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TECHNICAL PAPERS

The Influence of Temperature on the Forming Behavior of Metal/Polymer Laminates in Sheet Metal Forming

[+] Author and Article Information
M. Weiss1

Centre for Material and Fibre Innovation, Deakin University, Geelong, VIC 3217, Australiamatthias.weiss@deakin.edu.au

M. E. Dingle

Centre for Material and Fibre Innovation, Deakin University, Geelong, VIC 3217, Australiamatt@a-r-d.net

B. F. Rolfe

Centre for Material and Fibre Innovation, Deakin University, Geelong, VIC 3217, Australiabernard.rolfe@deakin.edu.au

P. D. Hodgson

Centre for Material and Fibre Innovation, Deakin University, Geelong, VIC 3217, Australiapeter.hodgson@deakin.edu.au

1

Corresponding author.

J. Eng. Mater. Technol. 129(4), 530-537 (Jun 15, 2007) (8 pages) doi:10.1115/1.2772329 History: Received September 24, 2006; Revised June 15, 2007

The influence of temperature on the forming behavior of an aluminum/polypropylene/aluminum (APA) sandwich sheet was studied. Shear and tensile tests were performed to determine the mechanical properties of the laminate and the component materials as a function of process temperature. The forming limit diagram (FLD) of the laminate was established for two different temperatures, and its springback behavior was examined in four-point bend and channel bend tests. Cup forming tests were performed at various test temperatures to determine the limiting drawing ratio (LDR) and the tendency for wrinkling at these temperatures. Although there was only a minor influence of temperature on the mechanical properties and the FLD values of the laminate, the bend test results reveal that springback can be reduced by forming at higher temperature. The decreasing strength of the core material with rising process temperature led to an increased tendency of the laminate to wrinkle in the heated cup drawing tests.

Copyright © 2007 by American Society of Mechanical Engineers
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References

Figures

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Figure 1

Schematic view of the APA sandwich sheet

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Figure 2

Effective stress-strain curves of the polypropylene core derived from the shear tests at different temperatures

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Figure 3

True stress strain curves for the laminate and the cover sheet material obtained from tensile tests at 26°C and 120°C

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Figure 4

Schematic of the tool setup for hemispherical dome tests

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Figure 5

(a) Forming limit diagram for the laminate at room temperature and (b) forming limit diagram for the laminate at 60°C

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Figure 6

Tooling arrangement for the four-point-bend test

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Figure 7

Angles measured before and after unloading in the four-point bend test to determine springback

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Figure 8

Decreasing measured bend angle θb with increasing test temperature

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Figure 9

(a) Final bend angle θb in the four-point bend test for different punch depths and temperatures. This is the angle measured before unloading. (b) Springback angle Δθ determined in the four-point bend test for different punch depths and temperatures.

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Figure 10

Channel bend test tooling

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Figure 11

Springback measurement in the channel test

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Figure 12

Wall and springback angle measurements for the laminate in the channel bend test for various temperatures

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Figure 13

Differences in curl defect C for strips deformed in the channel test at different temperatures

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Figure 14

Punch and die used in the circular cup drawing test

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Figure 15

Measured process range of the APA sandwich sheet at room temperature

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Figure 16

Number of wall wrinkles for cups of drawing ratio β0=1.4 and β0=1.45 drawn at various temperatures

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Figure 17

Forming limit diagram for low carbon steel

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