L. Bu, Y. Agbessi, J. Biglione, Y. Béreaux, J. Charmeau
{"title":"Thermal homogeneity in single screw channel polymer melt flows","authors":"L. Bu, Y. Agbessi, J. Biglione, Y. Béreaux, J. Charmeau","doi":"10.1063/1.5112668","DOIUrl":"https://doi.org/10.1063/1.5112668","url":null,"abstract":"Single-screw plastication, used in extrusion and in injection moulding, is a major way of processing commodity thermoplastics. In injection moulding, a high level of reliability is usually achieved that makes this process ideally suited to mass market production. Nonetheless, process fluctuations still appear that make moulded part quality control an everyday issue. During the plastication phase, prior to the injection phase, the polymeric material is melted by the combined effects of shear-induced self heating (viscous dissipation) and heat conduction coming from the barrel. A combined drag and pressure difference flow is imparted on the molten polymer along the screw channel. The low thermal diffusion coefficient of molten polymers implies that convection is dominant over diffusion and leads to very large Peclet numbers. However, the screw channel length is large enough for the flow to present significant diffusion effects. Therefore, the objective of this work is to study the capacity of this particula...","PeriodicalId":277705,"journal":{"name":"PROCEEDINGS OF THE 22ND INTERNATIONAL ESAFORM CONFERENCE ON MATERIAL FORMING: ESAFORM 2019","volume":"34 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-07-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115242129","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"ATLAS of yield surfaces for strongly textured FCC polycrystals","authors":"S. Dumoulin, T. Coudert, O. Hopperstad","doi":"10.1063/1.5112746","DOIUrl":"https://doi.org/10.1063/1.5112746","url":null,"abstract":"Discrete yield surfaces for several generic texture components, including randomness, found in aluminium alloys have been generated and used to calibrate the yield function Yld2004-18p. It is generally observed that the roundness of the corners of the yield surface increases, and the stress and strain ratios flatten towards isotropic values, as the ratio of random component increases. A short investigation on the effect of number of points and homogenization approach on calibration of the yield function seems to indicate that the number of points used in the calibration has a stronger effect than the homogenization approach. Furthermore, it is also shown that setting the exponent as a free parameter in calibrating the yield function could lead to better fits.","PeriodicalId":277705,"journal":{"name":"PROCEEDINGS OF THE 22ND INTERNATIONAL ESAFORM CONFERENCE ON MATERIAL FORMING: ESAFORM 2019","volume":"104 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-07-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115693597","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Lorenz Quentin, J. Kruse, Rüdiger Beermann, Carl Reinke, J. Langner, M. Stonis, M. Kästner, E. Reithmeier
{"title":"Analysis of mapped temperature data on geometry points to characterize the influence of temperature deviations on cross-wedge rolling","authors":"Lorenz Quentin, J. Kruse, Rüdiger Beermann, Carl Reinke, J. Langner, M. Stonis, M. Kästner, E. Reithmeier","doi":"10.1063/1.5112552","DOIUrl":"https://doi.org/10.1063/1.5112552","url":null,"abstract":"Within the Collaborative Research Centre (CRC) 1153 Tailored Forming a process chain for the manufacturing of hybrid high performance components is developed. Exemplary process steps consist of deposit welding of high-performance steel onto low cost steel and pre-shaping the component by cross-wedge rolling (CWR), supported by an optical quality control system. A combination of a fringe projection profilometry setup with a thermal imaging camera is used to monitor the components before and after the CWR process. Both geometry and thermal imaging data are combined, assigning temperature values to 3D data points.In this paper, the acquisition of combined temperature-geometry data is described. The data before and after the CWR is compared to the input and the result data of the forming simulation that was used to design the CWR process. The comparison shows the quality and sustainability of the heating process as well as the influence of the transportation of the hot component prior to forming. Additionally, the accuracy of the used simulation model and software are evaluated by data examination. The examination shows the limits of idealised and simplified assumptions for the simulation, e.g., a homogeneous temperature distribution before forming or the modelling of the heat transfer on contact surfaces.Within the Collaborative Research Centre (CRC) 1153 Tailored Forming a process chain for the manufacturing of hybrid high performance components is developed. Exemplary process steps consist of deposit welding of high-performance steel onto low cost steel and pre-shaping the component by cross-wedge rolling (CWR), supported by an optical quality control system. A combination of a fringe projection profilometry setup with a thermal imaging camera is used to monitor the components before and after the CWR process. Both geometry and thermal imaging data are combined, assigning temperature values to 3D data points.In this paper, the acquisition of combined temperature-geometry data is described. The data before and after the CWR is compared to the input and the result data of the forming simulation that was used to design the CWR process. The comparison shows the quality and sustainability of the heating process as well as the influence of the transportation of the hot component prior to forming. Additionally...","PeriodicalId":277705,"journal":{"name":"PROCEEDINGS OF THE 22ND INTERNATIONAL ESAFORM CONFERENCE ON MATERIAL FORMING: ESAFORM 2019","volume":"12 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-07-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"117273177","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"About localization on plane strain tensile test on bimaterial specimen","authors":"H. A. Phung, P. Balland, N. A. Sene, L. Tabourot","doi":"10.1063/1.5112742","DOIUrl":"https://doi.org/10.1063/1.5112742","url":null,"abstract":"The main idea of this paper is to improve our knowledge on localization in a specific case of heterogeneous materials: strips with both aluminium and steel in thickness. A characterization of each material separately has been done by tensile test and also by plane strain tensile test. Afterwards, these two tests are studied on the bimaterial. This study is both experimental with digital image stereo-correlation for strain measurements on both side (aluminium and steel) and numerical with a finite element simulation. A better understanding of the behaviour of a bimaterial can be deducted: aluminium makes mechanical resistance decrease but reinforces the resistance to localization. Some crossing effects have been revealed what induces a fine analyse for each study involving other configurations of bimaterials.","PeriodicalId":277705,"journal":{"name":"PROCEEDINGS OF THE 22ND INTERNATIONAL ESAFORM CONFERENCE ON MATERIAL FORMING: ESAFORM 2019","volume":"4 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-07-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121112789","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Yonghee Kim, Changsoo Jang, Naksoo Kim, L. Quagliato
{"title":"Investigation on the influence of temperature, pressure and curing time on the mechanical properties of metal skins and CFRP core sandwich panels manufactured by means of curing-by-forming process","authors":"Yonghee Kim, Changsoo Jang, Naksoo Kim, L. Quagliato","doi":"10.1063/1.5112511","DOIUrl":"https://doi.org/10.1063/1.5112511","url":null,"abstract":"In the research presented in this paper, the influence of the manufacturing process conditions on the elastic-plastic mechanical behavior of laminate structures made of metal skin (MS) and carbon fiber reinforced polymer (CFRP) core is investigated by means of laboratory experiments. The specimens are realized with 0.4 mm thick AISI-304 sheets, ±45° high modulus carbon fibers woven for the core (8 x 0.25 mm layers stacked) with a thin interlayer made of Loctite EA9460 epoxy adhesive utilized to increase to joining strength between steel skins and CFRP core. The MS-CFRP plates have been manufactured by means of curing-by-forming process considering the following levels for the DoE analysis: i) mold temperature: 130 °C, 150 °C and 170 °C; curing pressure: 4000 kgf, 6000 kgf, and 8000 kgf; and curing time: 10 min., 15min. and 20min., respectively. The manufactured plates have been cut by waterjet process and tested by means of 3-point bending tests, allowing to correlate the above-mentioned process parameters to the mechanical properties of the material. The results have been summarized in processing maps those allow predicting the mechanical properties of the material according to the process parameters utilized in the curing-by-forming process. Finally, based on previous research results, the improvement of the specific mechanical properties of the MS-CFRP structures, in comparison to monolithic AISI-304 steel, have been calculated showing an improvement ranging between 115.5% and 122.4%, for the flexural stiffness and in 306.0% and 569.7% for the failure stress, respectively, depending on the process parameters.In the research presented in this paper, the influence of the manufacturing process conditions on the elastic-plastic mechanical behavior of laminate structures made of metal skin (MS) and carbon fiber reinforced polymer (CFRP) core is investigated by means of laboratory experiments. The specimens are realized with 0.4 mm thick AISI-304 sheets, ±45° high modulus carbon fibers woven for the core (8 x 0.25 mm layers stacked) with a thin interlayer made of Loctite EA9460 epoxy adhesive utilized to increase to joining strength between steel skins and CFRP core. The MS-CFRP plates have been manufactured by means of curing-by-forming process considering the following levels for the DoE analysis: i) mold temperature: 130 °C, 150 °C and 170 °C; curing pressure: 4000 kgf, 6000 kgf, and 8000 kgf; and curing time: 10 min., 15min. and 20min., respectively. The manufactured plates have been cut by waterjet process and tested by means of 3-point bending tests, allowing to correlate the above-mentioned process parameter...","PeriodicalId":277705,"journal":{"name":"PROCEEDINGS OF THE 22ND INTERNATIONAL ESAFORM CONFERENCE ON MATERIAL FORMING: ESAFORM 2019","volume":"22 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-07-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125029949","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Numerical modeling of a hybrid forming process for three-dimensionally curved fiber-metal laminates","authors":"H. Werner, D. Dörr, F. Henning, L. Kärger","doi":"10.1063/1.5112524","DOIUrl":"https://doi.org/10.1063/1.5112524","url":null,"abstract":"Fiber-metal laminates (FML) are known for their excellent fatigue properties and for lightweighting. As a result, they are widely used in the aviation industry for the fuselage. The geometric compl...","PeriodicalId":277705,"journal":{"name":"PROCEEDINGS OF THE 22ND INTERNATIONAL ESAFORM CONFERENCE ON MATERIAL FORMING: ESAFORM 2019","volume":"19 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-07-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125267118","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Forming analysis of tailored tubes with an internal contoured wall thickness and external axial ribs manufactured by internal flow-turning","authors":"E. Wiens, W. Homberg","doi":"10.1063/1.5112535","DOIUrl":"https://doi.org/10.1063/1.5112535","url":null,"abstract":"Internal Flow-Turning is an innovative rolling process for the manufacture of tailored tubes with a variable wall thickness contour over the longitudinal axis. The wall thickness distribution is determined solely by the internal diameter created by a special roller tool. The wall thickness is defined by the gap between the roller element on the inside and a die ring on the outside of the tube. The outer diameter of the manufactured tube can remain constant, thus greatly simplifying further processing by hydroforming, for example, or can be structured by ribs in the longitudinal direction. For this reason, internal flow-turned parts offer beneficial characteristics when used as semi-finished parts and are favorable for downstream processing. Depending on the tool design, a wall thickness reduction of >90% of the initial wall thickness is possible. In addition, the roughness of the rolled surface can be significantly improved. Through the incorporation of cold hardening in the process, the strength and hardness of the processed work piece can be improved by up to 70% of the initial state. Internal Flow-Turning is also well-suited to the calibration of a tubular part, since it provides tighter dimensional and geometrical accuracy. By using a die with longitudinal grooves, it is possible to form axial rib elements on the outer surface of the tube. The main subject of this paper is a material flow and forming analysis of the Internal Flow-Turning process. The focus is on a forming analysis in respect of the wall thickness reduction and the shape of various formed axial ribs.Internal Flow-Turning is an innovative rolling process for the manufacture of tailored tubes with a variable wall thickness contour over the longitudinal axis. The wall thickness distribution is determined solely by the internal diameter created by a special roller tool. The wall thickness is defined by the gap between the roller element on the inside and a die ring on the outside of the tube. The outer diameter of the manufactured tube can remain constant, thus greatly simplifying further processing by hydroforming, for example, or can be structured by ribs in the longitudinal direction. For this reason, internal flow-turned parts offer beneficial characteristics when used as semi-finished parts and are favorable for downstream processing. Depending on the tool design, a wall thickness reduction of >90% of the initial wall thickness is possible. In addition, the roughness of the rolled surface can be significantly improved. Through the incorporation of cold hardening in the process, the strength and hard...","PeriodicalId":277705,"journal":{"name":"PROCEEDINGS OF THE 22ND INTERNATIONAL ESAFORM CONFERENCE ON MATERIAL FORMING: ESAFORM 2019","volume":"3 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-07-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125370876","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
M. Baldrich, F. Aldakheel, Steffen Beese, S. Löhnert, P. Wriggers
{"title":"A micro-thermo-mechanical model for a tailored formed joining zone deformed by die forging","authors":"M. Baldrich, F. Aldakheel, Steffen Beese, S. Löhnert, P. Wriggers","doi":"10.1063/1.5112558","DOIUrl":"https://doi.org/10.1063/1.5112558","url":null,"abstract":"In order to investigate new methodologies to produce light weight and load-adjusted hybrid solid components, a process chain using the technique of Tailored Forming is developed. Hereby, the two materials aluminium and steel are joined before being formed to a hybrid bearing bushing. A significant drawback of this technique is the weakened joining zone. This is due to the differences of material properties and the formation of an intermetallic phase at the joined zone, resulting in high stresses during the forming process that might lead to damage and failure. To achieve a high mechanical strength of the hybrid solid component, it is important to evaluate the sensitivity of different process parameters and to accurately adjust the material behaviour of the joining zone. Because of the strong dependence of the effective, macroscopic material behaviour on the thermomechanical influences at the microscopic level, the polycrystalline joining zone is investigated on the microscopic length scale. Material models are developed for each of the constituents steel and aluminium using the framework of dislocation density based crystal plasticity as well as an elastic material model for the brittle intermetallic phase. For the microscopic simulation of the die forging, a volume element of the joining zone is generated capturing the characteristic morphology of the different grains including their size distribution, non-convex shapes, elongation and volume fractions as well as the stochastic orientation of the grains. The microscopic boundary value problem is chosen to meet the macroscopically applied loads during the die forging of the bearing bushing.In order to investigate new methodologies to produce light weight and load-adjusted hybrid solid components, a process chain using the technique of Tailored Forming is developed. Hereby, the two materials aluminium and steel are joined before being formed to a hybrid bearing bushing. A significant drawback of this technique is the weakened joining zone. This is due to the differences of material properties and the formation of an intermetallic phase at the joined zone, resulting in high stresses during the forming process that might lead to damage and failure. To achieve a high mechanical strength of the hybrid solid component, it is important to evaluate the sensitivity of different process parameters and to accurately adjust the material behaviour of the joining zone. Because of the strong dependence of the effective, macroscopic material behaviour on the thermomechanical influences at the microscopic level, the polycrystalline joining zone is investigated on the microscopic length scale. Material model...","PeriodicalId":277705,"journal":{"name":"PROCEEDINGS OF THE 22ND INTERNATIONAL ESAFORM CONFERENCE ON MATERIAL FORMING: ESAFORM 2019","volume":"95 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-07-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122941826","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Julian Vorderbrüggen, B. Gröger, R. Kupfer, A. Hoog, M. Gude, G. Meschut
{"title":"Phenomena of forming and failure in joining hybrid structures – Experimental and numerical studies of clinching thermoplastic composites and metal","authors":"Julian Vorderbrüggen, B. Gröger, R. Kupfer, A. Hoog, M. Gude, G. Meschut","doi":"10.1063/1.5112580","DOIUrl":"https://doi.org/10.1063/1.5112580","url":null,"abstract":"This paper describes the influence of the process temperature and die design on the material structure as well as the load carrying capacity of clinched metal-glass fibre reinforced thermoplastics ...","PeriodicalId":277705,"journal":{"name":"PROCEEDINGS OF THE 22ND INTERNATIONAL ESAFORM CONFERENCE ON MATERIAL FORMING: ESAFORM 2019","volume":"50 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-07-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122592565","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Sonia Varela, Oscar H. Valbuena, J. Armentia, Francisco Larrucea, V. Manso, Maite Santos
{"title":"Material saving by a combination of rotary forging and conventional processes: Hybrid forging for net-shape gear","authors":"Sonia Varela, Oscar H. Valbuena, J. Armentia, Francisco Larrucea, V. Manso, Maite Santos","doi":"10.1063/1.5112549","DOIUrl":"https://doi.org/10.1063/1.5112549","url":null,"abstract":"This work was supported by the Basque Government under the CORONAT project (Hazitek program: IG2015/00331, ZL-2016/00070, ZL-2017/00109). The authors wish to thank FORGE ® NxT for their assistance on simulation methodology and INDUSTRIAS PUIGJANER S.A for use of the forging tool system developed.","PeriodicalId":277705,"journal":{"name":"PROCEEDINGS OF THE 22ND INTERNATIONAL ESAFORM CONFERENCE ON MATERIAL FORMING: ESAFORM 2019","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-07-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129864593","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}