An analysis on forming limits of aluminum/copper clad metal with different thickness ratio by finite element method and deep drawing process

Huang Chi Tseng, Ching-Hua Hung*, Chin Chuan Huang

*Corresponding author for this work

Research output: Contribution to conferencePaperpeer-review

Abstract

Recently, the applications of clad metal are becoming popular. The preparation of clad metal takes two or more different materials bounded by cold or hot rolling processes. The bounded clad metals not only preserve the original characteristics of the layer metals, but also create more functional properties and reduce total materials cost. Generally, the clad metal has various advantageous properties such as good heat conductivity, anti-corrosiveness, wear-resistance, and high strength etc., and thus can be applied to many fields, for example, the electronics, the marines, and the automobile industry. The forming performances and mechanical properties of clad metals are different from individual materials because all bounded layer metals should always hold to each other, especially in the form of clad metal sheets. Furthermore, the strength and formability of the clad metal sheets will be changed if the initial thickness ratios of layer metals are varied. Thus, the initial thickness ratio of the clad metal sheets is a significant factor for design and secondary processing. In this research, the forming limits of clad metal sheets with different initial thickness ratios (e.g. Al 1.0, 1.5, 2.0mm/Cu 1.0mm) are investigated via experiments (forming limits test) and finite element simulations (ABAQUS). The stress-strain curves of Al/Cu clad metal sheets were obtained by tensile tests. According to the experimental forming limit diagrams and the stress-strain curves, the fracture prediction, deformation, and stress/strain distribution of clad metal sheets are conducted by a finite element analysis first and compared to those of the forming limit experiments again. Moreover, deep drawing tests were also conducted to further verify the validation of finite element simulation. Finally, comparisons for different initial thickness ratios of clad metal were made both numerically and experimentally and significant differences in formability were found. The results from this research can be used to improve manufacture processes of clad metal sheets with difference thickness ratios, especially for secondary forming.

Original languageEnglish
Pages702-707
Number of pages6
StatePublished - 1 Jan 2008
Event9th International Conference on Technology of Plasticity, ICTP 2008 - Gyeongju, Korea, Republic of
Duration: 7 Sep 200811 Sep 2008

Conference

Conference9th International Conference on Technology of Plasticity, ICTP 2008
CountryKorea, Republic of
CityGyeongju
Period7/09/0811/09/08

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