–
Forming of mechanically interlocked aluminium and carbon fibre reinforced polymer parts with complex geometry
LATORRE Núria, CASELLAS Daniel, COSTA Josep, GARCIA-LLAMAS Eduard, PUJANTE Jaume
download PDFAbstract. Forming of aluminium-CFRP hybrid structures into complex shapes is key to decrease environmental impact in automotive industry. However, challenges such as preserving joint integrity after forming operations must be assessed. Therefore, the authors of this work have cold stamped hybrid aluminium-CFRP panels into omega shaped profiles with and without a mechanical interlocking joining technology. The effect of lubricant application, of the CFRP positioning (inside or outside the omega profile), and of the number of mechanical joints were studied. It was concluded that it is possible to cold stamp aluminium-CFRP prepreg panels even with mechanical joints into complex profiles when lubricant is used. Moreover, the position of the CFRP prepreg has a strong impact on the flange springback of the stamped part.
Keywords
Metal, CFRP, Punching, Stamping, Automotive
Published online 4/24/2024, 10 pages
Copyright © 2024 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: LATORRE Núria, CASELLAS Daniel, COSTA Josep, GARCIA-LLAMAS Eduard, PUJANTE Jaume, Forming of mechanically interlocked aluminium and carbon fibre reinforced polymer parts with complex geometry, Materials Research Proceedings, Vol. 41, pp 1640-1649, 2024
DOI: https://doi.org/10.21741/9781644903131-182
The article was published as article 182 of the book Material Forming
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
References
[1] J. Fleischer and J. Nieschlag, Introduction to CFRP-metal hybrids for lightweight structures, Prod. Eng., vol. 12, no. 2, pp. 109–111, 2018. https://doi.org/10.1007/s11740-018-0825-0
[2] A. Pramanik et al., Joining of carbon fibre reinforced polymer (CFRP) composites and aluminium alloys – A review, Compos. Part A Appl. Sci. Manuf., vol. 101, pp. 1–29, 2017. https://doi.org/10.1016/j.compositesa.2017.06.007
[3] Y. Ouyang and C. Chen, Research advances in the mechanical joining process for fiber reinforced plastic composites, Compos. Struct., vol. 296, no. March, p. 115906, 2022. https://doi.org/10.1016/j.compstruct.2022.115906
[4] A. Galińska, Mechanical joining of fibre reinforced polymer composites to metals—a review. Part I: Bolted joining, Polymers (Basel)., vol. 12, no. 10, pp. 1–48, 2020. https://doi.org/10.3390/polym12102252
[5] G. Di Franco, L. Fratini, and A. Pasta, Analysis of the mechanical performance of hybrid (SPR/bonded) single-lap joints between CFRP panels and aluminum blanks, Int. J. Adhes. Adhes., vol. 41, pp. 24–32, 2013. https://doi.org/10.1016/j.ijadhadh.2012.10.008
[6] F. Lambiase and D. C. Ko, Feasibility of mechanical clinching for joining aluminum AA6082-T6 and Carbon Fiber Reinforced Polymer sheets, Mater. Des., vol. 107, pp. 341–352, 2016. https://doi.org/10.1016/j.matdes.2016.06.061
[7] A. Galińska and C. Galiński, Mechanical joining of fibre reinforced polymer composites to metals-A review. Part II: Riveting, clinching, non-adhesive form-locked joints, pin and loop joining, Polymers (Basel)., vol. 12, no. 8, 2020. https://doi.org/10.3390/POLYM12081681
[8] N. Latorre, D. Casellas, and J. Costa, A punching process to join metal sheets and fibre reinforced polymer composites by mechanical interlocking, Compos. Part A, vol. 175, no. July, p. 107744, 2023. https://doi.org/10.1016/j.compositesa.2023.107744
[9] J. Heinrichs and S. Jacobson, The influence from shape and size of tool surface defects on the occurrence of galling in cold forming of aluminium, Wear, vol. 271, no. 9–10, pp. 2517–2524, 2011. https://doi.org/10.1016/j.wear.2011.01.077
[10] K. Lange, Handbook of Metal Forming, J. Appl. Metalwork., vol. 4, no. 2, p. 188, 1986. https://doi.org/10.1007/BF02834383
[11] J. Pujante, L. Pelcastre, M. Vilaseca, D. Casellas, and B. Prakash, Investigations into wear and galling mechanism of aluminium alloy-tool steel tribopair at different temperatures, Wear, vol. 308, no. 1–2, pp. 193–198, 2013. https://doi.org/10.1016/j.wear.2013.06.015
[12] M. Vilaseca, S. Molas, and D. Casellas, High temperature tribological behaviour of tool steels during sliding against aluminium, Wear, vol. 272, no. 1, pp. 105–109, 2011. https://doi.org/10.1016/j.wear.2011.07.007
[13] M. Vilaseca, J. Pujante, G. Ramírez, and D. Casellas, Investigation into adhesive wear of PVD coated and uncoated hot stamping production tools, Wear, vol. 308, no. 1–2, pp. 148–154, 2013. https://doi.org/10.1016/j.wear.2013.07.003
[14] J. Heinrichs and S. Jacobson, Laboratory test simulation of aluminium cold forming – influence from PVD tool coatings on the tendency to galling, Surf. Coatings Technol., vol. 204, no. 21–22, pp. 3606–3613, 2010. https://doi.org/10.1016/j.surfcoat.2010.04.025
[15] S. F. Hwang and Y. R. Li, Deep Drawing Behavior of Metal-Composite Sandwich Plates, Materials (Basel)., vol. 15, no. 19, 2022. https://doi.org/10.3390/ma15196612
[16] J. Gresham, W. Cantwell, M. J. Cardew-Hall, P. Compston, and S. Kalyanasundaram, Drawing behaviour of metal-composite sandwich structures, Compos. Struct., vol. 75, no. 1–4, pp. 305–312, 2006. https://doi.org/10.1016/j.compstruct.2006.04.010
[17] T. Heggemann and W. Homberg, Deep drawing of fiber metal laminates for automotive lightweight structures, Compos. Struct., vol. 216, no. December 2018, pp. 53–57, 2019. https://doi.org/10.1016/j.compstruct.2019.02.047
[18] K. Dohda, M. Yamamoto, C. Hu, L. Dubar, and K. F. Ehmann, Galling phenomena in metal forming, Friction, vol. 9, no. 4, pp. 665–685, 2021. https://doi.org/10.1007/s40544-020-0430-z
[19] A. Wang et al., Springback analysis of AA5754 after hot stamping: experiments and FE modelling, Int. J. Adv. Manuf. Technol., vol. 89, no. 5–8, pp. 1339–1352, 2017. https://doi.org/10.1007/s00170-016-9166-3
