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

Öz

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.  

Anahtar Kelimeler

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

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

Öz

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.

 

Anahtar Kelimeler

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

Kaynakça

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