Numerical and Experimental Investigation of Joining Aluminium and Carbon Fiber Reinforced Composites by Electromagnetic Forming Process
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Date
2016-04-27
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Abstract
Carbon fiber reinforced composites became so popular in automotive, aerospace, marine
and military industries in past years, because of their high strength, low weight and
subsequently high specific strength. The basic challenges of producing the CFRP
components are their forming and joining techniques. In this study, a finite element analysis
is carried out by the purpose that the optimum geometries to be selected for manufacturing
an electromagnetically assisted joining by forming system of two aluminium and CFRP
sheets. Electromagnetic forming is one of the high speed forming technologies that uses the
Lorentz force as a forming pressure. High speed and usually one-step forming process are
some of its advantages while, the necessity of high electrical conductivity of the work-piece
is an important restriction. Aluminium deformed in this study, so that its behaviour is
assumed to be dependent on the strain rate. Also, the hardening behaviour of aluminium is
described by the Johnson-Cook material model. The joining by forming system is modelled
in the finite element code by means of the ABAQUS 6.13 FEM software. The magnetic
pressure pulse of the coil is described by the VDLOAD subroutine to apply it to the lower
surface of the aluminium field shaper. Under influence of this force, the punch bulges the
aluminium sheet into the hole on the CFRP sheet and a cavity on die helps the bulged region
to form a mechanical interlock. In the experimental investigations, predrilled CFRP sheets
with different diameter holes and locations are used. The effect of geometrical parameters
such as metal thickness are studied on the quality of joints. The most important parameter
to be considered here, is the tensile strength of the joints. Therefore, the joint samples had
been applied under tensile test in order to consider failure modes, experimentally.
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Keywords
joining, finite element method (FEM), fiber reinforced plastic
Subjects based on RSWK
Fügen, Magnetumformen, Faserverstärkter Kunststoff, Finite-Elemente-Methode