Formability Analysis of Metal-Polymer Sandwich Composites Considering the Adhesion Strength

Abstract

Metal-Polymer-Metal (Mpm) Sandwich Composites Are In The Class Of Proficient Engineering Materials Which Give Superb Strength-To-Weight Ratios Because Of Their Comparatively Low Density. These Materials Are Vital Constituents Within The Automobile, Aerospace, Marine And Civil Construction Industries As Substitutes For Sheet Metals That Considerably Reduces Weight While Not Compromising Functionality. For These Materials To Be Utilized Within The Aforesaid Industries, They Need To Bear Numerous Forming Processes That Are Essential In Product Manufacturing. This ThesisInvestigates Formability Of Metal-Polymer Sandwich Composites Made Of ?�?Aw 6082?�? Pvc ?�? Aw 6082 (Apa)?�? And ?�?Galvanized Steel ?�? Pvc ?�? Galvanized Steel (Gpg)?�? Sandwich Sheets, Considering Epoxy Structural Adhesive As Binding Agent, Via Experimentation And Finite Element Simulation. Tensile Strength, Plastic-Strain Ratio (R-Value), Lowest Point On Flc (Flc0) And Adhesive Strength Are Obtained From Experimentation. These Values Are Fed Into Limiting Dome Height (Ldh) Simulation (Performed Using Altair Hyperworks Software) For Multiple Strain Path Analysis. The Results Are Forming Limit Diagram (Fld) And Dome Height At Diverse Conditions Of Punch Velocity And Friction. Aluminum And Apa Revealed More Anisotropic Behavior Compared To Galvanized Steel And Gpg Respectively. A Comparison Is Made To Represent The Best Combinations For Formability Of The Sandwich Composites. Maximum Formability And Dome Height (Ldh) Are Attained At Low Friction Conditions (Less Than 0.015) And Forming Speed (5000 Mm/Min). The Comparison Of Flc0 Values Obtained Revealed Acceptable Match Between Experimental And Simulation Values. Weight Reduction Of 9.777 % - For Apa ?�? And 27.75 % - For Gpg ?�? Are Achieved Compared To Aluminum Sheet And Galvanized Steel Sheet Respectively. The Results Indicate That The Studied Mpm Sandwich Composites Can Undergo Forming Operations.