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Research Papers

Prediction of Process Forces in Fiber Metal Laminate Stamping

[+] Author and Article Information
Marlon Hahn

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

Nooman Ben Khalifa

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

Arash Shabaninejad

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

1Corresponding author.

Manuscript received January 23, 2017; final manuscript received October 27, 2017; published online December 21, 2017. Assoc. Editor: Yannis Korkolis.

J. Manuf. Sci. Eng 140(3), 031002 (Dec 21, 2017) (9 pages) Paper No: MANU-17-1038; doi: 10.1115/1.4038369 History: Received January 23, 2017; Revised October 27, 2017

The stamping of fiber metal laminates (FMLs) at thermoforming temperature of the thermoplastic matrix is investigated. The studied FML types consist of a unidirectional carbon fiber-reinforced core that is attached to metal cover layers either made of a steel or magnesium alloy. An analytical model is established in order to predict the process forces during forming, which are the blankholder force required to make the metal covers yield plastically, the punch force, and the corresponding load distribution on the individual layers (outer layer, core layer, and inner layer). The global forces are primarily verified through experimental force measurements, while numerical simulations are mainly performed to assess the resulting load distribution with the help of strain distributions in the cover layers. The results show that the introduced model can be applied successfully if the stamp-forming process is dominated by friction-induced tensional loading rather than by bending.

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References

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Figures

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Fig. 1

Relative movement between FML layers: (a) initial configuration and (b) during pure bending

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Fig. 2

Static equilibria during FML stamping: (a) until plastification blankholder force and (b) above plastification blankholder force (Bpl)

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Fig. 3

Theoretical influence of friction coefficients on the blankholder intensity

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Fig. 4

Exploded view cut of the finite element (FE) model in Abaqus/CAE

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Fig. 5

Flow stress curves of the metal cover layers employed in the FE model

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Fig. 6

Experimental setup: (a) procedure and (b) tool and tested fiber orientations

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Fig. 7

Punch forces for different blankholder forces and fiber orientations for FMLs with steel covers: (a) 85 kN/0 deg, (b) 85 kN/90 deg, (c) 60 kN/0 deg, (d) 60 kN/90 deg, (e) 0 kN/0 deg, and (f) 0 kN/90 deg

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Fig. 8

Punch forces for different blankholder forces and fiber orientations for FMLs with Mg covers: (a) 60 kN/0 deg, (b) 60 kN/0 deg (part image), (c) 0 kN/0 deg, and (d) 0 kN/90 deg

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Fig. 9

Visualization of the path considered in the FE model for evaluating state variables (here: strain “LE11”)

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Fig. 10

Major strains extracted from FE results for an FML with Mg covers, 0 deg fiber orientation, and 60 kN blankholder force: (a) outer cover and (b) inner cover

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