Effects of process parameters on the formability of sheet metal during plastic injection forming
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Murat Sen
Abstract
Plastic injection forming (PIF) is an alternative sheet metal forming method for complex geometrical parts with dimensions in low tolerance. This method is a combination of injection molding and hydroforming in which a molten polymer material has been injected over a sheet metal via a plastic injection molding machine. In this study, aluminum sheets 1.5 mm thick were shaped by PIF at various injection pressures, melt temperatures and injection speed. The effects of these parameters on the formability of the sheet metal were investigated using the experimental design technique. The thinning rate, flange radius and the hardness values of the shaped sheets were considered in the experimental study. Injection pressure was found to be the most effective parameter and melt temperature was the second degree effective parameter for the thinning rate. The usability of the PIF process in industrial applications as an alternative method was emphasized by comparing PIF with conventional hydroforming by means of the finite element method (Ls-Dyna). A 2.07 % deviation was observed between the FE results for hydroforming and the experimental results for PIF.
© 2020 by Walter de Gruyter Berlin/Boston
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- Title
- CONTENTS
- Materials Testing
- FACHBEITRÄGE
- Identification parameters for accident reconstruction software at frontal car impact
- Effects of adding Ni and Co on microstructure and gamma prime phase stability in Ni superalloy Inconel 738 with 1 wt.-% Al
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- Development of a bond graph model for electromechanical actuators
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- The equilibrium optimization algorithm and the response surface-based metamodel for optimal structural design of vehicle components
- The mine blast algorithm for the structural optimization of electrical vehicle components
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- Multi-response optimization of AA 8011 and 12 wt.-% fly ash composites
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