produce a painted component direct from the injection moulding tool. This incorporates the pressure spraying of thermoset powders through a valve into a closed mould. The residual heat of the tool initially softens the thermoset. The high temperature of thermoplastic polymer injected in a standard injection moulding subsequently cures the thermoset. The resultant product combines both thermoplastic and thermoset in a single injection moulding cycle. This paper presents frames from high speed video capture of powder mould filling and the results of INSPIRE (in mould spray painting, impact reduced on the environment) initial injection moulding using thermoset polyester and acrylonitrile butadiene styrene (ABS). The parameters that affect material distribution are examined and discussed. Similarities to the coinjection moulding process are noted.
2 Jaguar Land Rover, UK AB STRACT: During sheet metal forming, one of the major measures of success for the material is to show forming strains below the safe limit of a forming limit curve (FLC) and to show minimum thinning in critical areas in the for ming die. To understand this behaviour, tensile tests and 7 point FLC tests were conducted to evaluate the forming limit of the alloy using Instron and Erichsen machines respectively. This paper presents the outcome of investigations into the forming characteristics of different thickness of aluminium 6xxx series alloys with T4 and T6 temper and compares them to results obtained from previously published investigations . Metallographic analyses were also conducted on these alloys in order to correlate the microstructure with the observed forming behaviour. The results presented indicate how both material thickness and tempering treatment affect the for ming limit of the material. INTRO DUCTIO NWith growing attention being given to the need for climate protection, the impetus for light weight vehicles with improved fuel efficiency to meet industry CO 2 emission targets has increased considerably. This has led to a growing demand for light weight alloys with higher strength and good formability characteristics. As a consequence, new aluminium alloys are being developed for use in automotive exterior and structural applications due to their light weight and high strength -to -weight ratio. This has led to a greater need for an understanding of the formability behaviour of these alloys in order to maintain the high level of dimensional stability and manufa cturing efficiency required [1-4]. The P remium Vehicle Lightweight Technology (P VLT) Centre of Excellence, established within WMG at the University of Warwick in conjunction with Jaguar Land Rover and a number of tier 1 suppliers from the metal for ming industry is being funded by AWM (Advantage West Midlands) and ERDF (European Regional Development Fund) to gain a greater understanding of these issues. The aluminium alloys widely used for automotive applications include 2xxx, 5xxx, 6xxx and 7xxx series. 5xxx series alloys are Al-Mg alloys which are non heattreatable and used as structural parts in automotive applications. 6xxx series aluminium alloys, which are Al-Mg-Si based alloys are used mainly for skin application although are beginning to be used structurally due to their higher strength in -service when compared to 5xxx series alloys and other age hardening alloy series such as 2xxx and 6xxx. The alloys also have good weldability, higher corrosion resistance and lower stress-corrosion cracking [5]. A for ming limit curve defines the different load conditions a material experiences during sheet metal for ming and thus provides a reliable tool for analysing the major and minor strains during sheet forming. It is known that a single FLC is valid for only one alloy, temper and gauge combination [6]. P revious work done by Barlat and Vasudevan on for ming limit studies of two aged condition (one underaged and a...
A pilot study has been carried out to examine the effect of specimen dimensions on the obtained tensile properties of aluminium and steel sheet. The materials used were DP600 grade steel and AA5754 grade aluminium sheet. Four types of dog-bone samples with varying dimensions were tested for both materials. Standard tensile test procedures were performed using a universal test machine together with contacting extensometry. The GOM Aramis photogrammetric 2D strain mapping technique was also applied. The results suggest that for both steel and aluminium sheet materials, differing specimen dimensions have little effect on the obtained mechanical properties. Depending on the gauge length of extensometer chosen and the position at where necking occurred on the sample, the extensometry results and 2D strain mapping results slightly differed towards to the end of stress-strain curve. The failure mode between the chosen grades of steel and aluminium samples was observed to differ, as did the percentage of failures that occurred within the gauge length. All steel samples fractured across the specimen perpendicularly to the test direction; whilst fracture of aluminium samples occurred approximately 30 degrees from the perpendicular.
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