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Adaptive forming of hybrid sheet metal components at elevated temperatures

Thursday (09.11.2017)
11:15 - 11:35
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One of the main areas of public policy and interest is a more efficient use of resources in a constantly changing environment with varying requirements. Since the primary energy consumption is very high for the production of aluminium alloys, it is desirable to significantly extend the service life of aluminium products. New strategies therefore also include the systematic reuse of parts and products. For composite materials recycling can be technologically challenging and expensive, providing another incentive to instead adapt and reuse in a second utilisation phase.

This paper presents a method for forming and multiple adaptions of an aluminium polymer composite sheet metal using a forming process at elevated temperatures creating the possibility for reuse of manufactured parts. This paper characterises the hybrid sheet metal regarding its reuse and adaption by forming. As a first step the influence of increased temperatures on the material characteristics are investigated both regarding forming limits and general changes in material behaviour. The results show an improved formability at elevated temperatures, but more importantly constant material characteristics after the heat was applied indicating no damage to the polymer metal interfaces or the polymer layer itself.

In a second step repeated formability of the hybrid material is demonstrated using a 4-point-bending test and heat treatment. The sheet metal is heated to a temperature that liquefies the intermediate polymer layer to a paste like consistency. Then the bending process is carried out and the specimen is allowed to cool down so that the polymer can set again. The sheet metal strips keep their bended shape with little springback. The forming can be completely reversed by a simple short heat treatment at the forming temperature, however, and the sheet metal strips return to their original flat shape. The forming process can subsequently be repeated without significant changes in forming forces or forming limits. For this paper a total of three bending and reversing cycles were completed.

The results of this paper show the possibility to adapt a hybrid part to changing geometrical requirements using an adapted reversible forming process triggered by a heat treatment in between forming stages.

Dipl.-Ing. Marc Tulke
Technische Universität Dresden
Additional Authors:
  • Christina Guilleaume
    Technische Universität Dresden
  • Prof. Dr. Alexander Brosius
    Technische Universität Dresden


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