The U-Bending Forming of Aluminum Foam Sandwich Panels

Chen, Sheng Gui; Chen, Hai Bin; Sun, Zhen Zhong; Li, Rong Yong; He, Wei Feng; Zou, Shun Qiang

doi:10.4028/www.scientific.net/AMM.477-478.1432

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HomeApplied Mechanics and MaterialsApplied Mechanics and Materials IIThe U-Bending Forming of Aluminum Foam Sandwich...

The U-Bending Forming of Aluminum Foam Sandwich Panels

Abstract:

The U-bending process of aluminum foam sandwich (AFS) is investigated, and a punch bending test is carried out in this paper. We discussed the bending deformation mode and generated the load & stroke curve of AFS panel by experiments. Macroscopic and microscopic punch forming mechanisms of AFS panels are analyzed by testing experiments and plasticity theory. We study the major deformation defects of AFS forming such as the delamination between the panel and the foam core, the excessive thinning of panels in the round corner, and shear stress cracks of the foam core. A conclusion is drawn on the panels variable blank holder force (VBHF) and the striking block control on the round corner, which would promote the forming technology of AFS.

Info:

Periodical:

Applied Mechanics and Materials (Volumes 477-478)

Main Theme:

Applied Mechanics and Materials II

Edited by:

Seung-Bok Choi, Yun-Hae Kim and Prasad Yarlagadda

Pages:

1432-1439

DOI:

https://doi.org/10.4028/www.scientific.net/AMM.477-478.1432

Citation:

S. G. Chen et al., "The U-Bending Forming of Aluminum Foam Sandwich Panels", Applied Mechanics and Materials, Vols. 477-478, pp. 1432-1439, 2014

Online since:

December 2013

Authors:

Sheng Gui Chen *, Hai Bin Chen, Zhen Zhong Sun, Rong Yong Li, Wei Feng He, Shun Qiang Zou

Keywords:

AFS, Deformation Defects, Forming Mechanism, U-Bending

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$41.00

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References

[1] Ashby M. F, Evans A, Fleck N.A., 2000. Metal Foams: A Design Guide, first ed. Butterworh-Heinemann, Boston, pp.65-75.

[2] Chen C，Harte A.M. ，Fleck N.A., 2001. The plastic collapse of sandwich beams with a metallic foam core, international Journal of Mechanical Sciences. 43, 1483-1506.

DOI: https://doi.org/10.1016/s0020-7403(00)00069-2

[3] Santosa Sigit, Banhart John, Wierzbicki Tomasz, 1999. Bending crush behavior of foam-filled section. In: Banhart, John (Eds. ), International Conference on Metal Foams and Porous Metal Structures, Verlag MIT. , Bremen, pp.337-345.

[4] Hanssen AG., Hopperstand OS., Langseth M., 2000. Bending of square aluminum extrusions with aluminum foam filler. Acta Mechanica. 142, 13-31.

DOI: https://doi.org/10.1007/bf01190010

[5] Santosa S, Banhart J, Wierzbicki T, 2001. Experimental and numerical analysis of bending of foam-filled sections. Acta Mechanica. 148, 199-213.

DOI: https://doi.org/10.1007/bf01183678

[6] XunKun, KouDongPeng, WangErHeng, YuJiLin, 2005. Static collapsed and bending behavior of thin-walled square tubes filled with aluminum foam. Solid Mechanics Journal. 26, 261-266. (In China).

Paper TitlePages

On the Finite Element Simulation of Secondary Operations on Metallic Foams

Authors: Luigino Filice, Livan Fratini, Domenico Umbrello

Abstract: Metallic foams have been recently introduced also as industrial materials due to their well known advantages. In fact, their low mass in conjunction with the good thermal and mechanical properties push toward an extensive diffusion in manufacturing industry. In the study here addressed, a very accurate investigation concerning the latter two aspects has been carried out. In fact, a secondary manufacturing process, i.e. the foam bending, has been taken into account. Anyway, all the knowledge derived for sheet metal bending is not directly applicable to the foams. A finite element code has been utilized for modeling the foam behavior during the bending processes and an accurate material rheology description was utilized based on a porous material model which includes the measured local density. The effectiveness of the utilized model has been verified through the comparison with a set of experimental data.

1886

Preparing Aluminum Foam Sandwich Panels by the Pack-Rolling-Powder Metallurgy Foaming Technique

Authors: Bin Na Song, Guang Chun Yao, Guo Yin Zu, Lei Wang, Hua Ding

Abstract: Billets of AFS with the thickness of 4.9 millimeters were manufactured by pack rolling process. SEM analysis for interfacial bonding and cell structures of AFS were carried out in detail. The results show that surface quality of the panel after pack rolling is obviously improved as compared to powder composite rolling using Al sheets. Macro-cracks of face sheets also completely disappear. The interfacial bonding in between Al tube and foamable precursor material have no micro-cracks and the existence of gap. Metallurgical bonding between Al face sheets and the core Al foams and uniform cell structures of AFS are achieved as the foaming temperature and foaming time are 700°C and 2 minutes, respectively.

613

Study on V-Bending of Aluminium Foam Sandwich Panels

Authors: Zhen Zhong Sun, Wei Feng He, Hai Bin Chen, Sheng Gui Chen, Rong Yong Li

Abstract: The forming of the completed aluminium foam sandwich (AFS) panels would determine an improvement in the manufacturing of parts and panels. In this paper the authors have investigated the formability of AFS through experiments. the load versus punch stroke curve and deformation procedures of Aluminium foam sandwiche panels was investigated by performing V-bending experiments. A serious problem encountered in the V-bending was bending-induced large transverse shear deformation of the skin-core layer. It causes the delamination of the AFS. It was found from experimental observations that the large shear defomation progresses rapidly only at the final stage of V-bending. Consequently, the air-bending operation for Aluminium foam sandwiche panels is recommended for suppressing the shear deformation of skin-core layer to within an acceptable limit.

281

Preparation of Al Foam Sandwiches and Analyzing on the Interface Solidification Microstructure

Authors: Lu Cai Wang, Xiao Hong You, Fang Wang, Jian Guo Wu

Abstract: Al Foam Sandwiches (AFS) has been created by a process of hot pressing Al-TiH2 precursor (core) made by cold pressing together with steel sheet, and then foaming. The microstructure and composition of Al-Fe interface has been analyzed by SEM and Element Linescanning Electron Microscopy (ELEM). The experiment and analysis show that during hot pressing process, firm mechanical bonding is formed between steel sheet and core, during foaming, the intermetallic compound FeAl3 and eutectic structure (FeAl3+Al) were formed by diffuse of Fe and Al elements each other at the interface, which gave a rise to a good metallurgical bonding interface between sheet and core.

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