Integrated stamping simulation of thermoplastic carbon fiber composite-aluminum alloy laminated structures

Abstract

The integrated stamping forming process of thermoplastic carbon fiber composite (CF/PA6) and aluminum alloy laminated structure has significant mechanical nonlinearity, anisotropy and multi-physical field coupling effects, which complicates the control of forming quality. This study takes the anti-collision beam of an automotive door as the research object, and builds a three-dimensional finite element model of the CF/PA6-7003 aluminum alloy laminated structure based on the ABAQUS/Explicit platform. Starting from the actual process flow, the influence laws of process parameters such as stacking sequence and stamping speed on forming defects (such as stress concentration and springback deformation) are explored. By comparing the simulation results of pure metal, pure composite material and two laminated structures (composite-metal-composite, metal-composite-metal), it is found that the metal-composite-metal structure can effectively suppress the springback of metal, and the outer layer of aluminum alloy can reduce the extrusion amount of composite resin, while the core layer of composite material can balance the springback deformation through reverse force. In addition, the stress concentration during stamping is mainly distributed at the large curvature corner and the deepest forming part, and the thickness of the composite material layer needs to be optimized specifically. The research results provide a theoretical basis and optimization direction for the high-precision stamping process of fiber metal laminated structures. Keywords: Thermoplastic carbon fiber composite material, Simulation, Forming