On the bending angle of aluminum-copper two-layer sheets in laser forming process

Abstract

The purpose of this paper is to numerically and experimentally investigate with optimized parameters laser thermal bending of aluminum-copper two-layer sheet. Due to the fact that laminated sheets have more ductility and lower manufacturing costs, in this article, the thermal bending behavior of this type of sheet is investigated. For this purpose, the optimal model is obtained using the Taguchi and finite element methods, with respect to the cost functions and the defined levels for the parameters. The effective parameters of the laser forming process such as the scanning speed, the laser beam power, and the laser beam diameter on the aluminum-copper two-layer sheet are optimally determined and subsequently the laser thermal bending of the aluminum-copper two-layer sheet is obtained by experimental tests. The Taguchi method is used to optimize the simulations required for the analysis. The Taguchi method with its own algorithm reduced the number of experiments to 9 design points. These experiments are simulated by the finite element method with a three-dimensional elastoplastic model. Then, to verify the numerical results of these optimized parameters, the samples are fabricated and the effect of optimal parameters on the behavior of this type of the aluminum-copper two-layer sheet is evaluated under experimental tests. The results showed that the laser beam power has a direct relation and the laser beam diameter and scanning speed have an inverse relation with the final bending angle.