Process Variables Optimisation of Polypropylene Based Fibre-Metal Laminates Forming Using Finite Element Analysis

DharMalingam, S.; Compston, Paul; Kalyanasundaram, Shankar

doi:10.4028/www.scientific.net/kem.410-411.263

Cited by 14 publications

(3 citation statements)

References 9 publications

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“…The authors investigated the effect of changes in the coefficient of friction between 0.1 and 0.3 on blank holder intensity during the forming of a non-symmetrical draw piece. Dharmalingam et al [31] used the statistical experiments and finite element method to determine the influence of the parameters of the forming process of 2/1-aluminium/composite consisting of two layers of comingled 2:2 twill weave glass-fibre/polypropylene composite prepreg and annealed EN AW-5005-H34 aluminium sheets. The coefficient of friction between the FML blank and the forming tools was arbitrarily assumed to be constant with a value of 0.031.…”

Section: Introductionmentioning

confidence: 99%

Assessment of the Tribological Properties of the Steel/Polymer/Steel Sandwich Material LITECOR

2022

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The article presents the results of tribological investigations into the steel/polymer/steel sandwich material LITECOR® developed by ThyssenKrupp Steel Europe for applications in the automotive industry. Friction tests were carried out by means of a strip drawing test with the use of a special tribotester mounted on a uniaxial tensile test machine. The influence of sheet deformation on the value of the coefficient of friction (COF) was considered. For this purpose, the samples were subjected to a pre-deformation of 4%, 8% and 12%. Friction tests were carried out with different force values and under different friction conditions, i.e., in dry friction conditions and lubrication of the sheet surface with L-AN 46 machine oil. The highest values of COF were observed for as-received sheets. In contrast, apart from the friction process under the conditions of the lowest force analysed, the lowest value of the COF was observed for pre-strained sheets with a deformation of 12%. The lubrication efficiency of the pre-strained strip specimens with ε = 4% was between 10.5% and 16.3%, with a trend of increasing lubrication efficiency with increasing force. For pre-strained sheets with deformation ε = 12%, there was a trend of decreasing effectiveness from 14.9% to 9.03% with an increase in force.

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Section: Introductionmentioning

confidence: 99%

Assessment of the Tribological Properties of the Steel/Polymer/Steel Sandwich Material LITECOR

2022

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“…Kalyanasundaram et al [26] showed that the use of high temperature in the forming process of FMLs with the thermoplastic base, melts the base material and in the deformation process, the layers slip over each other. DharMalingam et al [27], using finite element simulations, showed that the optimum temperature for achieving the highest FMLs formability with PP base is 130˚C. Valizadeh et al [28].conducted an experimental investigation on L-die bending of UNS C10100 copper/aluminum 1100 two layers' sheet.…”

Section: Introductionmentioning

confidence: 99%

Experimental study of the effect of temperature and velocity in channel forming of polyvinyl chloride composite reinforced by 3D-fiberglass with an aluminum middle layer

et al. 2022

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In this paper, the stamp forming process of a U-shaped cross-section channel with sharp corners of composite laminates including aluminum sheet and polyvinyl chloride (PVC) reinforced with 3D-fiberglass was investigated. The laminates were produced by manual layup and arrangement of fibers with different angles of [0°/90°] and [± 45°] degrees using hot press. The process of forming composite samples was carried out at temperatures of 25, 80, 120, 160°C and different velocities of punch. The effect of parameters including layup configuration, temperature, and forming speed on the spring-back of the formed laminates and the required forming force were evaluated. The results showed that as the forming temperature increased, the forming force decreased sharply. The lowest forming force was obtained for the laminate with [± 45°, Al, ± 45°] layout at 160°C temperature which was equal to 0.7KN. Also, with the increase in temperature, the spring-back angle has been reduced, the lowest of which is obtained with the laminate with [0°/90°] 3 layout equal to 8 degrees. Finally, it was concluded that increasing the speed of the forming process results in a decrease in the spring-back angle and this effect is more pronounced at higher temperatures. Graphical abstract

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“…Forming of thermoplastic FML systems has primarily been investigated using draw and cup forming [9][10][11][12][13][14]. Gresham et al showed that the blank holder force significantly affects the formability of the laminate.…”

Section: Introductionmentioning

confidence: 99%

Stretch forming studies on a fibre metal laminate based on a self-reinforcing polypropylene composite

Sexton

Cantwell

Kalyanasundaram

2012

Composite Structures

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This paper investigates the room temperature formability of a fibre metal laminate system comprised of aluminium and a self-reinforcing polypropylene composite. Blanks of varying geometry were stretch formed over a hemispherical punch in a custom built stamping press. A real-time three-dimensional photogrammetric measuring system was used to acquire the evolution of surface strain and the strain at failure during forming. The results from this work illustrate that these advanced light weight material systems are amenable to mass production through stamp forming. A significant finding from this work is that these material systems can exhibit forming characteristics that are comparable and sometimes superior to metal forming.

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Process Variables Optimisation of Polypropylene Based Fibre-Metal Laminates Forming Using Finite Element Analysis

Cited by 14 publications

References 9 publications

Assessment of the Tribological Properties of the Steel/Polymer/Steel Sandwich Material LITECOR

Assessment of the Tribological Properties of the Steel/Polymer/Steel Sandwich Material LITECOR

Experimental study of the effect of temperature and velocity in channel forming of polyvinyl chloride composite reinforced by 3D-fiberglass with an aluminum middle layer

Stretch forming studies on a fibre metal laminate based on a self-reinforcing polypropylene composite

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