Numerical and experimental investigations on the formability of three-dimensional aluminum alloy sandwich panels with egg-box-like cores

Cai, Zhongyi; Liang, Xidong; Chen, Qing-Min; Zhang, Xi

doi:10.1007/s00170-018-2499-3

Cited by 13 publications

(2 citation statements)

References 28 publications

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“…However, for many applications such as rocket and high-speed train, AFSPs are required as 3D shells rather than 2D sheets [3,4]. Previous researches [5][6][7] showed that direct plastic forming is an efficient method for manufacturing 3D curved sandwich panels, and the study of Zhang et al [8] proved the good formability of AFSP in cylindrical panels forming. To further facilitate the applications of curved AFSPs, it is necessary to investigate the plastic forming of complex 3D surfaces of AFSPs.…”

Section: Introductionmentioning

confidence: 99%

Numerical Study on the Plastic Forming of Doubly Curved Surfaces of Aluminum Foam Sandwich Panel Using 3D Voronoi Model

Zhang

Chen

Gao

et al. 2021

Metals

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This paper presents a numerical investigation on the plastic forming of doubly curved surfaces of aluminum foam sandwich panel (AFSP). A mesoscopic 3D Voronoi model that can describe the structure of closed-cell aluminum foam relatively realistically was established, and a series of numerical simulations using the model of the sandwich panel with a Voronoi foam core were conducted on the plastic forming of two typical doubly curved surfaces including spherical and saddle-shaped surfaces of AFSPs to analyze the deformation behaviors and the forming defects in detail. Multi-point forming experiments of spherical and saddle-shaped AFSPs with different target radii were implemented and the doubly curved panels with good forming quality were obtained. The simulated results of the surface illumination maps, the face sheet profiles, and the maximum strain differences in selected areas of the face sheet and the experimental results indicated that the Voronoi AFSP model can reflect the actual defects occurred in the plastic forming of doubly curved sandwich panels, and the high forming accuracy of the sandwich panel model was also demonstrated in terms of the shape error and the thickness variation.

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Section: Introductionmentioning

confidence: 99%

Numerical Study on the Plastic Forming of Doubly Curved Surfaces of Aluminum Foam Sandwich Panel Using 3D Voronoi Model

Zhang

Chen

Gao

et al. 2021

Metals

Self Cite

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show abstract

“…Cai et al [2][3][4] conducted multi-point forming (MPF) experiments and finite element (FE) analysis on the egg-box-like sandwich panel to study the forming performance of the sandwich panel in the plastic forming process, where they obtained the conclusion that the forming performance of the egg-box-like sandwich panel is mainly affected by the defect model occurred in the plastic forming process and geometric parameters of sandwich panels. Subsequently, Cai et al [5] successfully formed a defect-free double-curvature eggshell sandwich panel with positive and negative Gaussian curvature through MPF experiments. Zhang et al [6,7] constructed a three-dimensional tetrakaidekahedral model, cubic-spherical, and three-dimensional Voronoi model to study the plastic forming of double-curvature aluminum foam sandwich panels.…”

Section: Introductionmentioning

confidence: 99%

Plastic Forming of Sandwich Panels and Numerical Analyses of the Forming Processes Based on Elastoplastic Equivalent Model

Chen

Wang

et al. 2021

Materials

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This paper studies the plastic forming of sandwich panels and proposes a universal elastoplastic equivalent method suitable for sandwich panels. To verify the generality of the equivalent method, according to the different core structures, the cores of bi-directional trapezoidal sandwich (BTS) panels and aluminum foam sandwich (AFS) panels are equated to orthotropic and isotropic (special orthotropic) single-layer panels respectively. Through the finite element (FE) numerical simulation of the mesoscopic model of the sandwich panel, the elastoplastic constitutive relationship of the equivalent core model is established, and then the macroscopic equivalent model of the sandwich panel is established. The FE numerical simulation of plastic forming was carried out for the mesoscopic model and equivalent model of BTS panel and AFS panel, and plastic forming experiments were conducted for the sandwich panel through a multi-point forming (MPF) test machine. The results show that the relative errors of the section average stress at the same position of the equivalent model and the mesoscopic model of sandwich panels are all within 4%; compared with the experimental results, the equivalent model of the sandwich panel has high forming accuracy and small shape error, which verifies the high accuracy and generality of the equivalent method. Moreover, using the sandwich panel equivalent model effectively reduces the calculation time of the numerical simulation.

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Numerical investigation on the plastic forming of aluminum foam sandwich panel based on three-dimensional mesoscopic and macroscopic models

Zhang

Cai

Liang

et al. 2020

Int J Adv Manuf Technol

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Numerical and experimental investigations on the formability of three-dimensional aluminum alloy sandwich panels with egg-box-like cores

Cited by 13 publications

References 28 publications

Numerical Study on the Plastic Forming of Doubly Curved Surfaces of Aluminum Foam Sandwich Panel Using 3D Voronoi Model

Numerical Study on the Plastic Forming of Doubly Curved Surfaces of Aluminum Foam Sandwich Panel Using 3D Voronoi Model

Plastic Forming of Sandwich Panels and Numerical Analyses of the Forming Processes Based on Elastoplastic Equivalent Model

Numerical investigation on the plastic forming of aluminum foam sandwich panel based on three-dimensional mesoscopic and macroscopic models

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