Skip to main content
SpringerLink
Log in

Improving the formability of sandwich sheets by the hydrostatic effect of encapsulated media

  • Original Research
  • Published:
International Journal of Material Forming Aims and scope Submit manuscript

Abstract

Various sandwich structures have been developed as lightweight structures. They have excellent specific stiffness owing to their low density. However, owing to the existence of various failure modes, which are classified into core shear failure, tensile fracture of the face sheet, buckling of the face sheet, and delamination, it is difficult to deform sandwich sheets without any failure. A new forming strategy was proposed in this study. Buckling of the face sheet during drawing was suppressed by filling the encapsulated media in a 3D core between the face sheets to exploit its hydrostatic effect. This process is similar to the freeze-bend method, in which the pipe is filled with ice during bending to suppress wrinkles and flattening. Ice, wax, and low-melting alloys were used as the encapsulated media, and their formability and ease of removal were investigated. Further, a shear strength test was performed on the specimens that were cut out from the drawn products to evaluate failure during forming. Based on these experimental results, the characteristics required for the encapsulated media were summarized.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10

Similar content being viewed by others

References

  1. Sun Y, Li C, Wu H, Tan K, Zhang F (2018) Simulation and lightweight design for the structure frame of a flying car. Advances in Intelligent Systems Research Proceedings of the 2018 international conference on computer modeling, simulation and algorithm (CMSA 2018):25–29. https://doi.org/10.2991/cmsa-18.2018.7

  2. Zhang W, Xu J (2022) Advanced lightweight materials for automobiles: a review. Mater Des 221:110994. https://doi.org/10.1016/j.matdes.2022.110994

    Article  Google Scholar 

  3. Yanagimoto J, Ikeuchi K (2012) Sheet forming process of carbon fiber reinforced plastics for lightweight parts. CIRP Ann Manuf Technol 61(1):247–250. https://doi.org/10.1016/j.cirp.2012.03.129

    Article  Google Scholar 

  4. Zhang J, Zhou P, Guan C, Liu TQ, Kang WH, Feng P, Gao S (2021) An ultra-lightweight CFRP beam-string structure. Compos Struct 257:113149. https://doi.org/10.1016/j.compstruct.2020.113149

    Article  Google Scholar 

  5. Putnam J, Littell J (2019) Evaluation of impact energy attenuator and composite material designs of a UAM VTOL concept vehicle. Proceeding from the VFS 75th Annual Forum and Technology Display. https://core.ac.uk/works/85881033

  6. Zhang J, Yanagimoto J (2021) Topology optimization of microlattice dome with enhanced stiffness and energy absorption for additive manufacturing. Compos Struct 255:112889. https://doi.org/10.1016/j.compstruct.2020.112889

    Article  Google Scholar 

  7. Wei P, Li Z, Li X, Wang MY (2018) An 88-line MATLAB code for the parameterized level set method based topology optimization using radial basis functions. Struct Multidisc Optim 58(2):831–849. https://doi.org/10.1007/s00158-018-1904-8

    Article  MathSciNet  Google Scholar 

  8. Vinson JR (2001) Sandwich structures. Appl Mech Rev 54(3):201–214. https://doi.org/10.1115/1.3097295

    Article  MathSciNet  Google Scholar 

  9. Heimbs S (2009) Virtual testing of sandwich core structures using dynamic finite element simulations. Comp Mater Sci 45:205–216. https://doi.org/10.1016/j.commatsci.2008.09.017

    Article  Google Scholar 

  10. Seong DY, Jung CG, Yang DY, Kim JH, Chung WJ, Lee MY (2010) Bendable metallic sandwich plates with a sheared dimple core. Scr Mater 63(1):81–84. https://doi.org/10.1016/j.scriptamat.2010.03.022

    Article  Google Scholar 

  11. Mohr D (2005) On the role of shear strength in sandwich sheet forming. Int J Solids Struct 42(5–6):1491–1512. https://doi.org/10.1016/j.ijsolstr.2004.07.012

    Article  MATH  Google Scholar 

  12. Daniel IM, Gdoutos EE, Wang K-A, Abot JL (2002) Failure modes of composite sandwich beams. Int J Damage Mech 11:309–334. https://doi.org/10.1106/105678902027247

    Article  Google Scholar 

  13. Mohan K, Hon YT, Idapalapati S, Seow HP (2005) Failure of sandwich beams consisting of alumina face sheet and aluminum foam core in bending. Mater Sci Eng A 409(1–2):292–301. https://doi.org/10.1016/j.msea.2005.06.070

    Article  Google Scholar 

  14. Xiong J, Ghosh R, Ma L, Ebrahimi H, Hamouda AMS, Vaziri A, Wu L (2014) Bending behavior of lightweight sandwich-walled shells with pyramidal truss cores. Compos Struct 116:793–804. https://doi.org/10.1016/j.compstruct.2014.06.006

    Article  Google Scholar 

  15. Bühring J, Nuño M, Schröder KU (2021) Additive manufactured sandwich structures: mechanical characterization and usage potential in small aircraft. Aerosp Sci Technol 111:106548. https://doi.org/10.1016/j.ast.2021.106548

    Article  Google Scholar 

  16. Shibuya Y, Zhang J, Sato Y, Yanagimoto J (2022) Enhancement of mechanical property and formability of CFRP core sandwich sheets by additive manufacturing process-induced material and structural anisotropies. J Mater Process Technol 310:117778. https://doi.org/10.1016/j.jmatprotec.2022.117778

    Article  Google Scholar 

  17. Tashiro Y, Nakajima T (2003) Development of an energy-conserving bending method for double titanium Pipes. Yamaha motor technical review. https://global.yamaha-motor.com/jp/design_technology/technical/thesis/pdf/browse/37gr_08.pdf

  18. Morgan G (1999) Workholding with fusible alloys. Aircr Eng Aerosp Technol 71(6):576–578. https://doi.org/10.1108/00022669910303739

    Article  Google Scholar 

  19. Ohashi N, Ono Y, Nohara K (1977) Press formability of stainless steel sheets. Tetsu-To-Hagane 63:812–823. https://doi.org/10.2355/tetsutohagane1955.63.5_812

    Article  Google Scholar 

  20. ISO 4587 Adhesives — Determination of tensile lap-shear strength of rigid-to-rigid bonded assemblies (2003). https://www.iso.org/standard/34852.html

  21. Bowden FP (1953) Friction on snow and ice. Proc R Soc Lond A 217(1131):462–478. https://doi.org/10.1098/rspa.1953.0074

    Article  Google Scholar 

Download references

Acknowledgements

This work was financially supported by a Japan Society for the Promotion of Science (JSPS) Grant-in-Aid for Scientific Research (A) (Contract No. 20H00300).

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, The University of Tokyo, Tokyo, Japan

    Yuki Shibuya & Jun Yanagimoto

Authors
  1. Yuki Shibuya
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Jun Yanagimoto
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Yuki Shibuya.

Ethics declarations

Competing interests

The authors declare no conflict of interest.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Shibuya, Y., Yanagimoto, J. Improving the formability of sandwich sheets by the hydrostatic effect of encapsulated media. Int J Mater Form 16, 42 (2023). https://doi.org/10.1007/s12289-023-01768-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s12289-023-01768-x

Keywords

Search

Navigation