Effect of hydroforming process on the formability of fiber metal laminates using semi-cured preparation

Mirza

International Journal of Damage Mechanics

et al. 2022

Recently, hydroforming has paid dividends in composite forming due to its uniform pressure distribution, which helps in reducing the delamination defects. Considering the need to develop an appropriate criterion for evaluating the formability of FMLs, inspired by sheet metal forming and testing, the uniform pressure loading test was adopted to characterize the formability of semi-cured FMLs by forming limit curve ( FLC). In this paper, both theoretical analysis models considering and ignoring the tangential cohesive effect were established, and the stress expression of the critical zone was given. The results show that the tangential cohesive stress demonstrates a non-negligible influence on the FLC. A new form of comprehensive FLC was given by defining global equivalent strain and global strain ratio and analyzed by the finite element method. In addition, the numerical simulation model and the experimental parameters were verified. A simplified Hashin criterion was proposed and developed into the numerical simulation as a subroutine based on theoretical analysis. Parameters such as blank holder pressure, pressure rate, and temperature were considered both in experiments and simulation. Only fiber stretching damage was distinguished in the cross, single, and arc crack but no wrinkling. As predicted theoretically, a lower forming limit is expected when FMLs are subjected to greater tangential cohesive stress. Finally, with the help of numerical simulation, the influence of different boundary conditions on the comprehensive FLC was studied. Instead of a simple evaluation of FMLs, this comprehensive FLC could be used directly to optimize hydroforming processes in the engineering field.

Section: Uplt Methodsmentioning

confidence: 99%

Investigation into a comprehensive forming limit curve considering multi-parameters effects for semi-cured FMLs through uniform pressure loading test

Mirza

International Journal of Damage Mechanics

et al. 2022

Int J Adv Manuf Technol

“…Non-conventional blank holding techniques were studied by Wifi and Mosallam for the forming of 1mm thick Al-5182 blank and they found that a gap less than the total thickness of the blank successfully resulted in the elimination of wrinkles [28]. Lei li et.al found that a blank holder gap greater than laminate thickness results in wrinkling and found an optimized value of 1.15mm whereas the total thickness of laminate was 1.2mm [21]. Also, Blala et.…”

Section: Numerical Simulationmentioning

confidence: 99%

“…Blala et.al found that applying cavity pressure within the specified range had a good impact on the molded cup's quality and resulted in a greater depth [20]. Lei li et.al found that increment of cavity pressure reduced the delamination [21].…”

Section: Introductionmentioning

confidence: 99%

Numerical and experimental investigations on the effects of variable cavity pressure on the formability of GLARE using hydromechanical deep drawing

Tabasum

Lang

Mirza

et al. 2022

Self Cite

Excellent physical and mechanical properties of fiber metal laminates (FMLs) have made them a very popular and most suitable material to make high strength and lightweight products in different industries for example automobile, military, and aerospace. Glass fiber aluminum reinforced epoxy (GLARE) is one of the most used fiber metal laminate among the family of fiber metal laminates, but there are some challenges in its formability. Our study mainly focuses on the formability of the GLARE cup parts by using hydromechanical deep drawing. Forming depth with good quality (without any wrinkling, delamination, or fracture), failure mode analysis and wall thinning rate (%) distribution of the parts are the main criteria in the formability. The influence of variable cavity pressure (VCP) with respect to punch strokes had been investigated by using numerical simulations and experiments. Results showed that the variable cavity pressure in case of increasing or decreasing the cavity pressure had very much effect on the formability. Stepwise increasing the VCP with respect to punch strokes resulted in a maximum forming depth of 29.00mm as well as good quality whereas in the case of stepwise decreasing the variable cavity pressure, results were not encouraging.Commercially available code ABAQUS explicit was used for finite element analysis simulation which had shown close agreement with the experimental results.

“…The orientation of the fibres in relation to the successive layers of the FML determines the anisotropy or isotropy of the resultant composite [39,40]. Fibres used for their production can be continuous or discontinuous (staple fibres, whiskers) [41,42]. Numerous products made of single fibres, such as fabrics, mats, rovings, or preimpregnates [43,44], can also be used as reinforcement.…”

Section: Introductionmentioning

confidence: 99%

New Advances and Future Possibilities in Forming Technology of Hybrid Metal–Polymer Composites Used in Aerospace Applications

et al. 2021

Fibre metal laminates, hybrid composite materials built up from interlaced layers of thin metals and fibre reinforced adhesives, are future-proof materials used in the production of passenger aircraft, yachts, sailplanes, racing cars, and sports equipment. The most commercially available fibre–metal laminates are carbon reinforced aluminium laminates, aramid reinforced aluminium laminates, and glass reinforced aluminium laminates. This review emphasises the developing technologies for forming hybrid metal–polymer composites (HMPC). New advances and future possibilities in the forming technology for this group of materials is discussed. A brief classification of the currently available types of FMLs and details of their methods of fabrication are also presented. Particular emphasis was placed on the methods of shaping FMLs using plastic working techniques, i.e., incremental sheet forming, shot peening forming, press brake bending, electro-magnetic forming, hydroforming, and stamping. Current progress and the future directions of research on HMPCs are summarised and presented.