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Related Concept Videos

Plastic Deformations01:19

Plastic Deformations

Plastic deformation represents a fundamental concept in materials science, which explains the irreversible change in the shape of a material when it experiences stress beyond its elastic capability. This phenomenon is important in structural engineering, especially in designing and analyzing cantilever beams—structures that are securely fixed at one end and bear loads at the opposite end. When these beams are subjected to loads within their elastic range, they will return to their original...

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Deformation Behavior and Accuracy Control in Gas-Assisted Diaphragm Forming of Composites Using Multi-Point Flexible

Deyu Yue1, Ruixiang Luo1, Yuan Li1

  • 1Key Laboratory of Automobile Materials, Ministry of Education, School of Materials Science and Engineering, Jilin University, Changchun 130022, China.

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Summary

A new gas-assisted diaphragm forming (GADF) process using multi-point flexible dies (MPFDs) improves curved composite sheet accuracy. Optimal parameters reduce defects and enhance geometrical precision by over 38%.

Keywords:
dimple defectsgas-assisted diaphragm forminggeometrical accuracymulti-point flexible dieprocessing parameters

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Area of Science:

  • Materials Science
  • Manufacturing Engineering
  • Composite Materials

Background:

  • Multi-point flexible dies (MPFDs) offer reconfigurable forming for curved sheets but suffer from poor surface and geometrical accuracy in fiber-reinforced composites.
  • Existing MPFD limitations hinder widespread application in advanced composite component manufacturing.

Purpose of the Study:

  • To propose and investigate a novel gas-assisted diaphragm forming (GADF) process utilizing MPFDs for enhanced forming accuracy of curved basalt fiber/epoxy resin composite sheets.
  • To analyze the influence of process parameters (temperature, pressure, interpolator thickness) on defect formation and geometrical accuracy.
  • To develop a predictive model for optimizing MPFD configurations and achieving high-accuracy composite component forming.

Main Methods:

  • Implementation and precise control of temperature, pressure, and MPFD configuration within the GADF process.
  • Analysis of dimple defects and geometrical accuracy under varying process parameters.
  • Development of a response surface-based prediction model to correlate component structure with geometrical accuracy.
  • Compensation reconfiguration of MPFDs guided by the predictive model for accuracy enhancement.

Main Results:

  • Increasing pressure worsened dimple defects and reduced shape accuracy.
  • Optimal forming temperature was identified as 120 °C; deviations aggravated defects and errors.
  • Increased interpolator thickness reduced dimples but negatively impacted geometrical accuracy beyond an optimal point.
  • Optimal parameters determined: 5 kPa pressure, 120 °C temperature, and 2 mm interpolator thickness.

Conclusions:

  • The developed GADF process effectively addresses accuracy limitations in MPFD forming of composite sheets.
  • MPFD modification based on the response surface model significantly improved geometrical accuracy by 38.85%.
  • The study demonstrates a viable method for high-quality, accurate forming of curved composite components using GADF and MPFDs.