The punching of DP1000 automotive steel–Al laminate composite fabricated by explosive welding: Effect of tool geometry on cutting force and cut surfaces

The study focussed on the explosive welding of DP1000 steel and Al sheets. Secondarily, the punching of these sheets with various tips was performed, analysed and the cut surfaces were visually inspected (using electron and stereo microscopy). Moreover, a three-dimensional finite element modeling (FEM) analysis was conducted to predict the punching process of the welded sheet metal specimen. Additionally, the metal plate was subjected to a tensile test with the objective of obtaining data on its strength and ductility. DP1000-Al sheets can be welded successfully. The strength values of the composite (668 MPa) are lower than those of DP1000 but significantly higher than the Al sheet, showing that the composite has the properties of both materials. The cutting forces were reduced by 54.5%, 57%, 62%, and 72%, respectively, when the V16, R1, R2, and 16 punches were employed instead of the flat tip punch (P0). Reduced cutting force supports the laminate stability. The study of macro and micro images proved useful in understanding the surfaces and areas created by the cutting process. The findings of this study have the potential to establish a foundation for subsequent research, particularly concerning the implementation of sophisticated FEM and machine learning methodologies.