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research-article

An analytical model for non-hydrostatic sheet metal bulging process by means of polymer melt pressure

[+] Author and Article Information
Saeed Farahani

Department of Mechanical Engineering, Amirkabir University of Technology, 424 Hafez Ave, Tehran, 15875-4413, Iran
sfaraha@clemson.edu

Alireza Fallahi Arezodar

Department of Mechanical Engineering, Amirkabir University of Technology, 424 Hafez Ave, Tehran, 15875-4413, Iran
afallahi@aut.ac.ir

Bijan Mollaei Dariani

Department of Mechanical Engineering, Amirkabir University of Technology, 424 Hafez Ave, Tehran, 15875-4413, Iran
dariani@aut.ac.ir

Srikanth Pilla

Department of Automotive Engineering, Clemson University, 4 Research Drive, Greenville, SC, 29607, USA; Department of Materials Science and Engineering, Clemson University, 161 Sirrine Hall, 515 Calhoun Drive, Clemson, SC, 29634, USA; Clemson Composites Center, Clemson University, 575 Millennium Blvd, Greenville, SC 29607, USA
spilla@clemson.edu

1Corresponding author.

ASME doi:10.1115/1.4040429 History: Received March 27, 2018; Revised May 18, 2018

Abstract

In this paper, a theoretical approach to model free deformation of sheet metal via polymer injection pressure is presented. It is a general methodology that can be applied for any situation where a non-uniform pressure distribution is responsible for free deformation of sheet metal within a circular cavity. This approach is composed of two iterative approximation loops. In the outer loop, the radius of curvature at the tip of dome shape was optimized based on the boundary condition at the edge of clamped area while in the inner successive loop, principal stresses determined from plasticity theories were used to satisfy the equilibrium equations. While forming sheet metal via polymer injection is a revolutionary yet complex process, its modeling is challenging. Hence, before implementing this general approach to this process, the modeling methodology as such necessitates a simplified solution for melt flow analysis to obtain a pressure distribution encompassing the entire cavity. To evaluate the proposed model, a customized experimental setup was designed and fabricated, which allows sheet metal bulging with the plastic injection. The deformation of the AA1100-O sheet was investigated during the injection of the Polypropylene-Olefin compound. The comparison of the theoretical and experimental results shows that the general approach formulated here can be successfully applied to predict the surface strains and thickness distributions with maximum error of 6% while the deformed geometry remains within ± 0.35mm deviation in the final deformation stage.

Copyright (c) 2018 by ASME
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