FEM-based strain analysis study for multilayer sheet forming process

doi:10.1007/s11465-015-0371-9

Front. Mech. Eng.

2015, Vol. 10

Issue (4) : 373-379 https://doi.org/10.1007/s11465-015-0371-9

RESEARCH ARTICLE

FEM-based strain analysis study for multilayer sheet forming process

Rongjing ZHANG(

),Lihui LANG,Rizwan ZAFAR

School of Mechanical Engineering and Automation, Beihang University, Beijing 100191, China

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Abstract

Fiber metal laminates have many advantages over traditional laminates (e.g., any type of fiber and resin material can be placed anywhere between the metallic layers without risk of failure of the composite fabric sheets). Furthermore, the process requirements to strictly control the temperature and punch force in fiber metal laminates are also less stringent than those in traditional laminates. To further explore the novel method, this study conducts a finite element method-based (FEM-based) strain analysis on multilayer blanks by using the 3A method. Different forming modes such as wrinkling and fracture are discussed by using experimental and numerical studies. Hydroforming is used for multilayer forming. The Barlat 2000 yield criteria and DYNAFORM/LS-DYNA are used for the simulations. Optimal process parameters are determined on the basis of fixed die-binder gap and variable cavity pressure. The results of this study will enhance the knowledge on the mechanics of multilayer structures formed by using the 3A method and expand its commercial applications.

Keywords finite element method (FEM) strain analysis multilayer sheet forming

Corresponding Author(s): Rongjing ZHANG

Online First Date: 25 November 2015 Issue Date: 03 December 2015

Cite this article:

Rongjing ZHANG,Lihui LANG,Rizwan ZAFAR. FEM-based strain analysis study for multilayer sheet forming process[J]. Front. Mech. Eng., 2015, 10(4): 373-379.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-015-0371-9
https://academic.hep.com.cn/fme/EN/Y2015/V10/I4/373

Fig.1 The 3A method for multilayer blank forming invented by Zafar et al. [1,2]

Tab.1 Tensile properties of Al2014-O

Fig.2 Simulation setup for numerical study

Fig.3 Simulation and experimental forming of three layers at various cavity pressures at the same depth (37.50 mm). (a) Severe wrinkling at 25 MPa; (b) qualified part formed at 45 MPa; (c) fracture at 55 MPa

Fig.4 Effect of major and minor strains on failure modes

Fig.5 Effect of major strains in simulation and experiment at various cavity pressures at the same depth (37.5 mm). (a) Cavity pressure at 25 MPa; (b) cavity pressure at 45 MPa; (c) cavity pressure at 55 MPa

Fig.6 Surfaces with tensile and reverse tensile (compressive) loads

Fig.7 Relative nodal displacement between the three blank layers. (a) Nodal displacement at flange outer edge; (b) nodal displacement at 12 mm from flange outer edge; (c) nodal displacement at point inside die redius

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