Polymer injection forming (PIF) is a recent advancement in manufacturing of plastic– metal hybrid products. It is a combination of injection molding and sheet metal forming in which the molten polymer additionally serves as a pressure medium. This paper presents fundamental investigations on the use of polymer melt as a pressure medium in sheet metal forming. The development of forming pressure and localized blank temperature as a result of polymer injection is analyzed. The experiments are performed using aluminum alloy. The experiments comprise the bulging of a (free form) dome and stretch forming of a cup using thermoplastic polypropylene as a pressure medium. A simple approach is presented to model a combined process. An incremental lagrangian formulation is used to describe the polymer flow and sheet metal deformation. The Newtonian behavior of the polymer melt is modeled as rigid-viscoplastic medium. Standard finite element coupling is used to model the mutual metal–polymer interaction. The simulation results in the form of forming pressure profile, localized blank temperature profile, formed shape, and strain distribution are presented and validated with experimentally obtained results.
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e-mail: masood.hussain@iul.tu-dortmund.de
e-mail: Joerg.Witulski@iul.tu-dortmund.de
e-mail: Erman.Tekkaya@iul.tu-dortmund.de
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June 2012
Research Papers
An Experimental and Numerical Investigation on Polymer Melt Injected Sheet Metal Forming
Muhammad Masood Hussain,
Muhammad Masood Hussain
Institut für Umformtechnik und Leichtbau,
e-mail: masood.hussain@iul.tu-dortmund.de
Technische Universität Dortmund
, 44227 Dortmund, Germany
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Michael Trompeter,
Michael Trompeter
Institut für Umformtechnik und Leichtbau,
Technische Universität Dortmund
, 44227 Dortmund, Germany
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Jörg Witulski,
Jörg Witulski
Institut für Umformtechnik und Leichtbau,
e-mail: Joerg.Witulski@iul.tu-dortmund.de
Technische Universität Dortmund
, 44227 Dortmund, Germany
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A. Erman Tekkaya
A. Erman Tekkaya
Institut für Umformtechnik und Leichtbau,
e-mail: Erman.Tekkaya@iul.tu-dortmund.de
Technische Universität Dortmund
, 44227 Dortmund, Germany
Search for other works by this author on:
Muhammad Masood Hussain
Institut für Umformtechnik und Leichtbau,
Technische Universität Dortmund
, 44227 Dortmund, Germany
e-mail: masood.hussain@iul.tu-dortmund.de
Michael Trompeter
Institut für Umformtechnik und Leichtbau,
Technische Universität Dortmund
, 44227 Dortmund, Germany
Jörg Witulski
Institut für Umformtechnik und Leichtbau,
Technische Universität Dortmund
, 44227 Dortmund, Germany
e-mail: Joerg.Witulski@iul.tu-dortmund.de
A. Erman Tekkaya
Institut für Umformtechnik und Leichtbau,
Technische Universität Dortmund
, 44227 Dortmund, Germany
e-mail: Erman.Tekkaya@iul.tu-dortmund.de
J. Manuf. Sci. Eng. Jun 2012, 134(3): 031005 (13 pages)
Published Online: April 25, 2012
Article history
Received:
April 1, 2011
Revised:
January 9, 2012
Published:
April 24, 2012
Online:
April 25, 2012
Citation
Hussain, M. M., Trompeter, M., Witulski, J., and Tekkaya, A. E. (April 25, 2012). "An Experimental and Numerical Investigation on Polymer Melt Injected Sheet Metal Forming." ASME. J. Manuf. Sci. Eng. June 2012; 134(3): 031005. https://doi.org/10.1115/1.4006117
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