Numerical and experimental formability analysis of aluminum 3105 sandwich panels produced by continuous hot-press forming

Cagatay Elibol; Sadam Hamis Wapande

doi:10.1515/mt-2021-2003

Article

Numerical and experimental formability analysis of aluminum 3105 sandwich panels produced by continuous hot-press forming

Cagatay Elibol and Sadam Hamis Wapande
Sadam Hamis Wapande, born in 1990, received his B.Sc. degree in Mechanical Engineering at Erciyes University, Turkey, in 2015 with honor as the third best graduate in his department. From 2016 to 2019, he studied a joint master’s program in Manufacturing Technology between TU Dortmund University, Germany, and Turkish-German University, Turkey. During his master studies, he worked on formability analysis of different kinds of aluminum composites.

Published/Copyright: February 21, 2022

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From the journal Materials Testing Volume 64 Issue 1

Abstract

Aluminum–plastic composites as building materials are widely used for different construction purposes, for instance, for exterior wall cladding, ventilated facades, and interior decoration of buildings, in billboards, trains, and automotive industry. The main goal of this study is to investigate the formability of AA3105/LDPE/AA3105 sandwich composite in detail, which would exhibit a higher formability compared to AA3105 due to its higher strain rate sensitivity and strain hardening exponent. This is of decisive importance for the manufacturing process. The Nakajima tests are performed to experimentally determine the forming limit curves (FLCs) using in situ optical technique digital image correlation. Furthermore, numerical simulations of Nakajima tests are conducted using a modified Gurson–Tvergaard–Needleman damage model to compare the numerically and experimentally determined FLCs. The results show that the sandwich composite underwent inhomogeneous deformation during the Nakajima test, and that the FLC has no typical patterns exhibited by metal sheets. The FLCs predicted by the numerical model used in this study exhibit a very good correlation with the FLCs determined experimentally. The results of the present study provide new insights into the analysis and understanding of the deformation behavior of the sandwich composite sheet that may undergo complex stress and strain states.

Keywords: aluminum alloys; digital image correlation; finite element analysis; Nakajima tests; sandwich-structured composites

Corresponding author: Cagatay Elibol, Turkish-German University, Department of Materials Science and Technology, Istanbul, 34820, Turkey, E-mail: elibol@tau.edu.tr

About the author

Sadam Hamis Wapande

Sadam Hamis Wapande, born in 1990, received his B.Sc. degree in Mechanical Engineering at Erciyes University, Turkey, in 2015 with honor as the third best graduate in his department. From 2016 to 2019, he studied a joint master’s program in Manufacturing Technology between TU Dortmund University, Germany, and Turkish-German University, Turkey. During his master studies, he worked on formability analysis of different kinds of aluminum composites.

Acknowledgment

This research was carried out as a part of the master thesis research of Sadam Hamis Wapande under the supervision of Asst. Prof. Dr.-Ing. Cagatay Elibol from Turkish-German University, Turkey, and Prof. Dr.-Ing. Dr.-Ing. E.h. A. Erman Tekkaya from TU Dortmund, Germany. The authors would like to thank the Institute of Forming Technology and Lightweight Components (IUL) of TU Dortmund and the Research and Development Department of ASAS Aluminum Company (Sakarya, Turkey) for providing test materials and testing machines. Special thanks to Asst. Prof. Dr. Abdolvahed Kami from Semnan University (Iran) for the assistance related to the GTN damage model used in the present study for numerical simulation.

Author contributions: All the authors have accepted responsibility for the entire content of this submitted manuscript and approved submission.
Research funding: None declared.
Conflict of interest statement: The authors declare no conflicts of interest regarding this article.

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Published Online: 2022-02-21

Published in Print: 2022-01-27

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Keywords for this article

aluminum alloys; digital image correlation; finite element analysis; Nakajima tests; sandwich-structured composites