The effect of pre-heat temperature on the formability of a glass-fibre/polypropylene and steel-based fibre–metal laminate
Source abstract
Abstract
This paper presents an experimental and numerical investigation into the effect of pre-heat temperature on stretch forming of a fibre metal laminate (FML) comprised of alternating layers of steel and woven (0/90) glass-fibre polypropylene in a 2:1 configuration. Hourglass sample geometries were formed in an open die and real-time photogrammetry was used to measure the evolution of strain fields over the lower surface of each sample. The sample pre-heat temperatures were 140 °C (above the crystallization temperature) and 170 °C (melt temperature of polypropylene). For each temperature, a forming limit curve (FLC) was determined based on ISO 12004-2:2008 and compared to the FLC of the steel skin. The experimental results demonstrate that pre-heat temperature of 140 °C enables sufficient matrix flow such that the formability of the FML is comparable to the formability of the steel sheet. Furthermore, the FML stretch-forming process was simulated using commercial finite element software, LSDYNA, with an explicit solver. The glass-fibre polypropylene material behaviour was simulated with a curve fitting technique of material characterization test results. A user-defined subroutine (UMAT) was developed for the composite material modelling through all process temperatures. The simulation, justified with experiments, provided a numerical model of the hybrid material to utilise for forming complex shapes.
Source: openaire · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Mechanical Behavior of Composites · Composite Structure Analysis and Optimization · Textile materials and evaluations
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (30)
Show source-provided references
1. Reyes G, Cantwell WJ (2000) The mechanical properties of fiber-metal laminates based on a glass fibre reinforced polypropylene. Composites science and technology 9(7):211–216. https://doi.org/10.1016/S0266-3538(00)00002-610.1016/S0266-3538(00)00002-6 ↗
2. Reyes G, Kang H (2007) Mechanical behavior of lightweight thermoplastic fiber-metal laminates. J Mater Process Technol 186(1-3):284–290. https://doi.org/10.1016/j.jmatprotec.2006.12.05010.1016/j.jmatprotec.2006.12.050 ↗
3. Vogelesang LB, Vlot A (2000) Development of fibre metal laminates for advanced aerospace structures. J Mater Process Technol 103(1). https://doi.org/10.1016/S0924-0136(00)00411-810.1016/S0924-0136(00)00411-8 ↗
4. Compston P, Cantwell WJ, Jones C, Jones N (2001) Impact perforation resistance and fracture mechanisms of a thermoplastic based fiber-metal laminate. J Mater Sci Lett 20(7). https://doi.org/10.1023/A:101090493049710.1023/A:1010904930497 ↗
5. Botelho EC, Silva RA, Pardini LC, Rezende MC (2006) A review on the development and properties of continuous Fiber / epoxy / aluminum hybrid composites for aircraft structures. Mater Res 9(3). https://doi.org/10.1590/S1516-1439200600030000210.1590/S1516-14392006000300002 ↗
6. Keeler S, Backhofen W (1964) Plastic instability and fracture in sheet stretched over rigid punches. ASM Transactions Quarterly 56:25–48
7. Nakazima, K., Kikuma, T., Hasuka K (1968) Study on the formability of steel sheets. Technical Report Yawata Technical Report
8. Marciniak Z, Kuczyński K (1967) Limit strains in the processes of stretch-forming sheet metal. Int J Mech Sci 9(9):609–620. https://doi.org/10.1016/0020-7403(67)90066-510.1016/0020-7403(67)90066-5 ↗
9. ISO/DIS 12004–2 (2008) Metallic Materials - Sheet and Strip - Determination of Forming Limit Curves - Part 2: Determination of Forming Limit Curves in the Laboratory. International Organization for Standardization 20087. 2:12004
10. Sokolova O, Carradó A, Palkowski H (2010) Production of customized high-strength hybrid Sandwich structures. Adv Mater Res 137:81–128. https://doi.org/10.4028/www.scientific.net/AMR.137.8110.4028/www.scientific.net/AMR.137.81 ↗
11. Mosse L, Compston P, Cantwell WJ, Cardew-Hall M, Kalyanasundaram S (2006) Stamp forming of polypropylene based fibre-metal laminates: the effect of process variables on formability. J Mater Process Technol 172(2):163–168. https://doi.org/10.1016/j.jmatprotec.2005.09.00210.1016/j.jmatprotec.2005.09.002 ↗
12. Mosse L, Compston P, Cantwell WJ, Cardew-Hall M, Kalyanasundaram S (2006) The development of a finite element model for simulating the stamp forming of fibre-metal laminates. Compos Struct 75(1-4):298–304. https://doi.org/10.1016/j.compstruct.2006.04.00910.1016/j.compstruct.2006.04.009 ↗
13. Gresham J, Cantwell W, Cardew-Hall MJ, Compston P, Kalyanasundaram S (2006) Drawing behaviour of metal-composite sandwich structures. Compos Struct 75(1-4):305–312. https://doi.org/10.1016/j.compstruct.2006.04.01010.1016/j.compstruct.2006.04.010 ↗
14. Mosse L, Compston P, Cantwell WJ et al (2005) The effect of process temperature on the formability of polypropylene based fibre-metal laminates. In: composites part a: applied science and manufacturing, pp 1158–1166
15. Compston P, Cantwell WJ, Cardew-Hall MJ, Kalyanasundaram S, Mosse L (2004) Comparison of surface strain for stamp formed aluminum and an aluminum-polypropylene laminate. J Mater Sci 39(19):6087–6088. https://doi.org/10.1023/B:JMSC.0000041707.68685.7210.1023/B:JMSC.0000041707.68685.72 ↗
16. Sexton A, Cantwell W, Kalyanasundaram S (2012) Stretch forming studies on a fibre metal laminate based on a self-reinforcing polypropylene composite. Compos Struct 94(2):431–437. https://doi.org/10.1016/j.compstruct.2011.08.00410.1016/j.compstruct.2011.08.004 ↗
17. Rajabi A, Kadkhodayan M, Manoochehri M, Farjadfar R (2015) Deep-drawing of thermoplastic metal-composite structures: experimental investigations, statistical analyses and finite element modeling. J Mater Process Technol 215. https://doi.org/10.1016/j.jmatprotec.2014.08.01210.1016/j.jmatprotec.2014.08.012 ↗
18. Wollmann T, Hahn M, Wiedemann S, Zeiser A, Jaschinski J, Modler N, Ben Khalifa N, Meißen F, Paul C (2018) Thermoplastic fibre metal laminates: stiffness properties and forming behaviour by means of deep drawing. Archives of Civil and Mechanical Engineering 18(2). https://doi.org/10.1016/j.acme.2017.09.00110.1016/j.acme.2017.09.001 ↗
19. Jalali Aghchai A, Khatami S (2018) Experimental and numerical formability investigation of FML sheets with glass fiber reinforced core. Int J Adv Manuf Technol 96:9–12. https://doi.org/10.1007/s00170-018-1836-x10.1007/s00170-018-1836-x ↗
20. Zhu B, Yu TX, Tao XM (2009) Large shear deformation of E-glass/ polypropylene woven fabric composites at elevated temperatures. J Reinf Plast Compos 28(21):2615–2630. https://doi.org/10.1177/073168440809309510.1177/0731684408093095 ↗
21. Hou M, Friedrich K (1994) 3-D stamp forming of thermoplastic matrix composites. Appl Compos Mater 1(2):135–153. https://doi.org/10.1007/BF0056757510.1007/BF00567575 ↗
22. MacHado M, Murenu L, Fischlschweiger M, Major Z (2016) Analysis of the thermomechanical shear behaviour of woven-reinforced thermoplastic-matrix composites during forming. Compos A: Appl Sci Manuf 86:39–48. https://doi.org/10.1016/j.compositesa.2016.03.03210.1016/j.compositesa.2016.03.032 ↗
23. Tepex® Dynalite (2014) Material Data Sheet. http://bond-laminates.com/uploads/tx_lxsmatrix/ 600:7072
24. ARAMIS (2009) ARAMIS user manual
25. Marciniak Z, Duncan J, Hu SJ (2002) Mechanics of sheet metal forming
26. D 3518 (2007) Standard test method for in-plane shear response of polymer matrix composite materials by tensile test of a +−45 ° laminate. Annual Book of ASTM Standards https://doi.org/10.1520/D351810.1520/D3518 ↗
27. Bogetti TA, Hoppel CPR, Harik VM et al (2004) Predicting the nonlinear response and progressive failure of composite laminates. Failure Criteria in Fibre-Reinforced-Polymer Composites 64:402–428. https://doi.org/10.1016/B978-008044475-8/50017-210.1016/B978-008044475-8/50017-2 ↗
28. Wang W, Lowe A, Kalyanasundaram S (2016) Investigating the forming limits of a flax fibre-reinforced polypropylene composite in different water treatment conditions. International journal of advanced manufacturing technology 1–1110.1007/s00170-016-8492-9 ↗
29. Wang W, Lowe A, Davey S, Akhavan Zanjani N, Kalyanasundaram S (2015) Establishing a new forming limit curve for a flax fibre reinforced polypropylene composite through stretch forming experiments. Compos A: Appl Sci Manuf 77:114–123. https://doi.org/10.1016/j.compositesa.2015.06.02110.1016/j.compositesa.2015.06.021 ↗
30. Ls-dyna, software LS, Orporation TEC (2017) Theory Manual 01/26/18