Search Results (17)

Incremental sheet forming originated as an excellent alternative to conventional forming techniques for incrementally deforming flat metal sheets into complex three-dimensional profiles. Recently, its use has been extended to polymers and composites. Among these, the use of natural fiber-reinforced composites is increasing considerably compared to synthetic fiber-reinforced composites, due to the availability and unique properties of natural fibers in polymer applications. One of the dominant thermoplastics used as a matrix is polypropylene. This experimental study focuses on the incremental forming of natural fiber-reinforced polypropylene composites. Cones and spherical caps were manufactured from composite laminates of polypropylene reinforced with hemp and flax long-fiber fabrics. The formability limits, observed through failures and defects, as well as the forming forces, power, and energy consumption, were investigated to examine the feasibility of incremental forming applied to these composite materials; based on the results obtained, it is possible to say that the process can manufacture components with not very high wall angles but under low load conditions and allowing to limit the energy impact. Full article

Incremental sheet forming has emerged as an excellent alternative to other material forming procedures, incrementally deforming flat metal sheets into complex three-dimensional profiles. The main characteristics of this process are its versatility and cost-effectiveness; additionally, it allows for greater formability compared to conventional sheet forming processes. Recently, its application has been extended to polymers and composites. The following review aims to present the current state of the art in the incremental sheet forming of polycarbonate, an outstanding engineering plastic, beginning with initial studies on the feasibility of this process for polymers. Attention is given to the advantages, drawbacks, and main applications of incrementally formed polycarbonate sheets, as well as the influence of process parameters and toolpath strategies on features such as formability, forming forces, deformation and failure mechanisms, geometric accuracy, surface quality, etc. Additionally, new hybrid forming methods for process optimisation are presented. Finally, a discussion is provided on the technical challenges and future research directions for incremental sheet forming of polycarbonate and, more generally, thermoplastics. Thus, this review aims to offer an extensive overview of the incremental forming of polycarbonate sheets, useful to both academic and industrial researchers working on this topic. Full article

Thermoplastic polyimide (PI) matrixes, including PI-a (cc-34ODA) and PI-b (ct-34ODA) were prepared via the hot-pressing procedures of the resins derived from the 3,4′-oxydianiline (34ODA) and two alicyclic dianhydrides of 1S,2R,4S,5R-hydrogenated pyromellitic dianhydride (ccHPMDA) and 1R,2S,4S,5R-hydrogenated pyromellitic dianhydride (ctHPMDA), respectively. The resins exhibited thermoplastic features with good formability at higher temperatures. The afforded semi-alicyclic PI sheets exhibited enhanced properties in comparison to commercially available, wholly aromatic thermoplastic PIs, such as PI-ref1, which are derived from 3,3′,4,4′-oxydiphthalic anhydride (ODPA) and 4,4′-oxydianiline (44ODA), as well as PI-ref2, which is based on pyromellitic dianhydride (PMDA) and 4,4′-bis(3-aminophenoxy)biphenyl (mBAPB). In addition, the developed PI sheets exhibited high heat deflection temperatures (HDT) of 267.4 °C for PI-a and 268.6 °C for PI-b. There values were significantly higher when compared with those of PI-ref1 (Ratem^® YS20, HDT: 239.0 °C), PI-ref2 (Aurum^® PL450C, HDT: 238.0 °C), PI-ref3 (Ultem^® 1000, HDT: 206.0 °C), PI-ref4 (Therplim^® TO65, HDT: 180.0 °C), and PI-ref5 based on phthalic anhydride-terminated fluorinated PIs (HDT: 215.0 °C). In terms of mechanical properties, the current PI sheets showed superior flexural properties among the polymers with the flexural strength of 189.0 ± 11.7 MPa (PI-a) and 200.5 ± 4.2 MPa (PI-b), respectively. In addition, the PI sheets exhibited comparable compression properties, inferior impact strength, and tensile properties compared with the referenced PI counterparts. Basically, the PI-b sheet showed better comprehensive properties than those of the stereoisomeric PI-a analog. Full article

Carbon fiber reinforced polypropylene (CF/PP) thermoplastics integrate the superior formability of fabrics with the recoverable characteristics of polypropylene, making them a pivotal solution for achieving lightweight designs in new energy vehicles. However, the prevailing methodologies for designing the structural performance of CF/PP vehicular components often omit the constraints imposed by the manufacturing process, thereby compromising product quality and reliability. This research presents a novel approach for developing a stamping–bending coupled finite element model (FEM) utilizing ABAQUS/Explicit. Initially, the hot stamping simulation is implemented, followed by the transmission of stamping information, including fiber yarn orientation and fiber yarn angle, to the follow-up step for updating the material properties of the cured specimen. Then, the structural performance analysis is conducted, accounting for the stamping effects. Furthermore, the parametric study reveals that the shape and length of the blank holding ring exerted minimal influence on the maximum fiber angle characteristic. However, it is noted that the energy absorption and crushing force efficiency metrics of the CF/PP specimens can be enhanced by increasing the length of the blank holding ring. Finally, a discrete optimization design is implemented to enhance the bending performance of the CF/PP specimen, accounting for the constraint of the maximum shear angle resulting from the stamping process. The optimized design resulted in a mass reduction of 14.3% and an improvement in specific energy absorption (SEA) by 17.5% compared to the baseline sample. Full article

Thermoplastic composite organosheets (OSs) are increasingly recognized as a viable solution for automotive and aerospace structures, offering a range of benefits including cost-effectiveness through high-rate production, lightweight design, impact resistance, formability, and recyclability. This study examines the impact response, post-impact strength evaluation, and hot-pressing repair effectiveness of woven glass fiber nylon composite OSs across varying impact energy levels. Experimental investigations involved subjecting composite specimens to impact at varying energy levels using a drop-tower test rig, followed by compression-after-impact (CAI) tests. The results underscore the exceptional damage tolerance and improved residual compressive strength of the OSs compared to traditional thermoset composites. This enhancement was primarily attributed to the matrix’s ductility, which mitigated transverse crack propagation and significantly increased the amount of absorbed energy. To mitigate impact-induced damage, a localized hot-pressing repair approach was developed. This allowed to restore the post-impact strength of the OSs to pristine levels for impact energies below 40 J and by 83.6% for higher impact energies, when OS perforation was observed. The measured levels of post-repair strength demonstrate a successful restoration of OS strength over a wide range of impact energies, and despite limitations in achieving complete strength recovery above 40 J, hot-pressing repair emerges as a promising strategy for ensuring the longevity of thermoplastic composites through repairability. Full article

A series of Ti₄₁Zr₂₅Be_34-xNi_x (x = 4, 6, 8, 10 at.%) and Ti₄₁Zr₂₅Be_34-xCu_x (x = 4, 6, 8 at.%) bulk metallic glasses were investigated to examine the influence of Ni and Cu content on the viscosity, thermoplastic formability, and nanoindentation of Ti-based bulk metallic glasses. The results demonstrate that Ti₄₁Zr₂₅Be₃₀Ni₄ and Ti₄₁Zr₂₅Be₂₆Cu₈ amorphous alloys have superior thermoplastic formability among the Ti₄₁Zr₂₅Be_34-xNi_x and Ti₄₁Zr₂₅Be_34-xCu_x amorphous alloys due to their low viscosity in the supercooled liquid region and wider supercooled liquid region. The hardness and modulus exhibit obvious variations with increasing Ni and Cu content in Ti-based bulk metallic glasses, which can be attributed to alterations in atomic density. Optimal amounts of Ni and Cu in Ti-based bulk metallic glasses enhance thermoplastic formability and mechanical properties. The influence of Ni and Cu content on the hardness of Ti-based bulk metallic glasses is discussed from the perspective of the mean atomic distance. Full article

The newly-developed thermoplastic-based fibre metal laminates (T-FML) show good prospects for their application in the automotive industry because of their lightweight potential and thermal formability. This paper focuses on describing the tensile and bending properties of this hybrid material as structural components for load-bearing parts in vehicles. For this purpose, the uniaxial tensile and four-point bending behaviours of steel/glass fibre-reinforced polyamide 6 (GF-PA6)/steel-laminates are investigated. The effects of cover/core layer thickness ratio and fibre weaving style on their tensile and bending properties are considered, while the span-to-thickness ratio was kept constant. Testing of the mono-materials and laminates of Metal/PA6/Metal (MPM) is performed to be considered as a reference. Further, the analytical method is validated to predict the bending properties of the laminates. A good agreement between the analytical values and experimental results regarding the bending strength and modulus is revealed. T-FML showed better tensile and bending properties with increasing fibre content compared to the GF-PA6 mono-organosheet and MPM. Full article

This paper focuses on investigating the forming behaviour of sandwich materials composed of steel sheets and glass fibre-reinforced polyamide 6 (GF-PA6), i.e., thermoplastic-based fibre metal laminates (FML). Stretching and forming limit curve (FLC) determination of FML with different cover/core layer thickness ratios at various forming temperatures, i.e., at room temperature (RT), 200 and 235 °C, are the main approaches for characterizing their formability. In addition, the formability of mono-materials and non-reinforced sandwich materials is investigated as a reference. For a successful test and reliable results, several technical issues are considered, such as the suitable lubrication configuration and digital image correlation at elevated forming temperatures. The results revealed that the formability of non-reinforced sandwich materials with different core layer thicknesses exhibited compared formability to their monolithic steel sheet and no remarkable improvement in their formability with increasing the temperature up to 200 °C. Conversely, the formability of FML shows significant improvement (approx. 300%) with increasing temperature with a forming depth of about 33 mm at 235 °C compared to only 12 mm at RT. Full article

DcAFF (discontinuous aligned fibre filament) is a novel material for fused filament fabrication (FFF) 3D printing made of highly aligned discontinuous fibres produced using high performance discontinuous fibre (HiPerDiF) technology. It reinforces a thermoplastic matrix to provide high mechanical performance and formability. Accurate printing of DcAFF poses a challenge, especially for complex geometries, because: (i) there is a discrepancy between the path where the filament experiences the adhering pressure from the filleted nozzle and the nozzle path; and (ii) the rasters display poor adhesion to the build platform immediately after deposition, which causes the filament to be dragged when the printing direction changes. This paper explains the implication of these phenomena on steering capabilities and examines the techniques for improving DcAFF printing accuracy. In the first approach, the machine parameters were adjusted to improve the quality of the sharp turning angle without changing the desired path, but this showed insignificant effects in terms of precision improvements. In the second approach, a printing path modification with a compensation algorithm was introduced. The nature of the inaccuracy of the printing at the turning point was studied with a first-order lag relationship. Then the equation to describe the deposition raster inaccuracy was determined. A proportional–integral (PI) controller was added to the equation to calculate the nozzle movement in order to bring the raster back to the desired path. The applied compensation path is shown to give an accuracy improvement in curvilinear printing paths. This is particularly beneficial when printing larger circular diameter curvilinear printed parts. The developed printing approach can be applied with other fibre reinforced filaments to achieve complex geometries. Full article

Incremental sheet forming represents a relatively new process appointed to form sheets of pure metals, alloys, polymers, and composites for the manufacture of components in fields where customized production in a short time and at a low cost is required. Its most common variant, named single-point incremental forming, is a flexible process using very simple tooling; the sheet is clamped along the edges and a hemispherical-headed tool follows a required path, to deform the sheet locally. In so doing, better formability is reached without any dedicated dies and for low-forming forces, which represent some of the attractive features of this process. Nevertheless, and with special reference to thermoplastic sheets, incremental formed parts suffer from peculiar defects like twisting and wrinkling. In this numerical work, analyses were conducted through a commercial finite element code by varying the toolpath strategy of the incremental forming of polycarbonate sheets. The investigation of some features like the forming forces, the deformation states, the energy levels, and the forming time was carried out, to determine the toolpath strategy able to optimize the incremental forming process of polymer sheets. The results of the numerical analyses highlight a reduction of the forming forces when using toolpaths alternating diagonal up and vertical down steps and, presumably, a reduced risk of failures and defects. Furthermore, these toolpath strategies solutions also have a positive impact on the environment in terms of energy and do not significantly increase the manufacturing time. Full article

In this study, hot stamping tests on continuous glass fiber (GF)-reinforced thermoplastic (PP) composites were conducted under different process parameters using a self-designed hemispherical hot stamping die with a heating system. The effects of parameters such as preheating temperature, stamping depth, and stamping speed on the formability of the fabricated parts were analyzed using optical microscopy and scanning electron microscopy (SEM). The test results show that the suitable stamping depth should be less than 15 mm, the stamping speed should be less than 150 mm/min, and the preheating temperature should be about 200 °C. From the edge of the formed parts to their pole area, a thin-thick-thin characteristic in thickness was observed. Under the same preheating temperature, the influence of stamping depth on the thickness variation of the formed parts was more significant than the stamping speed. The primary defects of the formed parts were cracking, wrinkling, delamination, and fiber exposure. Resin poverty often occurred in the defect area of the formed parts and increased with stamping depth and stamping speed. Full article

A recycling process of waste thermosetting polyurethane plastics was proposed based on the mechanochemical method, aiming at the three-dimensional network cross-linking structure of thermosetting polyurethane. Orthogonal experimental design was adopted to select three factors of crushing speed, crushing time, and feed amount to determine the best crushing parameters. Then, the waste polyurethane insulation boards were crushed and degraded by the mechanism of regenerative forming with the adjustable speed test machine. Accordingly, the recycled powder was obtained. Finally, nine kinds of polyurethane recycled composite plates were prepared by hot pressing process. The degradation effect of thermosetting polyurethane was analyzed by Fourier transform infrared spectroscopy, scanning electron microscope, and X-ray diffraction. Moreover, the mechanical properties and thermal insulation properties of recycled composite plates were tested and analyzed. The results show that the network cross-linking molecular structure of waste thermosetting polyurethane plastics is destroyed by the effect of mechanochemical action, and methyl and aldehyde groups are decomposed. Therefore, a recycled powder with strong reactivity and plasticity is generated, which improves the activity regeneration ability. After adding thermoplastic resin, the mechanical properties and formability of recycled composite plates are enhanced, with maximum tensile strength up to 9.913 MPa. Correspondingly, the thermal insulation performance of plates is reduced. However, the minimum thermal conductivity can also reach 0.056 W/m·K. This study provides an effective method for the recycling of thermosetting polyurethane plastics. Full article

The poor thermoplastic formability of reactive Zr-based bulk metallic glass becomes the main limiting factor for replacing the noble-metal-based and Be-rich bulk metallic glasses in nanostructure fabrication. In our work, a (Zr_50.7Cu₂₈Ni₉Al_12.3)_98.5Y_1.5 bulk metallic glass with good thermoplastic formability has been developed by alloying, where Y addition enlarges the processing window and decreases the viscous resistance of supercooled liquid caused by the high free volume density. The prepared Zr-Cu-Ni-Al-Y bulk metallic glass nanostructure retains the amorphous characteristic and generates the complex oxidization products in the surface layer. The enhanced hydrophilicity of the as-embossed surface follows a Wenzel-impregnating wetting regime, and it can be attributed to the large roughness coefficient induced by the capillary effect. This study provides a low-cost and environmentally friendly bulk metallic glass system to manufacture the nanostructure with a broad prospect in the field of electrocatalysis. Full article

Multilayered fibre–metal laminates (FMLs) are composed of metal semifinished products and fibre-reinforced plastics, and benefit from the advantages of both material classes. Light metals in combination with fibre-reinforced thermoplastics are highly suitable for mass production of lightweight structures with good mechanical properties. As the formability of light metal sheets is sometimes limited at room temperature, increasing the process temperature is an appropriate approach to improve formability. However, the melting of thermoplastic materials and resulting loss of stiffness limit the processing temperature. Since single-ply layers have different through-thickness stiffnesses, the forming process changes the ply thickness of the multilayered laminate. In the present study, the deformation behaviour of multilayered FMLs was investigated using a two-dimensional finite-element model assuming plane strain. The thermoelastic-plastic finite-element analysis made investigation of the variation in thickness made possible by incorporating sufficient mesh layers in the thickness direction. The results indicate that a thermoelastic-plastic finite-element model can predict the delamination of plies during deformation, as well as in the final product. Additionally, the predicted changes in thickness of the plies are in good agreement with experimental results when a temperature-dependent friction coefficient is used. Full article

Developing bio-inspired functional surfaces on engineering metals is of extreme importance, involving different industrial sectors, like automotive or aeronautics. In particular, micro-embossing is one of the efficient and large-scale processes for manufacturing bio-inspired textures on metallic surfaces. However, this process faces some problems, such as filling defects and die breakage due to size effect, which restrict this technology for some components. Electrically assisted micro-forming has demonstrated the ability of reducing size effects, improving formability and decreasing flow stress, making it a promising hybrid process to control the filling quality of micro-scale features. This research focuses on the use of different current densities to perform embossed micro-channels of 7 μm and sharklet patterns of 10 μm in textured bulk metallic glass dies. These dies are prepared by thermoplastic forming based on the compression of photolithographic silicon molds. The results show that large areas of bio-inspired textures could be fabricated on magnesium alloy when current densities higher than 6 A/mm² (threshold) are used. The optimal surface quality scenario is obtained for a current density of 13 A/mm². Additionally, filling depth and depth–width ratio nonlinearly increases when higher current densities are used, where the temperature is a key parameter to control, keeping it below the temperature of the glass transition to avoid melting or an early breakage of the die. Full article