基于未固化 GLARE 成型极限曲线的新型双阶段失效标准

IF 6.7 2区 材料科学 Q1 ENGINEERING, INDUSTRIAL Journal of Materials Processing Technology Pub Date : 2024-08-22 DOI:10.1016/j.jmatprotec.2024.118567
Meng Zhang , Zheng-qiang Cheng , Yang-kai Chen , Yao Wang , Zheng-ping Zou , Zhen-li Mi , Yong Li
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引用次数: 0

摘要

成型极限曲线(FLC)是大规模制造中评估金属纤维层压板(FML)成型性的基本标准。然而,传统方法无法预测纤维内部的失效,对起皱缺陷非常敏感,导致测量精度和稳定性较低。因此,我们开发了一种新的双阶段失效标准,考虑了纤维层和金属层的渐进式失效,并通过利用缺口图案样品和典型的薄壁结构,以及四种典型的玻璃层压铝增强环氧树脂(GLARE),对该标准进行了验证。本研究对一系列不同宽度的凹槽图案和传统图案试样进行了中岛试验,结果表明凹槽图案在防止起皱和分层方面具有优越性,其边缘区域的三轴应力提高了 22.84%,压缩应变降低了 39.51%。值得注意的是,冲压反作用力和应变场分析揭示了纤维过早失效而铝保持完好的突变现象,数值和断续方法也验证了这一点。此外,在中岛试验中,采用声发射原位法监测了未固化 GLARE 的渐进损伤演变,为在突变部位发生纤维断裂提供了可靠支持。利用这些突变,设计了一系列双阶段成形极限曲线,以量化双轴拉伸条件下未固化 GLARE 的渐进损伤行为。最后,在一个箱形零件的制造过程中演示了这种新型双阶段成形极限曲线方法的实际应用,作为其有效性的概念验证。这项研究为表征金属纤维层压板的内在失效机理(尤其是各种应变条件下的内部纤维失效)提供了一个基础指南,从而提高了预测的准确性。
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A novel dual-stage failure criterion based on forming limit curve for uncured GLARE

Forming limit curve (FLC) is an essential criterion for evaluating the formability of fiber metal laminates (FMLs) in mass fabrication. However, conventional methodologies are unable to predict inner fiber failure, very sensitive to wrinkling defects, resulting in low measurement accuracy and stability. Hence, a novel dual-stage failure criterion considering the progressive failure of fiber and metal layers has been developed and validated by utilizing a notch-pattern sample and forming of typical thin-walled structure, with four typical categories of glass laminate aluminum reinforced epoxy (GLARE). The Nakajima tests of a series of notch-pattern and conventional pattern specimens with different widths were conducted in this study, demonstrating the superiority of wrinkling and delamination prevention of the notch-pattern by enhancing 22.84 % stress triaxiality and reducing 39.51 % compress strain in the edge area. Notably, punch reaction force and strain field analyses unveiled a mutation phenomenon indicative of premature fiber failure while the aluminum remained intact, which was also verified by numerical and interrupted methods. Furthermore, the acoustic emission in-situ method was adopted to monitor the progressive damage evolution of uncured GLARE in the Nakajima test, providing solid support for the occurrence of fiber failure at the mutation site. Leveraging these mutations, a list of dual-stage forming limit curves was devised to quantify the progressive damage behavior of uncured GLARE under biaxial tensile conditions. Finally, the practical application of this novel dual-stage forming limit curve methodology was demonstrated in the manufacturing process of a box-shaped part, serving as a proof of concept for its effectiveness. This study offers a foundational guideline for characterizing the intrinsic failure mechanisms of fiber metal laminates, particularly internal fiber failure under various strain conditions, thereby enhancing predictive accuracy.

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来源期刊
Journal of Materials Processing Technology
Journal of Materials Processing Technology 工程技术-材料科学:综合
CiteScore
12.60
自引率
4.80%
发文量
403
审稿时长
29 days
期刊介绍: The Journal of Materials Processing Technology covers the processing techniques used in manufacturing components from metals and other materials. The journal aims to publish full research papers of original, significant and rigorous work and so to contribute to increased production efficiency and improved component performance. Areas of interest to the journal include: • Casting, forming and machining • Additive processing and joining technologies • The evolution of material properties under the specific conditions met in manufacturing processes • Surface engineering when it relates specifically to a manufacturing process • Design and behavior of equipment and tools.
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