Abstract:Forming limit curve (FLC) is a suitable method for determining the metallic sheets formability. The purpose of the present research is to expose a simulation-based approach to predict the FLC in two-layer metallic sheets. In this paper, the formability of two-layer (AA3004-ST12) metallic sheets, with an aluminum inner layer (in contact with the punch) and a steel outer layer (in contact with the die) was numerically investigated. Two distinct criteria, including the acceleration (i.e. the second time derivativ… Show more
“…Table 1 shows the chemical composition of aluminum and copper sheets. In this paper, among different available procedures, 16 the layer sheets were attached through the use of the explosive welding method as it increases the strength of each layer sheet. 17 STM-50 (SANTAM company (electronic tensile machine with a constant velocity of 2 mm/min was employed to measure the mechanical properties of aluminum and copper.…”
Section: Experimental Methodsmentioning
confidence: 99%
“…Table 1 shows the chemical composition of aluminum and copper sheets. In this paper, among different available procedures, 16 the layer sheets were attached through the use of the explosive welding method as it increases the strength of each layer sheet. 17…”
This paper presents novel U-bending setups in order to investigate the effects of the curvatures created on the punch, die, or both on the spring-back/spring-go of the two-layer aluminum/copper sheets. Comparison of the new U-bending setups with the regular ones showed that the curvatures had important roles in reducing the spring-back/spring-go in the U-bending process. The results further indicated the good agreement between spring-back/spring-go and finite element simulations. Moreover, through finite element simulations, the effects of three effective parameters on reducing the spring-back/spring-go, including the curvature radius ( r) of the punch, the distance between curvature center and the fillet center ( d) in the punch, and the curvature radius at the end of the die ( R) were investigated. In achieving the desired state (90°), the results showed that the distance of curvature center from the fillet center ( d) was a more important parameter compared with the curvature radius at the end of the punch ( r) and the curvature radius at the end of the die ( R). This paper also focuses on the thicknesses of copper and aluminum as well as the stacking sequence of layers. Concerning the thicknesses of the implemented copper and aluminum change, the minimum angle of the spring-back/spring-go relative to the desired state was 75% Al/25% Cu thickness. Furthermore, the spring-back of aluminum/copper was lower than the copper/aluminum layer sheet. The effects of both thickness changing and stacking sequence of aluminum/copper layers on the spring-back/spring-go amounts of different sheets were due to the relocation of the neutral axis.
“…Table 1 shows the chemical composition of aluminum and copper sheets. In this paper, among different available procedures, 16 the layer sheets were attached through the use of the explosive welding method as it increases the strength of each layer sheet. 17 STM-50 (SANTAM company (electronic tensile machine with a constant velocity of 2 mm/min was employed to measure the mechanical properties of aluminum and copper.…”
Section: Experimental Methodsmentioning
confidence: 99%
“…Table 1 shows the chemical composition of aluminum and copper sheets. In this paper, among different available procedures, 16 the layer sheets were attached through the use of the explosive welding method as it increases the strength of each layer sheet. 17…”
This paper presents novel U-bending setups in order to investigate the effects of the curvatures created on the punch, die, or both on the spring-back/spring-go of the two-layer aluminum/copper sheets. Comparison of the new U-bending setups with the regular ones showed that the curvatures had important roles in reducing the spring-back/spring-go in the U-bending process. The results further indicated the good agreement between spring-back/spring-go and finite element simulations. Moreover, through finite element simulations, the effects of three effective parameters on reducing the spring-back/spring-go, including the curvature radius ( r) of the punch, the distance between curvature center and the fillet center ( d) in the punch, and the curvature radius at the end of the die ( R) were investigated. In achieving the desired state (90°), the results showed that the distance of curvature center from the fillet center ( d) was a more important parameter compared with the curvature radius at the end of the punch ( r) and the curvature radius at the end of the die ( R). This paper also focuses on the thicknesses of copper and aluminum as well as the stacking sequence of layers. Concerning the thicknesses of the implemented copper and aluminum change, the minimum angle of the spring-back/spring-go relative to the desired state was 75% Al/25% Cu thickness. Furthermore, the spring-back of aluminum/copper was lower than the copper/aluminum layer sheet. The effects of both thickness changing and stacking sequence of aluminum/copper layers on the spring-back/spring-go amounts of different sheets were due to the relocation of the neutral axis.
“…In this simulation, a sheet was modeled using the shell element with four integration points (S4R). Hill’s (1948) yield function and Holman hardening law 25–27 were used in the simulation. Figure 7.Flat finite element model.…”
Section: Methodsmentioning
confidence: 99%
“…14 modeled using the shell element with four integration points (S4R). Hill's (1948) yield function and Holman hardening law [25][26][27] were used in the simulation.…”
Section: The Sheets With Various Widths and Groove Anglesmentioning
Forming limit diagram is often used as a criterion to predict necking initiation in sheet metal forming processes. In this study, the forming limit diagram was obtained through the inclusion of the Marciniak-Kaczynski model in the Nakazima out-of-plane test finite element model and also a flat model. The effect of bending on the forming limit diagram was investigated numerically and experimentally. Data required for this simulation were determined through a simple tension test in three directions. After comparing the results of the flat and Nakazima finite element models with the experimental results, the forming limit diagram computed by the Nakazima finite element model was more convenient with less than 10% at the lower level of the experimental forming limit diagram.
“…In recent years, application of two-layer metallic sheets has been increased to manufacture the products with particular specifications, containing excellent mechanical and functional properties. These kinds of products are utilized in several applications such as industrial (the aerospace, electrical industries, and medical instruments) and domestic application [1][2][3].…”
The aim of this research was to introduce a simulation-based approach for determination of the Forming limit curve (FLC) in two-layer metallic sheets. In this study, the FLC of Aluminum-1100/Copper-C10100 two layer sheets were obtained through numerical simulations and experimental investigations. In order to construct the FLC, two different criterions including the acceleration (i.e., the 2 nd order of derivatives) of equivalent plastic strain and major strain were applied to obtain the onset of necking in the materials. Based on these methods, the localized necking would be started when the acceleration of the equivalent plastic strain or the major strain got its maximum value. To verify the numerical predictions, the experimental works were accomplished on the Aluminum-1100/Copper-C10100 two-layer sheets and a good agreement between the proposed methods and experimental works was observed.
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