The effect of process temperature on the formability of polypropylene based fibre–metal laminates

Mosse, Luke; Compston, Paul; Cantwell, W.J.; Cardew-Hall, Michael; Kalyanasundaram, Shankar

doi:10.1016/j.compositesa.2005.01.009

Cited by 68 publications

(34 citation statements)

References 7 publications

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“…were carried out which showed good agreement with experimental results. The simultaneous forming of multilayer blanks approach is more beneficial, especially when it is employed by using HDD technology as compared with the existing stamp forming technique [14][15][16][17][18][19][20] in terms of manufacturing complexity, productivity, and costs. The new process can eliminate the need of strict process controls, reheating/re-solidification steps, and can provide the engineers full leverage on using any type of resin/composite material at any required place after forming.…”

Section: Resultsmentioning

confidence: 99%

“…Binder corner radius is 6 mm and die corner radius is 10 mm. These part parameters were selected in order to compare the efficiency of our simultaneous multilayer forming method with the other approaches using nearly similar sized parts [14][15][16][17][18][19][20].…”

Section: Equipment and Toolingmentioning

confidence: 99%

“…Literature survey reveals that only two metallic blanks could be used so far due to enhanced process complexity with the greater quantity of blanks [14][15][16][17][18][19][20]. Other shortcomings of this approach are the risk of agglomeration or rupture of woven cloth (only chopped fibers are being used), only TP resins can be employed (thermosetting (TS) resin if once solidified, cannot be re-melted) and several controlled heating/solidification steps of blank assembly/tooling [14][15][16][17][18][19][20]. The above limitations of the stamp forming process make it quite difficult and inefficient to be applied for mass production of FML parts.…”

Section: Introductionmentioning

confidence: 99%

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Analysis of hydro-mechanical deep drawing and the effects of cavity pressure on quality of simultaneously formed three-layer Al alloy parts

Zafar

Zhang

2015

Int J Adv Manuf Technol

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Stamp forming method used for forming of relatively smaller and complex-shaped fiber metal laminate (FML) parts has inherent constraints such as fiber sheet rupture, metallic layers quantity, and repeated heating/ solidification of thermoplastic (TP) resin/tooling. As an alternate and efficient strategy, simultaneous forming of multiple blanks has been studied by using hydro-mechanical deep drawing (HDD) method. Also, the effect of process variables such as cavity pressure and blank holding force (BHF) and their role in wrinkles formation, thinning, edges movement and formability for the HDD process (performed with and without applying the cavity pressure) has been deliberated. Blanks made of Al 2024-O alloy sheet were used and the formability attributes, based on Barlat 2000 yield criteria, were estimated using DYNAFORM/LS-DYNA and compared with the experimental results. The results show that application of cavity pressure within certain limits has a positive effect on the quality of three-layer formed part as well as leads to higher depths as compared with the process when no cavity pressure was applied. Good agreement has been found between the predicted and the experimental results. The simultaneous forming strategy can give the advantage of eradicating the strict process controls which are needed in the conventional stamp forming method and can expand the application areas of FML parts for the aerospace and automobile industries.

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Section: Resultsmentioning

confidence: 99%

Section: Equipment and Toolingmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Analysis of hydro-mechanical deep drawing and the effects of cavity pressure on quality of simultaneously formed three-layer Al alloy parts

Zafar

Zhang

2015

Int J Adv Manuf Technol

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“…Porém, desta feita, polímeros termoplásticos (e.g., polipropileno, nylon e ABS), ao invés dos termorrígidos (e.g., epóxi, bismaleimida), são preferidos em vista da alta produtividade requerida pela indústria automotiva, assim como devido às múltiplas operações de conformação mecânica tipicamente empregadas na fabricação destas estruturas de veículos automotores [3][4][5]. Redução de peso (economia de combustível e/ou maior autonomia) e um bom desempenho sob impacto (crashworthiness) são aspectos claramente desejáveis também nestas aplicações.…”

Section: Figuraunclassified

Resistência e tolerância a impacto transversal de baixa energia de um laminado híbrido metal/fibra

Gualberto¹,

Gatt²,

Tarpani³

2009

Matéria (Rio J.)

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A energia absorvida no impacto transversal do laminado híbrido metal/fibra Glare ® foi determinada por três diferentes métodos. O primeiro método utiliza um sofisticado aparato Laser-Doppler que registra a aceleração e a desaceleração do impactador ao longo do evento de choque mecânico por queda-de-peso, enquanto que o segundo se baseia apenas nos dados de carga de impacto contra o tempo de contato do impactador com o espécime. Já o terceiro método considera somente as velocidades do impactador pré-e pós-impacto. Concluiu-se que as duas primeiras metodologias geram resultados bastante similares entre si, com o material em geral absorvendo cerca de 70% da energia disponibilizada no impacto, enquanto que a terceira abordagem apresentou resultados excessivamente não-conservadores. As propriedades residuais em flexão dos laminados previamente danificados por impacto demonstraram que o módulo de elasticidade é o parâmetro mais confiável para a monitoração do grau de integridade estrutural do compósito híbrido.Palavras chaves: danos por impacto de baixa energia, laminado metal/fibra, material compósito. Low-Energy transverse impact resistance and tolerance of hybrid fiber/metal laminate ABSTRACTThe absorbed energy during the low-velocity transversal impact of hybrid metal/fiber Glare ™ laminate was determined by three different analytical methods. The first method employs a sophisticated Laser-Doppler apparatus that registers the acceleration and deceleration of the impact tup along the dropweight test, whereas the second one is based only on the impact load-time history. The third method relies solely on the pre-and post-impact velocity of the striker. It has been concluded that the first two methodologies produce very similar results, with the material generally absorbing approximately 70% of the available energy, while the third methodology generated unduly non-conservative results. Residual flexural properties of previously impact damaged laminate specimens showed that the modulus of elasticity is the most valuable parameter for structural integrity monitoring of the hybrid composite.Keywords: Composite material, fiber/metal laminate, low-energy impact damage. INTRODUÇÃO Laminados metal/fibraA classe dos laminados híbridos metal/fibra (LMF) foi concebida na década de 50 na Universidade Delft (Holanda), em parceria com a empresa aeronáutica holandesa Fokker [1]. Tipicamente, os LMFs são compostos por camadas de uma liga metálica (e.g., aço, ligas-Al, -Mg ou -Ti) intercaladas com camadas de fibras resistentes (e.g., vidro, aramida, carbono ou polipropileno) pré-impregnadas com resina (termorrígida ou termoplástica), conforme ilustra a Figura 1.

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“…The second method uses the stamp forming (die/punch, etc.) to fabricate relatively smaller, deep drawn, complex profiled parts using thermoplastic resins (such as polypropylene-based short-fiber metal laminates) [7][8][9][10]. However, there are three main constraints being faced during forming of FMLs by using the second method.…”

Section: Introductionmentioning

confidence: 99%

Investigation into thinning and spring back of multilayer metal forming using hydro-mechanical deep drawing (HMDD) for lightweight parts

Zhang

Zafar

et al. 2015

Int J Adv Manuf Technol

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Lightweight, hybrid parts are extensively used in the manufacturing of modern aerospace or automobile structures like fiber metal laminates (FMLs) to replace the monolithic metallic parts. Presently, smaller and complex-shaped FML parts are made by applying the stamp-forming techniques. However, due to limited strain of the composite fibers, such techniques are unfit for forming complex profile laminated parts. This study focuses on the use of hydro-mechanical deep drawing (HMDD) for the three layers simultaneous forming of the metallic blanks to fabricate a hemispherical structure which will then be used to make a FML part. Orthogonal test strategy is formulated to investigate the influence of variables such as cavity/pre-bulging pressures, pre-bulging height, and die-binder gap to optimize the forming conditions. FE-based experimental study is done to research the thickness distribution and spring back of the formed multilayer structure. Results show that the research is sufficient in predicting these attributes and can provide a basis to understand the fundamental phenomenon for three-layered, simultaneously formed structures. Hybrid parts fabricated by using multilayer forming can expand the application areas of FMLs.

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The effect of process temperature on the formability of polypropylene based fibre–metal laminates

Cited by 68 publications

References 7 publications

Analysis of hydro-mechanical deep drawing and the effects of cavity pressure on quality of simultaneously formed three-layer Al alloy parts

Analysis of hydro-mechanical deep drawing and the effects of cavity pressure on quality of simultaneously formed three-layer Al alloy parts

Resistência e tolerância a impacto transversal de baixa energia de um laminado híbrido metal/fibra

Investigation into thinning and spring back of multilayer metal forming using hydro-mechanical deep drawing (HMDD) for lightweight parts

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