Abstract
In this paper, a new evaluation and prediction method for coating delamination during sheet metal forming is presented. On the basis of the forming limit diagram (FLD), the current study evaluates the delamination of PET coating by using a cross-cut specimen, dome test, and rectangular-cup drawing test. Dome test specimens were subjected to biaxial, plane strain, and uniaxial deformation modes. Rectangular cup-drawing test specimens were subjected to the deep-drawing deformation mode, and compression deformation mode. A vinyl-coated metal (VCM) sheet consists of three layers of polymer on the sheet metals: a protective film, a PET layer and a PVC layer. The areas with coating delamination were identified, and the results of the evaluation were plotted according to major and minor strain values, depicting coating delamination. The constructed delamination limit diagram (DLD) can be used to determine the forming limit of VCM during the complex press-forming process. ARGUS (GOM) was employed to identify the strain value and deformation mode of the delaminated surface after the press forming. After identifying the areas of delamination, the DLD of the PET coating can be constructed in a format similar to that of the FLD. The forming limit of the VCM sheet can be evaluated using the superimposition of the delamination limit strain of the coating onto the FLD of VCM sheet. The experimental results showed that the proposed test method will support the sheet metal forming process design for VCM sheets. The assessment method presented in this study can be used to determine the delamination limit strain under plastic deformation of other polymer coated metals. The experimental results suggested that the proposed testing method is effective in evaluating delamination for specific applications.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
References
R. Vayeda and J. Wang, Adhesion of coating to sheet metal under plastic deformation, International Journal of Adhesion and Adhesives, 27 (2007) 480–492.
J. Wang and R. Alexander, An experimental investigation of coating durability in forming pre-coated sheet metal, North American Manufacturing Research Institution of the Society of Manufacturing Engineers (2003) 57–63.
C. Gay, Does stretching affect adhesion? International Journal of Adhesion and Adhesives, 20 (2000) 387–393.
T. Chang, E. A. Sproat, Y. H. Lai, N. E. Shephard and D. A. Dillard, A test method for accelerated humidity conditioning and estimation of adhesive bond durability, Journal of Adhesion, 69 (1999) 99–120.
D. A. Dillard, B. Chen, T. Chang and Y. H. Lai, Analysis of the notched coating adhesion test, Journal of Adhesion, 69 (1999) 99–120.
J. Jaworski, S. R. Schmid and J. Wang, An experimental investigation of the formability and friction characteristics of tin coated and polymer laminated steels, Journal of Manufacturing Science and Engineering, 121 (1999) 232–237.
C. H. Huang, S. Schmid and J. Wang, Thermal effects on polymer laminated steel formability in ironing, Journal of Manufacturing Science and Engineering, 123 (2001) 225–230.
C. H. Huang, Ph.D thesis, Tribology of polymer films in manufacturing, University of Notre Dame (2001).
K, Hatanaka, M. Fukui, Y. Mukai and K. Toyose, Influence of drawing on organic-coating adgesion property in aluminum, Journal of Japan Institute of Metals, 39(9) (1989) 621–626.
F. Deflorian, L. Fedrizzi, S. Rossi, L. Benedetti amd P. Bonora, Effect of mechanical deformation on the degradation of coil coated stainless steel, Metallurgia Italiana, 91(5) (1999) 55–60.
H. Braunlich and M. Demmler, Behavior of organic coatings during forming, Metal forming, 32(12) (1998) 36–40.
R. Vayeda and J. Wang, Adhesion of coating to sheet metal under plastic deformation, International Journal of Adhesion and Adhesives, 27 (2007) 480–492.
Z. Marciniak, J. L. Duncan and S. L. Hu, Mechanics of sheet metal forming, Butterworth-Heinemann (1992) 30–43.
ASTM E 2218-02, Standard test method for determining forming limit curves, ASTM international (2008).
R. Ozturk and D. Lee, Experimental and numerical analysis of put-of-plane formability test, Journal of Materials Processing Technology, 170 (2005) 247–253.
V. Uthaisangsuk, U. Prahl, M Ünstermann and W. Bleck, Experimental and numerical failure criterion for formability prediction in sheet metal forming, Computational Materials Science, 43 (2008) 43–50.
D. Ravi kumar, Formability analysis of extra-deep drawing steel, Journal of Materials Processing Techmology, 130–131 (2002) 31–41.
C. J. Lee, S. K. Lee, D. C. Ko and B. M. Kim, Evaluation of Adhesive Properties using Cohesive Zone Model, Trans. of the KSME(A), 33(5) (2009) 474–481.
C. J. Lee, J. Y. Kim, S. K. Lee, D. C. Ko and B. M. Kim, Parametric study on mechanical clinching process for joining aluminum alloy and high strength steel sheets, J. of Mechanical Science and Technology, 24 (2010) 123–126.
C. M. Wichern, B. C. De Cooman and C. J. Van Tyne, Surface roughness of a hot-dipped galvanized sheet steel as a function of deformation mode, Journal of Materials Processing Technology, 160 (2005) 278–288.
Author information
Authors and Affiliations
Corresponding author
Additional information
Recommended by Associate Editor Vikas Tomar
Young-Ki Son is currently a Ph.D candidate at the Precision Manu-facturing Systems Division at Pusan National University in Busan, Korea. His current research interests include polymer coated metal forming.
Byung-Min Kim received his B.S., M.S. and Ph.D degrees from Pusan National University, Korea, in 1979, 1984 and 1987, respectively. He is currently a professor at the School of Mechanical Engineering at Pusan National University in Busan, Korea.
Rights and permissions
About this article
Cite this article
Son, Yk., Lee, Cj., Lee, Jm. et al. Experimental evaluation of coating delamination in vinyl-coated metal forming. J Mech Sci Technol 26, 3223–3230 (2012). https://doi.org/10.1007/s12206-012-0824-6
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12206-012-0824-6