Forming limit diagram of aluminum-copper two-layer sheets: numerical simulations and experimental verifications

Abstract

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.

Experimental evaluation of forming limit diagram and mechanical properties of nano/ultra-fine grained aluminum strips fabricated by accumulative roll bonding

“…The most well-known test in order to obtain FLDs experimentally is an out-of-plane test (e.g., Nakazima test) in which a sheet metal specimen is fixed between circular die rings and stretched by a hemispherical punch [31]. The laboratory test results demonstrated that the FLDs are influenced by many factors, including strain rate [32,33], strain hardening index, anisotropy coefficients [34,35], heat treatment [36,37], grain size and microstructure [38,39], strain path changes [40,41], and sheet thickness [42]. However, work has not been done so far to evaluate the FLDs of samples produced by ARB; FLD has been used to evaluate the formability of fine grained and ultra-fine grained sheet metals produced by other SPD methods, such as ECAR [43] and ECAP [44].…”

Comparison of experimental and numerical analysis of Quasi-Static punch shear test for stainless steel sheet material

“…Karajibani et al, on the other hand, presented a simulation-based approach for the determination of the forming layer curve (FLC) in bilayer metal sheets. In this study, they obtained the FLC of aluminum-1100 / copper-C10100 two-layer plate through numerical analysis and experimental research (Karajibani et al 2017). In another study, Çağdaş and Taşkın, 2020. developed a modified analytical expression to determine the quasi-static pre-indentation loads of foam core sandwich beams with thin laminated galvanized steel surfaces, which may be valuable in the preliminary design phase.…”

“…In addition, this test gives a preview of how sheet metal materials will behave during the press-forming process. Sheet materials are commonly converted into products by printing-forming methods (Karajibani et al 2017;Şener et al 2020;Vatansever & Esener 2019). It is thought that the experimental and numerical application of QS-PST to the material will be beneficial in overcoming the production problems encountered in this process.…”

Experimental and simulated comparison of finite element models of bimetallic sheets for deep drawing process

“…Thereby, no slippage permitted between layers. Karajibani et al [11] also used same modelling method for AL-Cu bimetallic sheet. As in previous studies, they fabricated the bimetallic sheets using explosive welding.…”