Skip to main content

Investigation into thinning and spring back of multilayer metal forming using hydro-mechanical deep drawing (HMDD) for lightweight parts

The International Journal of Advanced Manufacturing Technology volume 82, pages 817–826 (2016)Cite this article

Abstract

Lightweight, hybrid parts are extensively used in the manufacturing of modern aerospace or automobile structures like fiber metal laminates (FMLs) to replace the monolithic metallic parts. Presently, smaller and complex-shaped FML parts are made by applying the stamp-forming techniques. However, due to limited strain of the composite fibers, such techniques are unfit for forming complex profile laminated parts. This study focuses on the use of hydro-mechanical deep drawing (HMDD) for the three layers simultaneous forming of the metallic blanks to fabricate a hemispherical structure which will then be used to make a FML part. Orthogonal test strategy is formulated to investigate the influence of variables such as cavity/pre-bulging pressures, pre-bulging height, and die-binder gap to optimize the forming conditions. FE-based experimental study is done to research the thickness distribution and spring back of the formed multilayer structure. Results show that the research is sufficient in predicting these attributes and can provide a basis to understand the fundamental phenomenon for three-layered, simultaneously formed structures. Hybrid parts fabricated by using multilayer forming can expand the application areas of FMLs.

This is a preview of subscription content, access via your institution.

Access options

Buy single article

Instant access to the full article PDF.

USD 39.95

Price includes VAT (USA)
Tax calculation will be finalised during checkout.

References

  1. Asundi A, Choi AYN (1997) Fiber metal laminates: an advanced material for future aircraft. J Mater Process Technol 63:384–394

    Article  Google Scholar 

  2. Sinmazcelik T, Avcu E, Bora MO, Coban O (2011) A review: fibre metal laminates, background, bonding types and applied test methods. Mater Des 32:3671–3685

    Article  Google Scholar 

  3. Park SY, Choi WJ, Choi HS (2010) A comparative study on the properties of GLARE laminates cured by autoclave and autoclave consolidation followed by oven postcuring. Int J Adv Manuf Technol 49:605–613

    Article  Google Scholar 

  4. Kumar KV, Safiullah M, Ahmad ANK (2013) Root cause analysis of heating rate deviations in autoclave curing of CFRP structures. Int J Innov Res Stud 2(5):369–378

    Google Scholar 

  5. Dmitriev O, Mischenko S (2011) Optimization of curing cycles for thick-wall products of the polymeric composite materials. INTECH Open Access Publisher ISBN 978-953-307-150-3, pp. 141-160

  6. Thomas MM, Joseph B, Kardos JL (1997) Experimental characterization of autoclave-cured glass-epoxy composite laminates: cure cycle effects upon thickness, void content, and related phenomena. Polym Compos 18(3):283–299

    Article  Google Scholar 

  7. Mosse L, Compston P, Cantwell WJ, Cardew-Hall M, Kalyanasundaram S (2005) The effect of process temperature on the formability of polypropylene based fibre–metal laminates. Compos A: Appl Sci Manuf 36(8):1158–1166

    Article  Google Scholar 

  8. 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

    Article  Google Scholar 

  9. Kalyanasundaram S, DharMalingam S, Venkatesan S, Sexton A (2013) Effect of process parameters during forming of self reinforced–PP based fiber metal laminate. Compos Struct 97:332–337

    Article  Google Scholar 

  10. Gresham J, Cantwell W, Cardew-Hall MJ, Compston P, Kalyanasundaram S (2006) Drawing behaviour of metal–composite sandwich structures. Compos Struct 75(1):305–312

    Article  Google Scholar 

  11. Lang LH, Danckert J, Nielsen KB (2005) Multi-layer sheet hydroforming: experimental and numerical investigation into the very thin layer in the middle. J Mater Process Technol 170:524–535

    Article  Google Scholar 

  12. Tzou GY, Huang MN (2003) Analytical modified model of the cold bond rolling of unbounded double-layers sheet considering hybrid friction. J Mater Process Technol 140:622–627

    Article  Google Scholar 

  13. Zafar R, Lang L, Zhang R (2014) Experimental and numerical evaluation of multilayer sheet forming process parameters for light weight structures using innovative methodology. Int J Mater Form 1-13

  14. Tseng HC, Hung CH, Huang CC (2010) An analysis of the formability of aluminum/copper clad metals with different thicknesses by the finite element method and experiment. Int J Adv Manuf Technol 49:1029–1036

    Article  Google Scholar 

  15. Atrian A, Fereshteh-Saniee F (2013) Deep drawing process of steel/brass laminated sheets. Compos Part B 47:75–81

    Article  Google Scholar 

  16. Hino R, Goto Y, Yoshida F (2003) Springback of sheet metal laminates in draw-bending. J Mater Process Technol 139(1):341–347

    Article  Google Scholar 

  17. Kim HS, Koç M (2008) Numerical investigations on springback characteristics of aluminum sheet metal alloys in warm forming conditions. J Mater Process Technol 204(1):370–383

    Article  Google Scholar 

  18. Mohammadi SV, Parsa MH, Aghchai AJ (2011) Effect of the thickness distribution and setting condition on springback in multi-layer sheet bending. International Journal of Engineering, Sci Technol 3(4)

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering and Automation, Beihang University, 37#Xueyuan Road, Haidian District, Beijing, China, 100191

    Rongjing Zhang, Lihui Lang, Rizwan Zafar, Lijing Lin & Wenshang Zhang

Authors
  1. Rongjing Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Lihui Lang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Rizwan Zafar
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Lijing Lin
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Wenshang Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Rongjing Zhang.

Rights and permissions

Reprints and Permissions

About this article

Verify currency and authenticity via CrossMark

Cite this article

Zhang, R., Lang, L., Zafar, R. et al. Investigation into thinning and spring back of multilayer metal forming using hydro-mechanical deep drawing (HMDD) for lightweight parts. Int J Adv Manuf Technol 82, 817–826 (2016). https://doi.org/10.1007/s00170-015-7415-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-015-7415-5

Keywords

  • Hybrid
  • HMDD
  • Orthogonal tests
  • Wall thickness distribution
  • Spring back