International Journal of Material Forming最新文献

{"title":"A review of methods and effects for improving production robustness in industrial micro-deep drawing","authors":"Úlfar Arinbjarnar,&nbsp;Philipp Schumann,&nbsp;Jonas Moske,&nbsp;Alexander Breunig,&nbsp;Peter Groche,&nbsp;Chris V. Nielsen","doi":"10.1007/s12289-024-01832-0","DOIUrl":"10.1007/s12289-024-01832-0","url":null,"abstract":"<div><p>Deep-drawing is a method in which flat sheets of metal are formed into complex 3-dimensional geometries. Three main types of challenges arise when transitioning from the macro-scale to micro-deep drawing. These can be summarised as: (1) tribological effects, which mainly stem from the relative difference in surface characteristics between the two size scales, (2) material behaviour effects which arise from the increasing heterogeneity of materials that have a decreasing number of grains that are deformed in forming, and (3) dimensional effects which relate to difficulties in handling and inspection of small components at high rates and challenges in manufacturing and monitoring of tool components for use in micro-deep drawing. Various methods or effects can be applied to micro-deep drawing processes to tackle these challenges. This paper reviews research on methods and effects that can be used to improve the robustness in micro-deep drawing processes. Small changes, such as the choice of lubricant and slight changes to the punch geometry are considered, but so are larger changes such as the use of ultrasonic vibration to improve formability and adjustable tooling. The influence of process monitoring and simulation on process robustness is also considered. A summary of methods and effects is drawn at the end to highlight potential space for innovation.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"17 3","pages":""},"PeriodicalIF":2.6,"publicationDate":"2024-05-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140928681","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":"Engineering estimates of strain and strain rate in helical rolling of balls","authors":"Yan Beygelzimer,&nbsp;Emmanuil Beygelzimer,&nbsp;Daniel Hajduk","doi":"10.1007/s12289-024-01829-9","DOIUrl":"10.1007/s12289-024-01829-9","url":null,"abstract":"<div><p>The subject of the research is the process of helical rolling of balls with a diameter of 15 to 125 mm for grinding mills. Analytical estimates of the equivalent strain and the rate of equivalent strain averaged within the volume of the metal were obtained. A simple formal model of equivalent strain distribution within the ball in the direction of the rolling axis is also proposed. The proposed solutions predict that in the working ranges of the rolling parameters the value of the volume-averaged strain can vary from about 0.6 to 5, meanwhile in the jumper area the equivalent strain is two orders of magnitude higher than in the axial zone. It is shown that the principal influence on the magnitude of strain is caused by ovalization of the workpiece during rolling, which leads to multiple repeated deformation of the same volumes of metal when the workpiece rotates. As an example, the use of obtained estimates to calculate the strain, strain rate, flow stress, force and rolling torque under the conditions of the real experiment performed by other authors is shown. The proposed models allow solving engineering problems of certain classes (for example, calculation of energy-force parameters) without using FEM software packages and are recommended for optimization and real-time control of the helical rolling of balls.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"17 3","pages":""},"PeriodicalIF":2.6,"publicationDate":"2024-05-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140887336","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":"Influence of the sensitivity of plastic deformation to the third invariant on the stress state achievable during stretch forming of isotropic materials","authors":"Hernan Godoy,&nbsp;Benoit Revil-Baudard,&nbsp;Oana Cazacu","doi":"10.1007/s12289-024-01830-2","DOIUrl":"10.1007/s12289-024-01830-2","url":null,"abstract":"<div><p>For isotropic materials, the von Mises yield criterion is generally used to interpret bulge test data and assess formability. In this paper, we investigate the role played by the <span>({J}_{3})</span> dependence of the plastic response on the behavior during stretch forming under pressure. To this end, we consider the isotropic yield criterion of Drucker, which involves a unique parameter <i>c</i> expressible solely in terms of the ratio between the yield stresses in shear and uniaxial tension, <span>({tau }_{Y}/{sigma }_{T})</span>. In the case when <span>({tau }_{Y}/{sigma }_{T}=sqrt{3})</span>, the parameter <i>c</i> = 0 and the von Mises yield criterion is recovered, otherwise Drucker’s criterion accounts for dependence on both <span>({J}_{2})</span> and <span>({J}_{3})</span>. First, an analytical estimate of the ratio of the principal stresses at the apex of the dome is deduced. It is demonstrated that the stress ratio depends on the parameter <i>c,</i> the deviation from an equibiaxial stress state induced by changing the die aspect ratio is more pronounced for materials with higher <span>({tau }_{Y}/{sigma }_{Y})</span> ratio. Finite element predictions using the yield criterion and isotropic hardening confirm the trends put into evidence theoretically. Moreover, the F.E. simulations show that there is a correlation between the value of the parameter <i>c</i> that describes the dependence on <span>({J}_{3})</span> in the model and the strain paths that can be achieved in any given test, the level of plastic strains that develop in the dome, and the thickness reduction. Specifically, for a material characterized by <i>c</i> &gt; 0 (<span>({tau }_{Y}/{sigma }_{T}&lt;1/sqrt{3})</span>) under elliptical bulging, at the apex the plastic strain ratio is greater than in the case of a von Mises material, while the stress ratio is less. On the other hand, for a material characterized by <i>c</i> &lt; 0 (<span>({tau }_{Y}/{sigma }_{T}&gt;1/sqrt{3})</span>), the reverse holds true. The FE results also suggest that for certain isotropic materials neglecting the dependence of their plastic behavior on <span>({J}_{3})</span> would lead to an underestimation of the thickness reduction.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"17 3","pages":""},"PeriodicalIF":2.6,"publicationDate":"2024-05-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140830369","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":"Uncertainties on the mechanical behaviour of bronze sheets: influence on the failure in bending","authors":"Ghinwa Ouaidat,&nbsp;Amine Lagroum,&nbsp;Ahmed Kacem,&nbsp;Sandrine Thuillier","doi":"10.1007/s12289-024-01831-1","DOIUrl":"10.1007/s12289-024-01831-1","url":null,"abstract":"<div><p>Copper alloys are extensively used in the manufacture of electrical and electronic components, which strength depends on the material mechanical properties, which in turn depend on the metallurgical state. Even though the mechanical properties remain within the specifications, the subsequent formability limits may depend strongly on the material batch. Considering the forming stage to manufacture plug-in type connectors made of CuSn6P thin sheets, a crack may appear in the components, in the bent area subject to high strains, when changing the material batch. The aim of this study is to take account of these variations of the mechanical behavior through a probabilistic approach, to predict the formability limit. The mechanical properties of the materials from the two batches were characterized in tension, to highlight the differences. The initial yield stress and the tensile strength are higher for one material, while the maximum equivalent plastic strain at rupture, determined through a hybrid experimental-numerical approach, is lower. And a significant difference in the transverse anisotropy coefficient is evidenced. A 3D parametric finite element model of the forming stage is developed to investigate the role of some mechanical properties and process parameters on the formability limit in bending. The range of the parameter values comes from the experimental data. Their influence is evaluated through a design of experiments, with the aim of highlighting the influence of the variations of the mechanical properties and process parameters on the fracture criterion, using a probabilistic approach with Gauss’s law.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"17 3","pages":""},"PeriodicalIF":2.6,"publicationDate":"2024-04-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140657748","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":"Rotary compression test for determination of critical value of hybrid damage criterion for railway steel EA1T","authors":"Łukasz Wójcik,&nbsp;Tomasz Bulzak,&nbsp;Konrad Lis,&nbsp;Grzegorz Winiarski,&nbsp;Tomasz Kusiak","doi":"10.1007/s12289-024-01827-x","DOIUrl":"10.1007/s12289-024-01827-x","url":null,"abstract":"<div><p>The article presents and discusses the problem of determining and characterizing the cracking limits of cross-rolled specimens. The limit values were determined in accordance with the hybrid Pater criterion. For the study, the author’s test method was used, which allows the determination of the cracking moment, formed as a result of the Mannesmann effect during the compression of specimens in the channel. In order to determine the values needed to describe the cracking criterion, it was necessary to perform laboratory tests and numerical simulations of the process of compression in the channel of discs made of EA1T steel under hot forming conditions. Experimental tests were carried out for forming processes at 950 °C, 1050 °C and 1150 °C. The tested material had a disc shape with a diameter of 40 mm and a length of 20 mm, during the pressing process the diameter of the disc was reduced to a diameter of 38 mm. The increase in forming temperature caused a significant increase in the forming path until cracking occurred. Numerical tests were carried out in the finite element calculation environment Simufact.Forming 2021. The stress and strain distributions in the specimen axis were analysed during the tests, which were then used to calculate the hybrid cracking criterion limit according to Pater. After calculations according to the Pater criterion and after statistical analysis, the cracking criterion limits were obtained.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"17 3","pages":""},"PeriodicalIF":2.6,"publicationDate":"2024-04-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s12289-024-01827-x.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140612421","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":"Investigation on the forming process of polylactic acid in material extrusion additive manufacturing technique","authors":"Shijie Jiang,&nbsp;Chaoqun Yun,&nbsp;Hongwei Ying,&nbsp;Jiaqi Chen,&nbsp;Chunyu Zhao,&nbsp;Huisheng Yao","doi":"10.1007/s12289-024-01828-w","DOIUrl":"10.1007/s12289-024-01828-w","url":null,"abstract":"<div><p>The internal hydrodynamic parameters of extrusion liquefier and bonding neck have an important influence on the forming quality of material extrusion additive manufacturing (MEAM) products. To investigate the relationship, theoretical research and experimental analysis are carried out on both the melt flow behavior (MFB) of the molten polylactic acid (PLA) inside the extrusion liquefier and the bonding neck. They are theoretically modelled based on Newton's power law equation and the viscous sintering phenomenon of the extrudate, respectively. The measurement on the melt pressure drop is then performed with a self-made equipment, and the bonding neck of the sample is observed and measured by scanning electron microscope (SEM). Through the comparison between the predicted and measured results, the proposed theoretical models are validated, and they can give reliable predictions in terms of MFB and bonding neck. The results also show that increasing the extrusion temperature and width will reduce the hydrodynamic parameters (pressure drop, shear stress and apparent viscosity), and increase the bonding neck size of the sample, and thereby improve the forming quality of MEAM products. While for the printing speed, the situation is to the contrary.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"17 3","pages":""},"PeriodicalIF":2.6,"publicationDate":"2024-04-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140581048","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":"Numerical simulation of friction extrusion: process characteristics and material deformation due to friction","authors":"George Diyoke,&nbsp;Lars Rath,&nbsp;Rupesh Chafle,&nbsp;Noomane Ben Khalifa,&nbsp;Benjamin Klusemann","doi":"10.1007/s12289-024-01825-z","DOIUrl":"10.1007/s12289-024-01825-z","url":null,"abstract":"<div><p>This study employs a finite element thermo-mechanical model, using a Lagrangian incremental setting to investigate friction extrusion (FE) under varying process conditions. The incorporation of rotation in FE generates substantial frictional heat, leading to significantly reduced process forces in comparison to conventional extrusion (CE). The model reveals the interplay between temperature, strain, and strain rate across different microstructural zones of the resulting wire. Specifically, the sticking friction condition in FE enhances initial shear deformation, aligning with a homogeneous spatial strain distribution and predicting complete grain refinement in the extruded wire, as per Zener-Hollomon calculations. On the other hand, under the sliding friction condition in FE, the shear deformation is reduced which results in an inhomogeneous microstructure in the extruded wire. The analysis of material flow in the workpiece reveals distinct transitions from the base material to the thermo-mechanically affected zones. The simulated process force, thermal history, and microstructure during sliding friction conditions align well with the findings from performed friction extrusion experiments.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"17 3","pages":""},"PeriodicalIF":2.6,"publicationDate":"2024-04-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s12289-024-01825-z.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140581047","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":"Simulation and automation of aluminum panel shot peen forming","authors":"Vladislav Sushitskii,&nbsp;Pierre-Olivier Dubois,&nbsp;Hong Yan Miao,&nbsp;Martin Lévesque,&nbsp;Frédérick Gosselin","doi":"10.1007/s12289-024-01826-y","DOIUrl":"10.1007/s12289-024-01826-y","url":null,"abstract":"<div><p>We present a methodology for automated forming of metal plates into freeform shapes using shot peening. The methodology is based on a simulation software that computes the peening pattern and simulates the effect of its application. The pattern generation requires preliminary experimental characterization of the treatment. The treatment is applied by a shot peening robot. The program for the robot is generated automatically according to the peening pattern. We validate the methodology with a series of tests. Namely, we form nine aluminum plates into doubly curved shapes and we also shape model airplane wing skins. The article describes the complete workflow and the experimental results.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"17 3","pages":""},"PeriodicalIF":2.6,"publicationDate":"2024-04-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140580981","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":"Numerical simulation of 3D angle-interlock woven fabric forming and compression processes","authors":"Yongqiang Liu,&nbsp;Zhongxiang Pan,&nbsp;Jiajia Yu,&nbsp;Xiaoyu Hong,&nbsp;Zhiping Ying,&nbsp;Zhenyu Wu","doi":"10.1007/s12289-024-01824-0","DOIUrl":"10.1007/s12289-024-01824-0","url":null,"abstract":"<div><p>This paper provides a modeling method for predicting the internal structure of three-dimensional (3D) angle-interlock woven fabric. Inspired by the digital element method, the numerical model of micro-scale was established by using truss element. The numerical model was compared with the Computed Tomography (CT) cross-sectional scan of the actual fabric sample, and the results were consistent. The mechanical properties of the 3D angle-interlock woven fabric is closely related to the fabric’s structure. Therefore, by changing the tension at both ends of the yarn tows to explore the influence on the yarn tows’ geometry, it was found that different tensions affects the cross-sectional areas and crimp angles of the yarn tows. On the basis of fabric forming, multi-shape molds were designed to press the fabric into different shapes, which were semi-hexagonal, arc-shaped and L-shaped. The results of numerical simulation showed that the fabric will undergo inter-layer slip when compressed, especially in the region where the mold deformation is large.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"17 3","pages":""},"PeriodicalIF":2.6,"publicationDate":"2024-03-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140315895","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":"Analysis, simulation and experimental study of electromagnetic forming of titanium bipolar plate with arc-shaped uniform pressure coil","authors":"Qiangkun Wang,&nbsp;Junrui Xu,&nbsp;Shaobo Wang,&nbsp;Yudong Zhao,&nbsp;Yuanfeng Wang","doi":"10.1007/s12289-024-01818-y","DOIUrl":"10.1007/s12289-024-01818-y","url":null,"abstract":"<div><p>In the electromagnetic forming (EMF) titanium bipolar plates (BPPs), a reasonable coil structure can provide higher forming efficiency and repeatability. An arc-shaped uniform pressure coil (UPC) is proposed, and an efficient and reliable multiphysics sequentially coupled analytical model is established. Through the LS-DYNA numerical model and the fitted current curve obtained from experiments, the predictive capabilities of equivalent circuit parameters and dynamic phenomena are verified, and the rationality of the magnetic shielding assumption and magnetic flux uniform distribution are evaluated. Starting from the durability and forming efficiency of the coil, the optimal coil geometry in analytical form is constructed. The study found that there is an optimal solution for the height of the primary coil, wire thickness, primary and secondary side gap, which are 18.3 mm, 2.7 mm, and 3.2 mm, respectively. Based on this, under the discharge capacitor of 100 μF, acceleration distance of 2 mm, and driven by 0.3 mm thick Cu110, a TA1 titanium BPP with a channel depth-to-width ratio of 0.53 was successfully manufactured. Its maximum thinning rate is 18.2%, the maximum fluctuation rate does not exceed 2.5%, and the filling rate of the channel above 95%. Overall, this study provides theoretical basis and reference for the design of UPC in EMF for BPPs.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"17 3","pages":""},"PeriodicalIF":2.6,"publicationDate":"2024-03-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140196805","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}