Flexural behavior of open-cell aluminum foam sandwich under three-point bending

Aluminum foam sandwich (AFS) panels are one of an advanced material that has various advantages such as lightweight, excellent stiffness to weight ratio and high-energy absorption. Due to their advantages, many researchers’ shows an interest in aluminum foam material for expanding the use of foam structure. However, there is still a gap need to be filling in order to develop reliable data on mechanical behavior of AFS with different parameters and analysis method approach. There are two types of aluminum foam that is open-cell and closed-cell foam. Few researchers were focusing on open-cell aluminum foam. Moreover, open-cell metal foam had some advantages compared to closed-cell due to the cost and weight matters. Thus, this research is focusing on aluminum foam sandwich using open-cell aluminum foam core with grade 6101 attached to aluminum sheets skin tested under three point bending. The effect Skin to core ratio investigated on AFS specimens analyzed by constructing load-displacement curves and observing the failure modes of AFS. Design of experiment of three levels skin sheet thickness (0.2mm, 0.4mm, and 0.6mm) and two levels core thickness (3.2mm and 6.35mm). a full factorial of six runs were performed with three time repetition. The results show that when skin to core ratio increase, force that AFS panels can withstand also increase with increasing core thickness

Numerical analysis of aluminum foam sandwich subjected to compression loading

Demand using aluminum foam sandwich in various application of industry keep increasing. Hence, the reliable numerical models are still required and need to be enhanced by observing the mechanical behavior of the sandwich structure. Numerical analysis of aluminum foam sandwich that subjected to compression loading had been analyzed using LSDYNA software. Three different thickness of aluminum foam (3.2mm, 5.6mm, 6.35mm) and three different thickness of aluminum sheet (0.4mm, 0.6mm, 0.8mm) had been selected to investigate their pattern of force-displacement curves and energy absorbed. The numerical results have been validated by experimental results for comparison. The findings show that simulation results exhibit good agreement with the experimental results in terms of their trend in force-displacement curves and deformation behavior of the sandwich structures. The increment in peak force and energy absorbed affected by increasing the thickness of foam and aluminum sheet

Flexural behavior of open-cell aluminum foam sandwich under three-point bending

Aluminum foam sandwich (AFS) panels are one of an advanced material that has various advantages such as lightweight, excellent stiffness to weight ratio and high-energy absorption. Due to their advantages, many researchers’ shows an interest in aluminum foam material for expanding the use of foam structure. However, there is still a gap need to be filling in order to develop reliable data on mechanical behavior of AFS with different parameters and analysis method approach. There are two types of aluminum foam that is open-cell and closed-cell foam. Few researchers were focusing on open-cell aluminum foam. Moreover, open-cell metal foam had some advantages compared to closed-cell due to the cost and weight matters. Thus, this research is focusing on aluminum foam sandwich using open-cell aluminum foam core with grade 6101 attached to aluminum sheets skin tested under three point bending. The effect Skin to core ratio investigated on AFS specimens analyzed by constructing load-displacement curves and observing the failure modes of AFS. Design of experiment of three levels skin sheet thickness (0.2mm, 0.4mm, and 0.6mm) and two levels core thickness (3.2mm and 6.35mm). a full factorial of six runs were performed with three time repetition. The results show that when skin to core ratio increase, force that AFS panels can withstand also increase with increasing core thickness

Flank wear analysing of high speed end milling for hardened steel D2 using Taguchi method

One of the main challenges for any manufacturer is how to decrease the machining cost without affecting the final quality of the product. One of the new advanced machining processes in industry is the high speed hard end milling process that merges three advanced machining processes: high speed milling, hard milling and dry milling. However, one of the most important challenges in this process is to control the flank wear rate. Therefore a analyzing the flank wear rate during machining should be investigated in order to determine the best cutting levels that will not affect the final quality of the product. In this research Taguchi method has been used to investigate the effect of cutting speed, feed rate and depth of cut and determine the best level s to minimize the flank wear rate up to total length of 0.3mm based on the ISO standard to maintain the finishing requirements

Experimental Study of Stress-Strain Behaviour of Open-Cell Aluminium Foam Sandwich Panel for Automotive Structural Part

Because of high stiffness and strength to weight ratio, aluminium foam sandwich (AFS) has huge advantage in automotive industries in order to reduce the vehicle’s weight which consequently will reduce the fuel consumption. While reducing the weight, AFS must also maintain high strength and durability compared to other competitive materials used which perform same functionalities. AFS had been proved its suitability for industrial application by previous researchers such as in aerospace, automotive and architecture. However, there is still a gap need to be filled in order to expand the use of the AFS in another application. In this paper, the tensile strength of AFS panel made of from aluminium skin sheets and open-cell aluminium foam core with various thickness is investigated. Design of experiment was developed according to JUMP (JMP) statistical software and experimental work was done using universal testing machine. The stress-strain behavior was analysed. The result shows that the effect of skin to core ratio is significant on the stress-strain behavior

Experimental Study of Stress-Strain Behaviour of Open-Cell Aluminium Foam Sandwich Panel for Automotive Structural Part

Because of high stiffness and strength to weight ratio, aluminium foam sandwich (AFS) has huge advantage in automotive industries in order to reduce the vehicle’s weight which consequently will reduce the fuel consumption. While reducing the weight, AFS must also maintain high strength and durability compared to other competitive materials used which perform same functionalities. AFS had been proved its suitability for industrial application by previous researchers such as in aerospace, automotive and architecture. However, there is still a gap need to be filled in order to expand the use of the AFS in another application. In this paper, the tensile strength of AFS panel made of from aluminium skin sheets and open-cell aluminium foam core with various thickness is investigated. Design of experiment was developed according to JUMP (JMP) statistical software and experimental work was done using universal testing machine. The stress-strain behavior was analysed. The result shows that the effect of skin to core ratio is significant on the stress-strain behavior

Numerical analysis of aluminum foam sandwich subjected to compression loading

Demand using aluminum foam sandwich in various application of industry keep increasing. Hence, the reliable numerical models are still required and need to be enhanced by observing the mechanical behavior of the sandwich structure. Numerical analysis of aluminum foam sandwich that subjected to compression loading had been analyzed using LS-DYNA software. Three different thickness of aluminum foam (3.2mm, 5.6mm, 6.35mm) and three different thickness of aluminum sheet (0.4mm, 0.6mm, 0.8mm) had been selected to investigate their pattern of force-displacement curves and energy absorbed. The numerical results have been validated by experimental results for comparison. The findings show that simulation results exhibit good agreement with the experimental results in terms of their trend in force-displacement curves and deformation behavior of the sandwich structures. The increment in peak force and energy absorbed affected by increasing the thickness of foam and aluminum shee

Surface roughness optimization using Taguchi method of high speed end milling for hardened steel D2

The main challenge for any manufacturer is to achieve higher quality of their final products with maintains minimum machining time. In this research final surface roughness analysed and optimized with maximum 0.3 mm flank wear length. The experiment was investigated the effect of cutting speed, feed rate and depth of cut on the final surface roughness using D2 as a work piece hardened to 52-56 HRC, and coated carbide as cutting tool with higher cutting speed 120-240 mm/min. The experiment has been conducted using L9 design of Taguchi collection. The results have been analysed using JMP software

Experimental study of stress-strain behaviour of open-cell aluminium foam sandwich panel for automotive structural part

Because of high stiffness and strength to weight ratio, aluminium foam sandwich (AFS) has huge advantage in automotive industries in order to reduce the vehicle’s weight which consequently will reduce the fuel consumption. While reducing the weight, AFS must also maintain high strength and durability compared to other competitive materials used which perform same functionalities. AFS had been proved its suitability for industrial application by previous researchers such as in aerospace, automotive and architecture. However, there is still a gap need to be filled in order to expand the use of the AFS in another application. In this paper, the tensile strength of AFS panel made of from aluminium skin sheets and open-cell aluminium foam core with various thicknesses is investigated. To achieve the objectives of the research, experimental work has been conducted. Full factorial of two independent factors: core thickness with two levels and skin thickness with three levels. JMP software (version 11) has been used to analyse the data. Experimental work was done using universal testing machine. The stress-strain behaviour was analysed. The result shows that the effect of skin to core ratio is significant on the stress-strain behaviour