Channel deformation of bilayer material using tool rollers: part II-effect of layer thickness on springback

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ABSTRACT

In this second part of the two-part paper, the layer thickness in the top-layer aluminium alloy and bottom-layer aluminium alloy samples were changed to see the effect if layer thickness has any influence on the deformation and springback behaviour. Four thickness were considered 0.2, 0.4, 0.6, and 0.8 mm for aluminium layer either as a top layer or the bottom layer. To match the bilayer thickness of 1 mm, the remaining thickness was given to the carbon fibre composite layer. Again the 10-process variation were simulated for each layer thickness of aluminium material and results were presented. As found in the first part of the paper the fixed roller and no roller process provides the highest springback in all considered cases. Three distinct regions in the springback profiles were observed with the top-layer or the bottom-layer aluminium material. If the aluminium material layer is towards the punch side and punch rollers are fixed and if the aluminium alloy material is towards the die side and die rollers are fixed the springback profiles are in between the highest and lowest springback cases. It was also noted that the springback increases with increase in the aluminium layer thickness.

KEYWORDS:

• Channel forming
• springback
• bilayer
• layer thickness
• tool rollers
• residual stress

Acknowledgements

The author would like to thank Penn State Erie, The Behrend College, to perform this research and its unique open lab research facility.

Disclosure statement

No potential conflict of interest was reported by the author(s).