Theoretical, Numerical and Experimental Investigation on Formability of Al3105-St14 Two-Layer Sheet

Subject Areas : Engineering

H  Deilami Azodi ¹ (Department of Mechanical Engineering, Arak University of Technology, P.O.Box 38135-1177, Arak, Iran)
R  Darabi ² (Department of Mechanical Engineering, Arak University of Technology, P.O.Box 38135-1177, Arak, Iran)

Received: 2017-03-27 Accepted : 2017-05-23 Published : 2017-06-30

Keywords: Two-layer metallic sheet, Forming limit diagram (FLD), Forming limit stress diagram (FLSD), M-K theory, Bifurcation theory,

Abstract :

Two-layer metallic sheets have wide applications in various industries due to their superlative characteristics. This paper presents analytical model to investigate the formability of two-layer sheets based on Marciniak and Kuckzinsky (M-K) method using Barlat and Lian non-quadratic yield criterion. FEM simulation is also performed to calculate the forming limits based on bifurcation theory. Forming limit diagrams (FLDs) and forming limit stress diagrams (FLSDs) determined by analytical and numerical approaches are compared with experimental results of Al3105-St14 two-layer sheet to verify the validity of theoretical models. The formability of two-layer sheet is also compared with the formability of its components. The results show that the forming limit diagram of two-layer sheet is located between the FLDs of separate layers. The effects of the anisotropy and the orientation of layers on formability of two-layer sheet are studied. The higher formability will be achieved in the case of coincidence of rolling directions of layers.

References:

Keeler S. P., 1968, Circular grid system - a valuable aid for evaluating sheet metal formability, SAE International 77: 371-379.
[2] Goodwin G. M. , 1968, Application of strain analysis to sheet metal forming problems in press shop, SAE International 77 : 380-387.
[3] Semiatin S. L., Piehler H. R., 1979, Deformation of sandwich sheet materials in uniaxial tension, Metallurgical Transactions A 10: 85-96.
[4] Semiatin S. L., Piehler H. R., 1979, Formability of sandwich sheet materials in plane strain compression and rolling, Metallurgical Transactions A 10: 97-107.
[5] Mori T., Kurimoto S., 1996, Press-formability of stainless steel and aluminum clad sheet, Journal of Materials Processing Technology 56: 242-253.
[6] Yoshida F., Hino R.,1997, Forming limit of stainless steel- clad aluminum sheets under plane stress condition, Journal of Materials Processing Technology 63: 66-71.
[7] Kim K. J., Kim D., Choi S. H., Chung K., Shin K. S., Barlat F., Oh K. H., Youn J. R., 2003, Formability of AA5182/polypropylen/AA5182 sandwich sheets, Journal of Materials Processing Technology 139 : 1-7.
[8] Lang L., Danckert J., Nielsen K. B., 2005, Multi-layer sheet hydroforming: experimental and numerical investigation into the very thin layer in the middle, Journal of Materials Processing Technology 170: 524-535.
[9] Jalali Aghchai A., Shakeri M., Mollaei Dariani B., 2008, Theoretical and experimental formability study of two-layer metallic sheet Al1100/St12, Proceedings of the Institution of Mechanical Engineers Part B , Journal of Engineering Manufacture 222 (9) : 1131-1138.
[10] Jalali Aghchai A., Shakeri M., Mollaei Dariani B., 2012, Influences of material properties of components on formability of two-layer metallic sheets, International Journal of Advanced Manufacturing Technology 66: 809-823.
[11] Liu J., Liu W., Xue W., 2013, Forming limit diagram prediction of AA5052 /polyethylene /AA5052 sandwich sheets, Materials & Design 46: 112-120.
[12] Parsa M. H., Ettehad M., Matin P. H., 2013, Forming limit diagram determination of Al 3105 sheets and Al 3105/polypropylene/Al 3105 sandwich sheets using numerical calculations and experimental investigation, Journal of Engineering Materials and Technology 135: 031003.
[13] Barlat F., Lian K., 1989, Plastic behavior and stretchability of sheet metals. Part I: A yield function for orthotropic sheets under plane stress conditions, International Journal of Plasticity 5: 51-66.
[14] Marciniak Z., Kuczynski K., 1967, Limit strains in the processes of stretch-forming sheet metal, International Journal of Mechanical Sciences 9: 609-620.
[15] Gronstajski J. Z., Zimniak Z., 1992, The effect of changing of heterogeneity with strain on the forming limit diagram, Journal of Materials Processing Technology 34: 457-464.
[16] Dariani B. M., Azodi H. D., 2003, Finding the optimum Hill index in the determination of the forming limit diagram, Proceedings of the Institution of Mechanical Engineers Part B , Journal of Engineering Manufacture 217 (12): 1677-1683.