Experimental and FEM study of partial roll bonding with prepared channels for wire position and the analysis of the wire effect on the entire system
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The task was to continue with an already existing master thesis and to develop the process further.
The first step was to insert two channels into the aluminum sheets, in which where aluminum wires placed.
The problem was that the channels were not straight and did not have the same depth.
On the other hand the channels in the opposite aluminum sheet must be at the same spot, for a good connection of the aluminum-wire-sandwich.
The preparation of the test samples depends on many different factors and is a very difficult and long process. The repeatability of the experiment must be possible, too.
As well the simulation of the process in QForm was a important part. Simulated were the basic partial roll bonding process with the wire between the sheets.
Especially interesting was the position of the wire in and at the end of the process. The goal is that the wire build the edges of the inflatable channels and strengthens them.
The inflation of the samples was also simulated.