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Research Papers

An Experimental and Numerical Investigation on Polymer Melt Injected Sheet Metal Forming

[+] Author and Article Information
Muhammad Masood Hussain

Institut für Umformtechnik und Leichtbau,  Technische Universität Dortmund, 44227 Dortmund, Germanymasood.hussain@iul.tu-dortmund.de

Michael Trompeter

Institut für Umformtechnik und Leichtbau,  Technische Universität Dortmund, 44227 Dortmund, Germany

Jörg Witulski

Institut für Umformtechnik und Leichtbau,  Technische Universität Dortmund, 44227 Dortmund, GermanyJoerg.Witulski@iul.tu-dortmund.de

A. Erman Tekkaya

Institut für Umformtechnik und Leichtbau,  Technische Universität Dortmund, 44227 Dortmund, GermanyErman.Tekkaya@iul.tu-dortmund.de

J. Manuf. Sci. Eng 134(3), 031005 (Apr 25, 2012) (13 pages) doi:10.1115/1.4006117 History: Received April 01, 2011; Revised January 09, 2012; Published April 24, 2012; Online April 25, 2012

Polymer injection forming (PIF) is a recent advancement in manufacturing of plastic– metal hybrid products. It is a combination of injection molding and sheet metal forming in which the molten polymer additionally serves as a pressure medium. This paper presents fundamental investigations on the use of polymer melt as a pressure medium in sheet metal forming. The development of forming pressure and localized blank temperature as a result of polymer injection is analyzed. The experiments are performed using aluminum alloy. The experiments comprise the bulging of a (free form) dome and stretch forming of a cup using thermoplastic polypropylene as a pressure medium. A simple approach is presented to model a combined process. An incremental lagrangian formulation is used to describe the polymer flow and sheet metal deformation. The Newtonian behavior of the polymer melt is modeled as rigid-viscoplastic medium. Standard finite element coupling is used to model the mutual metal–polymer interaction. The simulation results in the form of forming pressure profile, localized blank temperature profile, formed shape, and strain distribution are presented and validated with experimentally obtained results.

Copyright © 2012 by American Society of Mechanical Engineers
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References

Figures

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Figure 17

Pressure–dome height (experiment and simulation)

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Figure 18

Temperature–dome height (experiment and simulation)

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Figure 19

Simulation results at higher melt/mold temperature

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Figure 20

Pressure–time (experiment and simulation)

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Figure 21

Shape deviation between experiment and simulation

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Figure 22

Strain along the cup section (experiment and simulation)

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Figure 16

Flow stress curves of processed materials

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Figure 15

Simplified FE model (axisymmetric)

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Figure 14

Simplification of injection geometry

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Figure 13

Equivalent strain along the cup section at different pressure stages

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Figure 12

Pressure-bottom radius (different forming media)

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Figure 11

Pressure development in cup forming

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Figure 10

Sheet metal blank before and after the cup forming process with molded plastic component

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Figure 9

Influence of the injection rate on the sheet metal temperature

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Temperature development at the apex of the dome

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Temperature-dependent flow curve of AA5754

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Figure 6

Pressure–dome height progress for different forming media

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Pressure and dome height progress in free forming

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Sheet metal blank before and after the free forming process with molded plastic component

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Figure 3

Measurement technique for process monitoring

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Figure 2

Experimental setup for free forming and cup forming

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Figure 1

Products involving polymer injection forming [20]

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