Abstract
The corrugated sheet is a crucial component of the metal honeycomb structure. This study investigates the size effects on the deformation behavior of ultra-thin-walled corrugated sheets in the roll bending process using experimental and simulation methods. A precision roll bending device was developed, which incorporated a specifically designed eccentric fine-tuning module and a pneumatic module to prevent the distortion and insufficient deformation of the ultra-thin-walled corrugated sheets. The experimental results showed that micro-scratches and orange peel phenomenon appeared in the bending region of ultra-thin-walled corrugated sheets due to the lack of grain deformation coordination. Decreasing the ratio of foil thickness to grain diameter (t/d value) resulted in a slight increase in edge lengths, but a sharp decrease in the thickness of the bending region of ultra-thin-walled corrugated sheets. For the ultra-thin-walled corrugated sheet with a t/d value of 1.2, its thickness was reduced by 14%, leading to a high risk of rupture. Consequently, a finite element model of the roll bending process was established with consideration of the heterogeneity of grain shape and grain orientation. The simulation results indicate that the prediction error of the model for the springback angle was less than 15%. The random distribution of elastic deformation and plastic penetration zones is responsible for the great scatter of the springback angle of ultra-thin-walled corrugated sheets. This research provides a theoretical foundation for the precision manufacturing of ultra-thin-walled corrugated sheets.
Similar content being viewed by others
Data availability
Data will be made available on request.
References
Qiu K, Ming W, Shen L, An Q, Chen M (2017) Study on the cutting force in machining of aluminum honeycomb core material. Compos Struct 164:58–67. https://doi.org/10.1016/j.compstruct.2016.12.060
Ismail Z, Ong ZC (2012) Honeycomb damage detection in a reinforced concrete beam using frequency mode shape regression. Measurement 45(5):950–959. https://doi.org/10.1016/j.measurement.2012.01.049
Eichenhueller B, Egerer E, Engel U (2007) Microforming at elevated temperature - forming and material behaviour. Int J Adv Manuf Technol 33(1–2):119–124. https://doi.org/10.1007/s00170-006-0731-z
Zheng W, Wang G, Zhao G, Wei D, Jiang Z (2013) Modeling and analysis of dry friction in micro-forming of metals. Tribol Int 57:202–209. https://doi.org/10.1016/j.triboint.2012.06.031
Lai X, Peng L, Hu P, Lan S, Ni J (2008) Material behavior modelling in micro/meso-scale forming process with considering size/scale effects. Comput Mater Sci 43(4):1003–1009. https://doi.org/10.1016/j.commatsci.2008.02.017
Chan WL, Fu MW, Lu J, Liu JG (2010) Modeling of grain size effect on micro deformation behavior in micro-forming of pure copper. Mater Sci Eng A 527(24):6638–6648. https://doi.org/10.1016/j.msea.2010.07.009
Mahabunphachai S, Koç M (2008) Investigation of size effects on material behavior of thin sheet metals using hydraulic bulge testing at micro/meso-scales. Int J Mach Tools Manuf 48(9):1014–1029. https://doi.org/10.1016/j.ijmachtools.2008.01.006
Janssen PJM, Hoefnagels JPM, de Keijser TH, Geers MGD (2008) Processing induced size effects in plastic yielding upon miniaturisation. J Mech Phys Solid 56(8):2687–2706. https://doi.org/10.1016/j.jmps.2008.03.008
Fu MW, Chan WL (2013) Micro-scaled progressive forming of bulk micropart via directly using sheet metals. Mater Des 49:774–783. https://doi.org/10.1016/j.matdes.2013.02.045
Liu JG, Fu MW, Chan WL (2012) A constitutive model for modeling of the deformation behavior in microforming with a consideration of grain boundary strengthening. Comp Mater Sci 55:85–94. https://doi.org/10.1016/j.commatsci.2011.11.018
Cao J, Zhuang W, Wang S, Lin J (2010) Development of a VGRAIN system for CPFE analysis in micro-forming applications. Int J Adv Manuf Technol 47(9–12):981–991. https://doi.org/10.1007/s00170-009-2135-3
Ma Z, Peng X, Wang C, Cao Z (2020) Modeling of material deformation behavior in micro-forming with consideration of individual grain heterogeneity. T Nonferr Metal Soc 30(11):2994–3005. https://doi.org/10.1016/S1003-6326(20)65437-1
Funding
This work was supported by financial support from the Jiangsu Graduate Scientific Research and Innovation Program (grant No. KYCX23_3308), State Administration of Science, Technology and Industry for National Defense (No. JCKY2020203B056), the Natural Science Foundation of Jiangsu Province (BK20222010, BK20220636), the National Natural Science Foundation of China (No. 51875128 and No. 51905362), Six Talent Peaks in Jiangsu Province (GDZB-069), and the Natural Science Foundation of Jiangsu Higher Education Institutions of China (No. 20KJA460003).
Author information
Authors and Affiliations
Contributions
JY: writing—original, draft, and analysis. QM: investigation, methodology, and analysis. YZ: original draft and analysis. BZ: supervision and analysis. CW: investigation. ZM: analysis and investigation.
Corresponding authors
Ethics declarations
Competing interests
The authors declare no competing interests.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Ye, J., Ma, Q., Zhang, Y. et al. Size effects on deformation behavior of ultra-thin-walled corrugated sheets in roll bend forming process. Int J Adv Manuf Technol 130, 1749–1758 (2024). https://doi.org/10.1007/s00170-023-12791-2
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-023-12791-2