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Single point incremental forming of Cu-Al composite sheets: A comprehensive study on deformation behaviors

100%

Liu Z. , Li G.

Archives of Civil and Mechanical Engineering

2019

tom Vol. 19, no. 2

484--502

Compared with monolithic metal sheet, Single Point Incremental Forming (SPIF) of bimetal composite sheet has attracted increasing attention, as it takes advantages of materials with different superior properties, such as high strength, low density, and good corrosion resistance. However, deformation behaviors of bimetal composite sheet in SPIF may differ from the single-layer sheet, which depends on the layer arrangements and mechanical properties of each layer. In this regard, a comprehensive study was conducted to investigate the deformation behaviors of roll-bonded Cu-Al composite sheets in SPIF through predictive modeling, including analytical, empirical as well as numerical approaches, and extensive experimental work taking into consideration effects of key process parameters. It was demonstrated that overall, the formability, surface roughness, thickness variation and forming force in different layer arrangements, in terms of various process parameters, follow the similar trends to single-layer sheets. However, it was further revealed that deformation mode of layer-up sheet tends to a compression state and that of layer-down sheet tends to a stretching state. This leads to higher formability and larger forming force in Al/Cu layer arrangement compared to Cu/Al layer arrangement, as the exterior thinner but stronger Cu layer could endure more stretching deformation.

Mechanical performances of metal-polymer sandwich structures with 3D-printed lattice cores subjected to bending load

80%

Liu Z. , Chen H. , Xing S.

Archives of Civil and Mechanical Engineering

2020

tom Vol. 20, no. 3

368--384

In this article, we propose a new class of metal-polymer architected sandwich structures that exhibit different mechanical behaviors. These lightweight sandwich structures have been made of aluminum face sheets and 3D-printed lattice cores with 2D (Bi-grid, Tri-grid, Quadri-grid and Kagome-grid) and 3D (face-centered cubic-like and body-centered cubic-like) topologies. Finite element simulation and experimental tests were carried out to evaluate mechanical performances of the proposed sandwich structures under quasi-static three-point bending load. Specifically, the damage-tolerant capability, energy absorption and failure mechanisms of these sandwich structures were investigated and evaluated through a combination of analytical, numerical and experimental methods. It is found that sandwich structures with 3D face and body-centered cubic-like cores can provide more excellent flexural stiffness, strength and energy absorption performance. These enhanced mechanical features could be further explained by a so-called ‘Stress Propagation’ mechanism through finite element analysis (FEA) that can facilitate sandwich structures with 3D cores, especially body-centered cubic-like one, to transfer bending loads from central lattice units across neighboring ones more efficiently than 2D cores. Furthermore, core cracking is the main failure mode for the proposed sandwich structures, which is primarily caused and dominated by bending-induced tensile stress followed by shear stress. It is worth mentioning that our findings provide new insights into the design of novel lightweight sandwich composites with tailored mechanical properties, which can benefit a wide variety of high-performance applications.