Channel deformation of bilayer material using tool rollers: Part I-Springback

Abstract

ABSTRACT In this two-part paper, the bilayer material is created by sandwiching the aluminium alloy and carbon fibre composite and then deforming through the conventional channel forming. In both aluminium alloy and polymer, the common problem is the springback due to their lower modulus of elasticity. To reduce the springback mechanically, the patented process is used in this work. In this novel manufacturing process, the die and punch radii are converted in rollers. These rollers can be fixed or rotated depending on the necessity. The first part of this paper involves investigating the bilayer material deformation and springback through the novel manufacturing process. For this the bilayer material was created with equal thickness of aluminium alloy and composite. In one sample the aluminium alloy was the top layer and, in another sample, the aluminium alloy material was bottom layer. From the results it was found that the top layer aluminium alloy composite material with punch roller rotating in counterclockwise and die roller rotating in clockwise direction shows lowest springback. The residual stress graph shows that the rollers rotation changes the stress patterns in the material which results in lower springback.