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Research Papers

Experimental and Numerical Determination of Limiting Drawing Ratio of Al3105-Polypropylene-Al3105 Sandwich Sheets

[+] Author and Article Information
M. H. Parsa1

School of Metallurgy and Materials Engineering, University College of Engineering, University of Tehran, P.O. Box 11155/4563, Tehran 30806, Iranmhparsa@ut.ac.ir

M. Ettehad

Zachry Department of Civil Engineering, Texas A&M University, College Station, TX 77843

P. H. Matin

Department of Engineering and Aviation Sciences, University of Maryland, Eastern Shore, Princess Anne, MD 21853

S. Nasher Al Ahkami

School of Metallurgy and Materials Engineering, University College of Engineering, University of Tehran, P.O. Box 11155/4563, Tehran 30806, Iran

1

Corresponding author.

J. Eng. Mater. Technol 132(3), 031004 (Jun 15, 2010) (11 pages) doi:10.1115/1.4001264 History: Received August 25, 2009; Revised January 30, 2010; Published June 15, 2010; Online June 15, 2010

Sandwich structures are gaining wide applications in aeronautical, marine, automotive, and civil engineering. Since such sheets can be subjected to stamping processes, it is crucial to characterize their forming behavior before trying out any conventional forming process. To achieve this goal, sandwich sheets of Al 3105/polymer/Al 3105 were prepared using thin film hot melt adheres. Different sandwich specimens with different thickness ratios (of polymer core to aluminum face sheet) were prepared. Throughout an experimental effort, the limiting drawing ratios (LDRs) of the sandwich sheets were determined. Besides, the LDR of the sandwich sheets were predicted using finite element analysis simulations by considering Gurson–Tvergaard–Needleman damage model. The results show the capability of the damage model to predict the LDR and the location of damaged zone in a workpiece during a forming operation.

Copyright © 2010 by American Society of Mechanical Engineers
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References

Figures

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Figure 1

Schematic view of sandwich sheets

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Figure 2

Procedure of incorporating of GTN parameter in the commercial finite element program (21)

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Figure 3

Typical Traction-Separation CZM response

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Figure 4

FEM model of deep drawing process

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Figure 5

True stress-strain curve

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Figure 6

Comparison between experimental and modeled tensile test specimen

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Figure 7

Dimension of the tools in schematic view

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Figure 8

Fibrillation by cohesive mode polymer debonding from aluminum face sheet

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Figure 9

Experimentally deep-drawn sandwich sheet: (a) 1.2 mm, (b) 1.5 mm, and (c) 2 mm thicknesses

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Figure 10

Comparison between experimentally and numerically obtained LDR as function of the polymer core thickness

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Figure 11

Crack formation at upper aluminum face sheet

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Figure 12

Cross section comparison of experimentally and numerically obtained specimen

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Figure 13

(a) Mean stress (b) through-thickness void volume fraction for sandwich sheets

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Figure 14

Thickness strain distribution on upper aluminum face sheet

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Figure 15

(a) Through thickness maximum principal stress and (b) thickness strain for monolayer and sandwich sheets

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Figure 16

Restricting mechanism: (a) wrinkling and (b) specimen fracture

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Figure 17

Fracture and wrinkling limiting curves

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