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<p>The present study quantified the effect of changing metal state and polymer thickness on the accuracy of a metal/polymer laminate in the incremental sheet forming (ISF) process. These effects were associated with the relaxation behavior for gaining an in-depth understanding of springback behavior. A series of tests were conducted to determine the relaxation parameters and mechanical properties of unformed monolithic sheets and laminates. Shapes from monolithic sheets and laminates were produced through ISF, followed by accuracy measurement. The results revealed that regardless of the metal state, the accuracy of the formed laminates was a way lower (min 60%) than that of the formed monolithic polymer sheets. Also, the accuracy irrespective of the metal state increased as the polymer thickness in the laminate was increased reasoning to a corresponding reduction in the strain relaxation. However, on comparing findings of the two sets of laminates, it appeared that laminates based on annealed metal suffered from slightly more springback than those based on the rolled metal attributing to their greater strain relaxation. As regard to the metal state effect on accuracy, it was about ~ 14% (max) and that of changing polymer thickness was about ~ 28% (max). Correlations of yield ratio and yield strength with strain relaxation and accuracy were also examined, and their role on springback was identified. Finally, it is proposed to employ rolled metal and thicker polymer sheets to produce laminates in order to create components with improved accuracy.</p>

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Characterizing the effect of metal state on forming accuracy of Al/HDPE laminates in novel incremental forming process: insights into stress/strain relaxation and springback behavior

  • 期刊论文

  • 发表日期：

    2025年12月8日

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  • Abdul Qadeer,
  • Nashmi H. Alrasheedi,
  • Wajid Khan,
  • Borhen Louhichi,
  • Babar Khan,
  • Wasim A. Khan,
  • Hongyu Wei,
  • Ghulam Hussain

摘要

The present study quantified the effect of changing metal state and polymer thickness on the accuracy of a metal/polymer laminate in the incremental sheet forming (ISF) process. These effects were associated with the relaxation behavior for gaining an in-depth understanding of springback behavior. A series of tests were conducted to determine the relaxation parameters and mechanical properties of unformed monolithic sheets and laminates. Shapes from monolithic sheets and laminates were produced through ISF, followed by accuracy measurement. The results revealed that regardless of the metal state, the accuracy of the formed laminates was a way lower (min 60%) than that of the formed monolithic polymer sheets. Also, the accuracy irrespective of the metal state increased as the polymer thickness in the laminate was increased reasoning to a corresponding reduction in the strain relaxation. However, on comparing findings of the two sets of laminates, it appeared that laminates based on annealed metal suffered from slightly more springback than those based on the rolled metal attributing to their greater strain relaxation. As regard to the metal state effect on accuracy, it was about ~ 14% (max) and that of changing polymer thickness was about ~ 28% (max). Correlations of yield ratio and yield strength with strain relaxation and accuracy were also examined, and their role on springback was identified. Finally, it is proposed to employ rolled metal and thicker polymer sheets to produce laminates in order to create components with improved accuracy.