International Journal of Material Forming最新文献

{"title":"Calibration and stress-state transfer of anisotropic yield functions for sheet metals: an eight-material comparison supported by a 62-record inventory","authors":"Mehmet Firat","doi":"10.1007/s12289-026-02101-y","DOIUrl":"10.1007/s12289-026-02101-y","url":null,"abstract":"<div><p>Anisotropic yield functions for sheet forming are commonly selected from their agreement with directional yield stresses and Lankford coefficients. This study examines whether close calibration agreement also indicates stable coefficient identification, convexity, and accurate predictions outside the fitted loading conditions. A literature inventory contains 62 sheet-material records; eight provide the common seven-direction and balanced-biaxial measurements used for quantitative comparison. Seven yield-function families are represented by eight formulations, including Hill48, Yld89, Yld2000-2d, reduced Yld2004-18p, two BBC2008 variants, Cazacu (2018), and HomPol6. Coefficients are identified separately using transformed and conventional residuals with paired initial values. Greater flexibility reduces calibration errors but does not ensure identifiable coefficients or convex surfaces. Two exact polynomial perturbations explain why the selected observations cannot identify all fifteen normalized HomPol6 coefficients. Seven of eight BBC2008-p16 fits are numerically rank deficient under each objective; the remaining conventional-objective case is sensitive to the rank threshold. Prediction errors in loading conditions not used for calibration depend on the fitting measure: the Hill48 and Yld2004-18p ordering changes, while their exploratory material-level intervals include zero. A separate compression, plane-strain, shear, and flow assessment uses DP980, QP980, and AA5754-O. Hill48 gives the smallest mean radial stress error under both objectives (4.28–4.47%), whereas Yld89 gives the smallest plastic-strain-ratio angle error (3.17–3.20 degrees). Yield-function selection should therefore reflect the available anisotropy measurements, coefficient determination, surface admissibility, and the particular stress or plastic-flow response required.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 4","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-11-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149338109","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"POD-GPR-assisted cohesive zone modelling of peel behaviour in 3D-printed PLA re-entrant core sandwich structures and experimental validation","authors":"Phul Babu,&nbsp;Nelson Muthu,&nbsp;R. Ganesh Narayanan","doi":"10.1007/s12289-026-02103-w","DOIUrl":"10.1007/s12289-026-02103-w","url":null,"abstract":"<div><p>This study investigates the peeling behaviour of 3D-printed polylactic acid (PLA) re-entrant core sandwich structures (SWSs). The study aimed to characterize interfacial peel failure in 3D-printed PLA re-entrant core SWSs using a bilinear cohesive zone modelling (CZM) based finite element (FE) framework. Two process configurations, differing in facesheet thickness and resin-to-hardener ratio, were compared as a comparative case study. Cohesive parameters were identified using a conventional trial-and-error approach and a Proper Orthogonal Decomposition–Gaussian Process Regression (POD-GPR) assisted inverse framework, which combined FE simulations, dimensionality reduction, surrogate modelling, and optimization. Peel experiments were conducted on two case study samples fabricated using fused filament fabrication (FFF). FE model successfully reproduced the elastic response, peak load, and progressive debonding observed in experiments. For case 1, using the POD-GPR framework reduced the peak force prediction error from 0.2% to 0.08% and the displacement error at peak force from 36.36% to 18.18% compared with the trial-and-error approach. Similarly, for case 2, errors are reduced from 5.02% to 0.99% and from 13.38% to 11.46% for peak force and displacement at peak force, respectively. Overall, the proposed CZM and POD-GPR-assisted inverse framework offers an efficient approach to characterizing adhesive interfaces in 3D-printed sandwich structures and can be extended to other bonded composite systems.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 4","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-10-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149339194","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Warm stamping process optimization of 1500 MPa ultra-high strength full martensitic steel: significant springback reduction with maximum strength","authors":"Junjie Luo,&nbsp;Xingyun Liu,&nbsp;Wurong Wang,&nbsp;Yangyang Zhao","doi":"10.1007/s12289-026-02102-x","DOIUrl":"10.1007/s12289-026-02102-x","url":null,"abstract":"<div><p>Motivated by the automotive industry’s demands for energy efficiency and emission reduction, warm stamping has emerged as a promising solution to overcome the limitations of both cold forming and hot stamping of high-strength steels. This study proposes an innovative warm stamping process specifically designed for 1500 MPa-grade cold-rolled martensitic steel. The process is compatible with existing industrial hot stamping lines, enabling seamless integration with existing infrastructure, while achieving significant springback reduction without substantial strength loss. A systematic investigation was conducted to evaluate the effects of holding temperature and time on microstructural evolution, mechanical properties, and springback behavior. The optimal process parameters were determined to be a holding temperature of 500 °C for 3 min. Under these conditions, the sidewall and flange springback angles decreased by 71.2% and 48.1%, respectively, compared with cold stamping. The formed parts retained approximately 88% of the as-received tensile strength, while elongation at break increased from 4.02% for cold-stamped parts to 5.18%. Microstructural analysis using SEM, EBSD, and TEM revealed critical mechanisms such as tempered lath martensite recovery and carbide precipitation, which govern the trade-off between strength and ductility. This work establishes a comprehensive process-microstructure-property correlation framework for the warm stamping of cold-rolled martensitic steels. The proposed approach demonstrates both theoretical significance and practical industrial value, offering a viable alternative to conventional cold or hot forming routes for the production of high-strength automotive components.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 4","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-10-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149339173","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Determination of critical damage value for hot deformation cracking in heavy forgings","authors":"Hongping An,&nbsp;Jianguo Wu,&nbsp;Wenwu He,&nbsp;Yaqin Tian","doi":"10.1007/s12289-026-02100-z","DOIUrl":"10.1007/s12289-026-02100-z","url":null,"abstract":"<div><p>Heavy forgings for power and petrochemicals, with extremely large dimensions, are made from hundreds-tonne steel ingots via multi-pass hot forging, where repeated thermo-mechanical loading promotes damage and raises cracking risk. Accurate cracking prediction for heavy forgings using finite element simulation is essential for forging safety and economics. Focusing on 2.25Cr1Mo0.25 V steel, this study systematically investigated the critical damage value (CDV) for the normalized Cockcroft and Latham model and its applicability, with emphasis on cracking prediction in industrial-scale simulations through experimental and theoretical approaches. A conventional hybrid experimental–numerical approach (HENA) was first used to calibrate the CDV, revealing a nonlinear decrease with increasing element size, an effect attributable to numerical errors in FE analysis. The HENA-based CDV is only suitable for scaled-down simulations of heavy forgings, as it inherently couples with small elements (0.2–1.6 mm). To overcome this limitation, a macroscopic equivalent damage method (MEDM) was proposed to determine the CDV for full-scale simulations, and its analytical expression was established. A characteristic element size was derived from the generalized Hillerborg fracture energy equation, which theoretically pairs the MEDM-based CDV with this size, yielding a value of 19.73 mm upon regression of experimental data. The applicability of the four CDVs for different-sized elements was preliminarily supported by three laboratory upsetting experiments and one heavy forging case, demonstrating their potential for crack prediction. A dual-scale strategy was thus established to determine the CDV according to simulation scale, thereby providing a pathway to extend cracking prediction of heavy forgings from laboratory research to industrial practice.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 4","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-10-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149338613","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"SHAP and LIME-based interpretation of metaheuristic-optimized least square support vector machine in high-performance concrete chloride penetration assessment","authors":"Jitendra Khatti,&nbsp;Aleksandra Bogdanovic,&nbsp;Asmaa A. Mashaly","doi":"10.1007/s12289-026-02099-3","DOIUrl":"10.1007/s12289-026-02099-3","url":null,"abstract":"<div><p>Chloride ion corrosion is considered one of the primary causes of durability deterioration in reinforced concrete structures exposed to marine environments or chlorine-containing deicing salts. This research introduces a significant soft computing model to assess the chloride penetration of metakaolin concrete by comparing the Artificial Bee Colony (ABC), Genetic Algorithm (GA), Grey Wolf Optimizer (GWO), Harris Hawks Optimization (HHO), Particle Swarm Optimization (PSO), and Salp Swarm Optimization (SSO) algorithm-based least square-support vector machine (LSSVM) models. For this purpose, two hundred one datasets were used to develop, train (161), and test (40) the models. The performance comparison showed that the SSO_LSSVM model assessed chloride penetration with a performance index (PI) of 1.8702, variance accounted for (VAF) of 95.9727, performance (R) of 0.9798, and root mean square error (RMSE) of 336.1474 C. In addition, several analyses, such as score, regression error characteristics curve, generalizability, uncertainty, computational cost, reliability, objective function criterion, and validation dataset, confirmed the reliability and capabilities of the SSO_LSSVM model. Conversely, the multicollinearity analysis revealed that the binder and fine aggregate significantly affected the performance of hybrid LSSVM models. The analysis of variance (ANOVA) supported the research hypothesis for the binder, aggregates, metakaolin content, and compressive strength features. The Anderson–Darling test indicated statistically significant departures from normality (<i>p</i> &lt; 0.005) for the actual and model-predicted chloride penetration data; however, the SSO_LSSVM predictions exhibited an AD statistic closest to that of the actual observations, indicating comparatively similar distributional characteristics. The fundamental study of algorithms reveals that SSO exhibited superior optimization performance for the present problem, as evidenced by its favorable fitness-evolution trajectory and the lowest final convergence MSE. Additionally, it requires fewer parameters to tune than GA and PSO. The SHAP and LIME analyses revealed that the compressive strength (fc) is the most significant feature in assessing the chloride ingress of metakaolin concrete.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 4","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-10-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149338614","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Experimental and numerical investigation on thermally-assisted self-piercing riveting of DP980 steel and 5052 aluminum alloy","authors":"De’an Meng,&nbsp;Zhilong Zhu,&nbsp;Liangyu Fei,&nbsp;Xinyu Zhang,&nbsp;Hao Liu,&nbsp;Chengcheng Zhu,&nbsp;Kaichao Zhang","doi":"10.1007/s12289-026-02097-5","DOIUrl":"10.1007/s12289-026-02097-5","url":null,"abstract":"<div><p>To address the difficulty of joining dissimilar high-strength steel and aluminum alloy sheets, this study proposes a thermally assisted self-piercing riveting (TA-SPR) process based on the thermal softening of DP980 steel. The TA-SPR behavior of DP980 high-strength steel and 5052 aluminum alloy was investigated through a combined experimental and numerical approach. Temperature-dependent constitutive and failure models for DP980 steel were first established and implemented in a thermomechanical simulation framework to evaluate rivet penetration, sheet deformation and interlock formation under different preheating conditions. A dedicated TA-SPR experimental system was then developed, and the resulting joints were characterized by cross-sectional observation, lap-shear testing, failure-mode analysis and microhardness measurement. The results show that preheating markedly improves joint formation by reducing the deformation resistance of the DP980 upper sheet. The optimum joint was obtained at 600 °C, with a maximum shear force of 6927.7 N, an energy absorption of 32.94 J and an interlock distance of 0.70 mm. At 700 °C, excessive softening reduced rivet flaring and promoted premature interlock failure. The proposed TA-SPR process therefore provides an effective route for steel/aluminum dissimilar joining in lightweight vehicle structures.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 4","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149234317","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Interpretable machine learning and hybrid metaheuristic algorithms for multi-objective optimization in injection molding","authors":"Liuyu Zhu,&nbsp;Xiying Fan,&nbsp;Yonghuan Guo,&nbsp;Dazhen Zhu,&nbsp;Zhijiang Wang,&nbsp;Lie Li","doi":"10.1007/s12289-026-02095-7","DOIUrl":"10.1007/s12289-026-02095-7","url":null,"abstract":"<div><p>Warpage deformation and volumetric shrinkage defects in injection molding significantly affect the quality and service life of plastic products. To address this issue, this study proposes a multi-objective process parameter optimization approach. First, MIC screening was applied to 152 central-composite-design/Moldflow samples, and a GAN generated 48 additional samples, producing a 200-sample modeling dataset. Then, a hybrid framework combining the Kepler Optimization Algorithm (KOA) and Ivy Optimization Algorithm (IVYA) was applied for hyperparameter tuning. Furthermore, the interpretability of the Extreme Gradient Boosting (XGBoost) model was enhanced using Shapley Additive Explanations (SHAP), which also provided refined search ranges for process parameters. Finally, multi-objective chaotic game optimization (MOCGO) was used to identify the Pareto front and select a compromise solution. Compared with the initial settings, the selected solution reduced warpage deformation and volumetric shrinkage by 35.7% and 10.1%, respectively.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 4","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-10-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149189024","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Finite element analysis of the response of DP800 steel sheet in a new laboratory forming test","authors":"Rahul Rakshit,&nbsp;Benoit Revil-Baudard,&nbsp;Oana Cazacu","doi":"10.1007/s12289-026-02092-w","DOIUrl":"10.1007/s12289-026-02092-w","url":null,"abstract":"<div><p>Owing to the good formability combined with low yield-to-ultimate tensile strength ratio, DP800 steel is widely used in the automotive industry. For process optimization and analysis of the feasibility and resulting part quality, it is essential to use a suitable constitutive model. To assess the predictive capabilities of models for forming applications, very recently a benchmark focusing on simulation of a new laboratory forming test, called material under control (MUC) was launched. In this paper, we show that an elastoplastic model with yielding described by the 3-D orthotropic yield criteria of Hill48 [1] and Cazacu [2], and isotropic hardening accurately predict the observed plastic anisotropy of the DP800 steel. The predictive capabilities of these models are demonstrated through comparisons between simulation results and experimental data in uniaxial tension and MUC-Tests, including punch force-displacement curves and surface strain distributions for all specimen geometries. Furthermore, the effect of specimen orientation on the strain path experienced by the material during a MUC test was investigated using Cazacu [2] criterion. The results presented suggest that the use of 3-D orthotropic yield criteria and isotropic hardening may provide reliable virtual assessments of DP800 steel for forming operations.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 4","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-10-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149189037","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Data-efficient surrogate modeling using Laplace-Beltrami shape-features: a case study on a cup drawing process","authors":"Daniela Steffes-lai,&nbsp;Lukas Morand,&nbsp;Rodrigo Iza-Teran,&nbsp;Tom Niklas Klein,&nbsp;Dirk Helm,&nbsp;Raoul Heese,&nbsp;Jochen Garcke","doi":"10.1007/s12289-026-02091-x","DOIUrl":"10.1007/s12289-026-02091-x","url":null,"abstract":"<div><p>Process control and optimization are important aspects of manufacturing processes. Surrogate models, i.e. data driven models obtained from numerical simulations, are often employed to predict the process outcome for given process parameters in real time. In this work, we investigate a Laplace-Beltrami shape-feature approach for constructing a surrogate model for cup drawing process simulations. The resulting surrogate model captures local changes in deformations and field quantities on mesh geometries more accurately than standard methods. However, comparing mesh distortions, especially local mesh qualities, is challenging. To address this, we introduce a measure of improvement of mesh distortion to analyse the obtained error distributions. We demonstrate the benefits of the proposed method in contrast to variance-based methods such as principal component analysis, which do not adequately model local variations.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 4","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-10-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s12289-026-02091-x.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149132764","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Springback suppression in 3D bending-torsion combined forming of hollow rectangular aluminum profiles using magnetorheological elastomer inner support","authors":"Yu Wen,&nbsp;Jicai Liang,&nbsp;Yi Li,&nbsp;Ce Liang","doi":"10.1007/s12289-026-02093-9","DOIUrl":"10.1007/s12289-026-02093-9","url":null,"abstract":"<div><p>Magnetorheological elastomers (MREs), due to their excellent controllable mechanical properties, have broad application prospects in assisting forming processes. In this study, several MREs with varying carbonyl iron powder (CIP) contents are prepared and used for the three-dimensional bending-torsion combined forming of hollow rectangular 6005 A aluminum profiles. A numerical-analytical (FE-TA) model is established to analyze the springback of the profile. The FE-TA model and numerical simulations are used to investigate the effects of varying CIP content and magnetic field strength on the profile’s springback. The results indicate that adding MRE increases the springback of the profile, with magnetic field strength having a more significant effect on springback than CIP content. The maximum error between the springback amount calculated by the FE-TA model and the value obtained by numerical simulation is only 6.75%. Finally, experiments verified the influence of magnetic field strength on profile springback and the accuracy of the numerical simulation.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 4","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-10-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149132522","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}