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Research Papers

Springback Behavior of Carbon-Fiber-Reinforced Plastic Laminates With Metal Cover Layers in V-Die Bending

[+] Author and Article Information
Marlon Hahn

Institute of Forming Technology
and Lightweight Construction,
TU Dortmund University,
Baroper Street 303,
Dortmund 44227, Germany
e-mail: marlon.hahn@iul-tu-dortmund.de

Nooman Ben Khalifa

Institute of Forming Technology
and Lightweight Construction,
TU Dortmund University,
Baroper Street 303,
Dortmund 44227, Germany
e-mail: Nooman.Ben_Khalifa@iul.tu-dortmund.de

Christian Weddeling

Institute of Forming Technology
and Lightweight Construction,
TU Dortmund University,
Baroper Street 303,
Dortmund 44227, Germany
e-mail: Christian.Weddeling@iul.tu-dortmund.de

Arash Shabaninejad

Institute of Forming Technology
and Lightweight Construction,
TU Dortmund University,
Baroper Street 303,
Dortmund 44227, Germany
e-mail: Arash.Shabaninejad@tu-dortmund.de

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received August 17, 2016; final manuscript received August 23, 2016; published online September 29, 2016. Editor: Y. Lawrence Yao.

J. Manuf. Sci. Eng 138(12), 121016 (Sep 29, 2016) (8 pages) Paper No: MANU-16-1437; doi: 10.1115/1.4034627 History: Received August 17, 2016; Revised August 23, 2016

The V-die bending of a carbon-fiber-reinforced thermoplastic laminate bonded to thin cover layers made of microalloyed steel was investigated. Such hybrid semifinished products are gaining importance in transport-related lightweight designs. Experiments were conducted for different forming temperatures and dwell times to determine suitable process parameters. The punch radius was varied to evaluate its influence on the springback/negative springback of the fiber–metal laminate (FML). The results, which are in good accordance with a simple analytical model, showed that the solidification of the composite core can compensate for the springback of the metal layers. Micrographs further revealed that the fiber orientation can affect the thickness distribution in the bend area.

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References

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Figures

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Fig. 1

Micrographs of FML specimens before forming: (a) 0-deg fiber orientation and (b) 90-deg fiber orientation

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Fig. 2

Basic setup for v-die bending experiments (preheating oven not displayed)

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Fig. 3

Sketch of path-controlled punch travel during v-die bending for both fiber orientations

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Fig. 4

Example x–y-plots of FML bending arms after v-die bending

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Fig. 5

Comparative v-die bending experiment with unbonded cover layers (punch is not depicted)

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Fig. 6

Sequential application of the assumptions of the analytical model (tool is not displayed)

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Fig. 7

Temperature history result of Table 1 for a preheat temperature of 240 °C

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Fig. 8

Temperature history result of Table 1 for a preheat temperature of 180 °C; 0-deg fiber orientation

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Fig. 9

Springback ratio versus dwell time graphs (compare Table 2) for a preheat temperature of 240 °C

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Fig. 10

Springback versus punch radius graphs (compare Table 3) for the 0-deg orientation, a preheat temperature of 240 °C, and a dwell time of 10 s

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Fig. 11

Springback versus punch radius graphs (compare Table 3) for the 90-deg orientation, a preheat temperature of 240 °C, and a dwell time of 10 s

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Fig. 12

Micrographs of FML specimens bent with a punch radius of 1.5 mm: (a) 90-deg orientation and (b) 0-deg orientation

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Fig. 13

Micrographs of FML specimens bent with a punch radius of 4.5 mm: (a) 90-deg orientation and (b) 0-deg orientation

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