Temperature-dependent anisotropic material modeling of the sheet metal component within the polymer injection forming process
In the course of this work, an extended material model for a carbon steel sheet metal has been developed based on Hill’48 yield criterion, considering temperature-dependent plastic anisotropy coefficients. This material model is applied on a polymer injection forming process in which the sheet metal heats up to a critical forming temperature through the contact with the plastic melt. At this temperature range blue brittleness occurs. The elastic properties, the yield stress as well as the plastic anisotropy coefficients of the sheet material become significantly different compared to those at room temperature. It should be emphasized that especially temperature-dependent anisotropy coefficients are not yet considered in most common material models. With the help of the presented modelling approach a more precise modelling of the temperature-dependent carbon steel material behavior can be realised.
Hybrid Single Shot Manufacturing of Multi-Materials Structure for Automotive Applications
.............................................................................................................................ii DEDICATIONS ........................................................................................................................ v ACKNOWLEDGMENTS ....................................................................................................... vi LIST OF TABLES .................................................................................................................... x LIST OF FIGURES ................................................................................................................ xi 1. MOTIVATION AND INTRODUCTION ........................................................................... 1 1.1 Hybrid components ......................................................................................................... 1 1.2 Thermoset-thermoplastic components ........................................................................... 4 1.3 Introduction of Hybrid Single Shot (HSS) method .......................................................... 10 2. LITERATURE REVIEW AND RESEARCH GAPS ......................................................13 2.1 Literature review ........................................................................................................... 13 2.2 Similar processes ........................................................................................................... 18 2.3 Summary of research gaps ............................................................................................ 20 3. AIMS AND ORGANIZATION OF THE WORK ............................................................22 4. FEASIBILITY STUDY FOR MANUFACTURING CF/EPOXY—THERMOPLASTIC HYBRID STRUCTURES IN A SINGLE OPERATION .....................................................25 4.1 Experimental investigations .......................................................................................... 26 4.1.1 Experimental setup and manufacturing approach................................................. 26 4.1.2 Materials ................................................................................................................ 27 4.1.3 Experimental procedure ........................................................................................ 28 4.1.4 Experimental results and discussion ...................................................................... 29
Finite element analysis of forming of sheet metal blank in manufacturing metal/polymer macro-composite components via injection moulding
A new approach to manufacture metal/polymer macro-composite components is presented, in which the injected polymer melt from the injection machine forces the sheet metal blank to deform according to the contour of the mould and the space between the formed sheet blank acts as the moulding cavity of the polymer melt. As the melt cools down, it adheres to the surface of the formed sheet blank. The mechanism of adhesion bonding between the polymer and the surface of the formed sheet blank is discussed briefly. The deformation characteristics and evolution of plastic strains of the sheet blank during the manufacturing process, the distribution of plastic strains and thickness of the formed sheet blank, and the effects of drawing-in of the flange on these have been analysed by the finite element method and experiment. According to deformation characteristics, the formed sheet blank can be divided into five regions. It is shown that deep drawing is the dominating process when the pressure increases from 0 to about 30 MPa; after this stage, stretch forming of the sheet blank that has already been in the mould cavity is the dominating process and two highly strained zones with severe thickness reduction are developed.