A review on forming techniques for manufacturing lightweight complex—shaped aluminium panel components

Zheng, Kailun; Politis, Denis J.; Wang, Liliang; Lin, Jianguo

doi:10.1016/j.ijlmm.2018.03.006

Cited by 160 publications

(93 citation statements)

References 151 publications

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“…Aluminium alloys are difficult to deform in conditions of conventional sheet metal formation using rigid tools. As ISF is a die-less process, a higher value of sheet deformation may be achieved [ 35 ] than that with die forming.…”

Section: Resultsmentioning

confidence: 99%

Strength Analysis of a Rib-Stiffened GLARE-Based Thin-Walled Structure

et al. 2020

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This paper presents a new product, a glass laminate aluminium-reinforced epoxy (GLARE)-based thin-walled structure with a stiffener in the form of a longitudinal rib. The stiffening rib in an outer metallic layer of a GLARE-based panel was fabricated by the incremental sheet forming technique and Alclad 2024-T3 aluminium alloy sheets were used as adherends. The strength properties of the adhesive joint between the layers of the fibre metal laminates (FMLs) were determined in a uniaxial tensile test, peel drum test, tensile/shear test and short-beam three-point-bending test. Two variants of FMLs were considered, with an adhesive film and without an adhesive film between the adherends and the epoxy/glass prepreg. The FMLs were tested at three different temperatures that corresponded to those found under real aircraft operating conditions, i.e., −60 °C, room temperature and +80 °C. It was found that the temperatures do not affect the tensile strength and shear strength of the FMLs tested. However, there was a noticeable increase in the stiffness of samples stretched at reduced temperature. An additional adhesive film layer between the adherends and the glass/epoxy prepreg significantly improves the static peeling strength of the joint both at reduced and at elevated temperatures. A clear increase in the critical force at which buckling occurs has been clearly demonstrated in the uniaxial compression test of GLARE-based rib-stiffened panels. In the case of GLARE-based rib-stiffened panels, the critical force averaged 15,370 N, while for the non-embossed variant, it was 11,430 N, which translates into a 34.5% increase in critical force.

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Section: Resultsmentioning

confidence: 99%

Strength Analysis of a Rib-Stiffened GLARE-Based Thin-Walled Structure

et al. 2020

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“…In 2012, an average aluminum content of about 140 kg was registered for European cars, 26 kg of which in the car body (hoods, doors, fenders, bumpers, and interiors) [2]. The use of Al-alloys for BIW is more and more investigated for the production of lighter vehicles [3] and the increasing interest in the use of aluminum alloy in this field is confirmed by recent reviews on forming [4] and joining [5] of Al-alloys for automotive applications. Lightweight aluminum sheets are being used for automotive applications due to a number of benefits: they offer high potential weight saving, improve vehicle fuel efficiency, and reduce the total greenhouse gas emission throughout the life of the vehicle [6].…”

Section: Introductionmentioning

confidence: 99%

“…Moreover, aluminum alloy sheets can meet important requirements of the BIW such as strength (e.g., structural stability and durability, dent resistance, crashworthiness), good formability, joining rers is nowadays the weight and satisfy the international (BIW) vehicle structure, for a roduction community, about teel ones. In 2012, an average 6 kg of which in the car body ys for BIW is more and more asing interest in the use of rming [4] and joining [5] of re being used for automotive ight saving, improve vehicle out the life of the vehicle [6]. of the BIW such as strength ss), good formability, joining…”

Section: Introductionmentioning

confidence: 99%

High Strain Rate Behavior of Aluminum Alloy for Sheet Metal Forming Processes

Ubertalli

Matteis

Ferraris

et al. 2020

Metals

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Aluminum alloy sheets are gaining increasing interest in the construction of some or all components of the car body in view of their lightweight properties which can allow significant fuel consumption reduction. In order to be suitable for car body application, aluminum alloy sheets should have sufficient mechanical properties both in static (e.g., structural stability and durability) and dynamic conditions (e.g., crash test). Static and dynamic mechanical tests (strain rates: ε ˙ ≈ 1 × 10−3 s−1 and ε ˙ ≈ 5 × 102 s−1 respectively) were conducted on AA6016 alloy sheet (1 mm thick), in T4 and T6 temper and for the longitudinal, transverse, and diagonal rolling directions by means of standard static tensile test and modified Hopkinson bar dynamic tests. Microstructural and fracture morphology observations are also reported. The results show that the ultimate tensile strength increases by 13−14%, and the elongation at fracture increases by 75−105%, depending on the temper, by increasing the strain rate.

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“…However, as aluminum hot stamping process was conducted at elevated temperatures, more obvious complexity can be observed during experiments compared with cold stamping [6]. The influence of forming temperatures on formability should be specially considered in the evaluation of aluminum hot stamping formability [7,8]. Therefore, this study focused on the behavior and modeling of forming limits of AA7075 sheet at elevated temperatures.…”

Section: Introductionmentioning

confidence: 99%

Behaviors and modeling of thermal forming limits of AA7075 aluminum sheet

Xiao

Wang

2020

Archiv.Civ.Mech.Eng

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The aluminum hot stamping process has been widely studied to produce lightweight parts in automobile industry. As forming limit of aluminum sheet at elevated temperatures plays a vital role in judging stamping formability, this study aims at experimentally investigating the forming limits and establishing a constitutive model to predict them. In this study, isothermal deformation test (Nakajima test) of AA7075 was conducted to determine its forming limits at temperatures of 300-450 °C and stamping speeds of 13-40 mm/s. Based on the experimental results, a constitutive model considering continuum damage mechanics was established to predict the forming limits under different deformation conditions. It was found that the formability of the material is best at 400 °C, and a higher strain rate can improve formability slightly. The comparisons between model predictions and experimental results were evaluated; results indicated a good prediction accuracy of the model in describing forming limits of AA7075 at elevated temperatures. Moreover, comparison between different studies on the thermal forming limits of AA7075 was discussed in detail.

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A review on forming techniques for manufacturing lightweight complex—shaped aluminium panel components

Cited by 160 publications

References 151 publications

Strength Analysis of a Rib-Stiffened GLARE-Based Thin-Walled Structure

Strength Analysis of a Rib-Stiffened GLARE-Based Thin-Walled Structure

High Strain Rate Behavior of Aluminum Alloy for Sheet Metal Forming Processes

Behaviors and modeling of thermal forming limits of AA7075 aluminum sheet

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