Numerical Simulation Analysis on Surface Quality of Aluminum Foam Sandwich Panel in Plastic Forming
The surface quality of an aluminum foam sandwich panel (AFSP) is very important for its appearance and application. This paper mainly studies the surface quality of AFSP after plastic forming. Combined with three-dimensional (3D) scanning technology, the normal deviation between the experimental AFS...
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MDPI AG
2022-12-01
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| Series: | Metals |
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| author | Weiguang Zhang Zhongyi Cai Xi Zhang Jiaxin Gao Mingwei Wang Qingmin Chen |
| author_facet | Weiguang Zhang Zhongyi Cai Xi Zhang Jiaxin Gao Mingwei Wang Qingmin Chen |
| author_sort | Weiguang Zhang |
| collection | DOAJ |
| description | The surface quality of an aluminum foam sandwich panel (AFSP) is very important for its appearance and application. This paper mainly studies the surface quality of AFSP after plastic forming. Combined with three-dimensional (3D) scanning technology, the normal deviation between the experimental AFSP and the target surface was obtained, and the surface quality parameters <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><msub><mi>S</mi><mi>q</mi></msub></mrow></semantics></math></inline-formula>, <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><msub><mi>S</mi><mi mathvariant="normal">z</mi></msub></mrow></semantics></math></inline-formula> and <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><msub><mi>d</mi><mrow><mi>max</mi></mrow></msub></mrow></semantics></math></inline-formula> were calculated to evaluate surface quality. The AFSP models with cubic-spherical (CS) and tetrakaidecahedral (TKD) as foam structures were established respectively. A series of numerical simulations of multi-point forming (MPF) were then carried out. Equivalent strain and deformation characteristics of spherical and saddle-shaped AFSP were discussed. The main surface defects produced by AFSP in plastic forming, such as surface wrinkle, the local straight face effect and surface dimpling were analyzed. Finally, MPF experiments were carried out, and it was found that the numerical simulation results were significantly corresponded to the experimental AFSP in terms of the degree and distribution of normal deviation and surface quality evaluation parameters. The TKD model was more consistent with the experimental results than the CS model. Moreover, the results show that the surface quality can be improved by thicker face sheets and smaller core cell sizes. |
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| last_indexed | 2024-03-09T11:42:34Z |
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| spelling | doaj.art-775b2520dd204bae9d2d640d4cc184c22023-11-30T23:30:14ZengMDPI AGMetals2075-47012022-12-011316510.3390/met13010065Numerical Simulation Analysis on Surface Quality of Aluminum Foam Sandwich Panel in Plastic FormingWeiguang Zhang0Zhongyi Cai1Xi Zhang2Jiaxin Gao3Mingwei Wang4Qingmin Chen5College of Materials Science and Engineering, Jilin University, Changchun 130025, ChinaCollege of Materials Science and Engineering, Jilin University, Changchun 130025, ChinaCollege of Materials Science and Engineering, Jilin University, Changchun 130025, ChinaCollege of Materials Science and Engineering, Jilin University, Changchun 130025, ChinaCollege of Materials Science and Engineering, Jilin University, Changchun 130025, ChinaRoll Forging Research Institute, Jilin University, Changchun 130025, ChinaThe surface quality of an aluminum foam sandwich panel (AFSP) is very important for its appearance and application. This paper mainly studies the surface quality of AFSP after plastic forming. Combined with three-dimensional (3D) scanning technology, the normal deviation between the experimental AFSP and the target surface was obtained, and the surface quality parameters <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><msub><mi>S</mi><mi>q</mi></msub></mrow></semantics></math></inline-formula>, <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><msub><mi>S</mi><mi mathvariant="normal">z</mi></msub></mrow></semantics></math></inline-formula> and <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><msub><mi>d</mi><mrow><mi>max</mi></mrow></msub></mrow></semantics></math></inline-formula> were calculated to evaluate surface quality. The AFSP models with cubic-spherical (CS) and tetrakaidecahedral (TKD) as foam structures were established respectively. A series of numerical simulations of multi-point forming (MPF) were then carried out. Equivalent strain and deformation characteristics of spherical and saddle-shaped AFSP were discussed. The main surface defects produced by AFSP in plastic forming, such as surface wrinkle, the local straight face effect and surface dimpling were analyzed. Finally, MPF experiments were carried out, and it was found that the numerical simulation results were significantly corresponded to the experimental AFSP in terms of the degree and distribution of normal deviation and surface quality evaluation parameters. The TKD model was more consistent with the experimental results than the CS model. Moreover, the results show that the surface quality can be improved by thicker face sheets and smaller core cell sizes.https://www.mdpi.com/2075-4701/13/1/65aluminum foam sandwich panelsurface quality evaluationplastic formingmulti-point formingnumerical simulation |
| spellingShingle | Weiguang Zhang Zhongyi Cai Xi Zhang Jiaxin Gao Mingwei Wang Qingmin Chen Numerical Simulation Analysis on Surface Quality of Aluminum Foam Sandwich Panel in Plastic Forming Metals aluminum foam sandwich panel surface quality evaluation plastic forming multi-point forming numerical simulation |
| title | Numerical Simulation Analysis on Surface Quality of Aluminum Foam Sandwich Panel in Plastic Forming |
| title_full | Numerical Simulation Analysis on Surface Quality of Aluminum Foam Sandwich Panel in Plastic Forming |
| title_fullStr | Numerical Simulation Analysis on Surface Quality of Aluminum Foam Sandwich Panel in Plastic Forming |
| title_full_unstemmed | Numerical Simulation Analysis on Surface Quality of Aluminum Foam Sandwich Panel in Plastic Forming |
| title_short | Numerical Simulation Analysis on Surface Quality of Aluminum Foam Sandwich Panel in Plastic Forming |
| title_sort | numerical simulation analysis on surface quality of aluminum foam sandwich panel in plastic forming |
| topic | aluminum foam sandwich panel surface quality evaluation plastic forming multi-point forming numerical simulation |
| url | https://www.mdpi.com/2075-4701/13/1/65 |
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