The aluminium alloy AW-5754 with a sheet thickness of 1 mm was used. The FRP component was made of unidirectional glass-fibre-reinforced PA6 (GRP) with a fibre volume content of about 40 %. FRPs with a thickness of 1.2 mm and 2.5 mm were employed. As shown in Fig. 3, the semi-finished products were joined
without an adhesion promoter during the forming process, using the adhesive properties of the thermoplastic only and formed in one step. The surface temperature of the tool components (punch, die, down holder) was set to 270 °C. To ensure the joining of the half-finished products, a die with a bottom was used. By this, the sheets were compressed in the lower point and thus can form a compound. In order to avoid excessive squeezing-out of the thermoplastics in the flange, the down holder device was detached. The chosen distance was 0.5 mm less than the overall height of the sandwich. In the side wall area, a free deformation zone was implemented in order to consider the forming behaviour without constrain. For this, a punch diameter of 100 mm and a drawing die diameter of 120 mm were used. The targeted drawing depth was 35 mm. In the lowest process point the forming process was stopped and the part was removed after cooling.
The aluminium alloy AW-5754 with a sheet thickness of 1 mm was used. The FRP component was made of unidirectional glass-fibre-reinforced PA6 (GRP) with a fibre volume content of about 40 %. FRPs with a thickness of 1.2 mm and 2.5 mm were employed. As shown in Fig. 3, the semi-finished products were joinedwithout an adhesion promoter during the forming process, using the adhesive properties of the thermoplastic only and formed in one step. The surface temperature of the tool components (punch, die, down holder) was set to 270 °C. To ensure the joining of the half-finished products, a die with a bottom was used. By this, the sheets were compressed in the lower point and thus can form a compound. In order to avoid excessive squeezing-out of the thermoplastics in the flange, the down holder device was detached. The chosen distance was 0.5 mm less than the overall height of the sandwich. In the side wall area, a free deformation zone was implemented in order to consider the forming behaviour without constrain. For this, a punch diameter of 100 mm and a drawing die diameter of 120 mm were used. The targeted drawing depth was 35 mm. In the lowest process point the forming process was stopped and the part was removed after cooling.
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