A Novel Application in Sheet Metal Forming: Shaping Metals by Plastic Injection Molding based on Fluid Pressure Forming

Year 2017, Volume: 32 Issue: 4, 241 - 252, 15.12.2017

Murat Şen Mihrigül Altan

https://doi.org/10.21605/cukurovaummfd.383451

Abstract

Plastic injection molding,  even though it is a  manufacturing method for plastics, can be used
for forming sheet metals based on fluid pressure forming. In this study, aluminum
sheets with 1.5 mm thikcness
were deformed under different injection pressure, melt temperature and
injection rate on a plastic injection molding machine. The effects of these parameters
on deformability of the sheet metal were investigated by experimental
measurement techniques and Taguchi, ANOVA, regression, surface response
methods. The thinning rate, radius along the flange and the hardness values
were considered. As a result of the experimental study, it has been seen
that  injection pressure was  the first degree effective parameter and melt
temperature was the second degree effective parameter on thinning rate. The
increment of hardness  of the deformed
part from center to the flange, verified the high deformability of  the sheet metal in these regions.  

Keywords

Aluminium, Hydroforming, Thinning rate, Plastic injection molding, Taguchi

Sac Metallerin Şekillendirilmesinde Farklı bir Uygulama: Plastik Enjeksiyon Kalıplamada Akışkan Basıncıyla Alüminyum Sacın Şekillendirilmesi

Abstract

Plastik
enjeksiyon ile kalıplama yöntemi,  plastikler için bir imalatı yöntemi olmasına rağmen,  sıvı basıncı ile şekillendirme esas alınarak
sac metallerin şekillendirilmesi için kullanılabilmektedir. Bu çalışmada,   plastik enjeksiyon makinasında, 1,5 mm
kalınlığındaki alüminyum saclar, polistirenin farklı enjeksiyon basıncı,
ergiyik sıcaklığı ve enjeksiyon hızı değerlerinde şekillendirilmiştir Bu
parametrelerin sac metalin şekillendirilmesi üzerine etkileri, deneysel ölçüm
metotların yanı sıra Taguchi, ANOVA, cevap yüzey metodu ve regresyon analizi
teknikleri ile de incelenmiştir. Metalin şekillendirilebilirliği incelenirken,
sac metalin şekillendirme sonrası incelme oranı, flanş bölgesindeki yarıçap
değeri ve sertlik değerleri dikkate alınmıştır. Yapılan deneysel çalışmanın
sonucunda, enjeksiyon basıncının şekillendirme üzerindeki en etkili parametre
olduğu ve ikinci dereceden en etkili parametrenin ise ergiyik sıcaklığı olduğu
görülmüştür. Şekillendirilen parçanın, merkezinden flanş bölgelerine doğru
artan sertlik değeri sonuçları, sac metalin bu bölgelerde yüksek oranda
şekillendirilebildiğini doğrulamıştır.

 

Keywords

Aluminyum, Hidroforming, İncelme oranı, Plastik enjeksiyon kalıplama, Taguchi

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