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Investigation on the effect of blank holder gap in the hydroforming of cylindrical cups, made of fiber metal laminate

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Abstract

Although fiber metal laminates (FMLs) were invented a few decades ago, large-scale manufacturing, especially the forming process of small and complex-shaped products, has not been matured yet. The forming difficulty comes with the limited strain rate of the fiber layers compared to the metallic layers. As a result, the conventional approaches to form FML parts are not very suitable. Understanding the material behavior during the forming process is critical to find a new technique for relatively intricate and smaller FML parts. The blank holder gap (BHG) is one of the effective parameters to control the material flow in the deep drawing process, but in the case of the FMLs, the situation is completely different due to the laminate constituent. The compression of the fiberglass and thermo-plastique resin to the blank holder force (BHF) is not the same as the metals. The resin acts like a rubber, which decreases the thickness of the laminate and affects the friction between the laminate layers, especially when forming semi-cured laminates, which makes it hard to define an ideal BHF. This paper presents the results of numerical and experimental investigation of the effect of the BHG on the hydromechanical deep drawing (HDD) of a cylindrical cup made with 2/1 Glare sheets. It is found that the optimized BHF and cavity pressure (CP) with a BHG of 1.1 mm, smaller than the laminate’s initial thickness of 1.2 mm, resulted in a good part with a significant depth improvement of 35 mm. Results also exhibited that FML parts manufactured by considering the BHG can enhance its applications and lead to a reduction of time and effort spent in mass production.

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Funding

This work was supported by the National Science Foundation of China under grant 51675029 and the Science and Technology Project of Sichuan Province under grant 2019YFSY0034.

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Authors and Affiliations

  1. School of Mechanical Engineering and Automation, Beihang University, No. 37 Xueyuan Road, Haidian District, Beijing, 100191, People’s Republic of China

    Hamza Blala, Lihui Lang, Lei Li, Ehsan Sherkatghanad & Sergei Alexandrov

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  1. Hamza Blala
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  2. Lihui Lang
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  3. Lei Li
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  4. Ehsan Sherkatghanad
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  5. Sergei Alexandrov
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Correspondence to Hamza Blala or Lihui Lang.

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Blala, H., Lang, L., Li, L. et al. Investigation on the effect of blank holder gap in the hydroforming of cylindrical cups, made of fiber metal laminate. Int J Adv Manuf Technol 108, 2727–2740 (2020). https://doi.org/10.1007/s00170-020-05467-8

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