International Journal of Material Forming最新文献

{"title":"Utilizing hybrid BIGRU-LIGHTGBM model for mechanical characteristics prediction in aluminium alloys","authors":"Lakshmi Rajan P.,&nbsp;Sujatha I.,&nbsp;Arun M. S.","doi":"10.1007/s12289-026-02068-w","DOIUrl":"10.1007/s12289-026-02068-w","url":null,"abstract":"<div><p>The growing requirement for lightweight yet high-performance materials has resulted in a major progress in aluminium (Al) alloys, especially in optimizing their mechanical properties. Conventional predictive models struggle to capture the intricate relationships among alloy composition, processing conditions, and mechanical properties. To address this challenge, this research proposes a new hybrid model combining a Bidirectional Gated Recurrent Unit (BiGRU) and a Light Gradient Boosting Machine (LightGBM), optimized using AdamW-based Bayesian Optimization (AdamW-BO). The model is trained and tested on experimental data sets, accurately predicting key mechanical properties such as yield strength (YS), tensile strength (TS), and elongation. The proposed BiGRU-LightGBM model with and without AdamW-BO achieves superior performance, with an R² value of 0.979 and 0.96, respectively and less errors, demonstrating its efficacy in accurately forecasting mechanical characteristics. The findings suggest that the hybrid approach can serve as a robust predictive tool for material design and quality control in Al alloy manufacturing.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 3","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-08-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148751202","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":"Study on wrinkling behavior and process optimization of 316L stainless steel bipolar plate channel Roller embossing","authors":"Shengqi Gao,&nbsp;Fuqiang Zhao,&nbsp;Shengqian Chen,&nbsp;Qingxue Huang","doi":"10.1007/s12289-026-02066-y","DOIUrl":"10.1007/s12289-026-02066-y","url":null,"abstract":"<div><p>To address lateral-edge wrinkling in 0.1 mm-thick 316L stainless steel metallic bipolar plates during roller embossing, this study investigates the wrinkling mechanism and optimizes key forming parameters. A finite element wrinkling model was established and combined with energy-based analysis and shell bending theory to analyze wrinkle evolution and instability behavior during roller embossing. Experimental validation was further conducted under different mold and constraint conditions. The results indicate that wrinkling is mainly induced by compressive stress instability on both sides of the transverse deformation zone, while shear stress contributes to the inclined wrinkle morphology. Multi-channel forming coupling intensifies residual compressive stress concentration and promotes nonlinear wrinkle amplification. Parametric analysis shows that increasing the blank-holder diameter reduces wrinkling, whereas increasing the mold fillet radius aggravates wrinkling. In contrast, the influence of mold side clearance exhibits a non-monotonic trend. Based on response surface methodology, multi-objective optimization of the process parameters was performed. Statistical analysis shows that the blank-holder diameter is the most significant factor affecting wrinkling under the investigated conditions. The optimized parameter combination was obtained as follows: mold fillet radius of 0.1 mm, mold side clearance of 0.27 mm, and blank-holder diameter of 49.90 mm. Compared with the parameter set showing the lowest wrinkling level in the experimental design, the optimized condition reduced the wrinkle amplitude and fluctuation index by 6.12% and 10.04%, respectively. These results provide a mechanistic understanding and parameter selection reference for reducing lateral-edge wrinkling in metallic bipolar plate channel roller embossing.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 3","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-08-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148750818","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":"Accurate cold forged parts through adjustable dies","authors":"Christian Siedbürger,&nbsp;Peter Groche","doi":"10.1007/s12289-026-02055-1","DOIUrl":"10.1007/s12289-026-02055-1","url":null,"abstract":"<div><p>In response to the growing demands for both sustainability and precision in metal forming, this study investigates the potential of an adaptive die system for cold forging processes. The system allows of control of die preload during the main forming and ejection phases, thus offering two degrees of freedom to influence product properties. Through a combination of experimental and numerical investigations, the interdependence between the final part diameter, axial residual stresses, and ejection forces is systematically analyzed. It is shown that increasing the preload during forming reduces the final diameter. Conversely, preload applied during ejection has a direct influence on the resulting ejection force and surface stresses. This decoupling capability enables targeted tuning of individual product properties. To experimentally represent the variability of material batches, three different steel grades were selected, spanning a broad range of flow stresses. The resulting process maps reveal how fluctuations in material properties affect forming outcomes, and how the adaptive die system can be used to compensate these effects. The experimental trends were confirmed by finite element simulations, which support the physical interpretation of preload-related elastic and plastic interactions within the tooling system. The study shows that adjusting the preload intelligently enables dimensional corrections and residual stress or ejection force optimization. The primary focus is on understanding and modeling the process-property relationships. The results lay the foundation for potential control strategies, such as inline or part-to-part adaptation. These strategies can be integrated into future forming lines for increased robustness and flexibility.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 3","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-08-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s12289-026-02055-1.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148750819","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":"Experimental and numerical investigation on fracture mechanisms of copper foils during laser shock forming","authors":"Guofang Zhang,&nbsp;Chao Zheng,&nbsp;Guoxin Lu,&nbsp;Zijie Meng,&nbsp;Zhong Ji","doi":"10.1007/s12289-026-02062-2","DOIUrl":"10.1007/s12289-026-02062-2","url":null,"abstract":"<div><p>Fracture is one of the most common defects encountered in laser shock forming of thin foils. In this study, the fracture mechanisms of copper foils during laser shock bulging were investigated experimentally and numerically under different ratios of laser beam diameter (<i>d</i>) to die cavity diameter (<i>D</i>). The failure locations, surface morphologies, and fracture modes predicted by simulation are in good agreement with the experimental results. Three distinct fracture modes were identified: a tensile fracture mode occurring near the loading edge, driven by tensile stress at <i>d</i>/<i>D</i> = 0.5; a shear fracture mode at the die fillet, induced by shear stress at <i>d</i>/<i>D</i> = 1.25; and a mixed tensile-shear fracture mode developing at both the loading edge and the die fillet, caused by combined tensile and shear stresses at <i>d</i>/<i>D</i> = 0.75. Further analyses of the stress, strain, and thickness distributions reveal that fracture initiates in regions exhibiting severe thickness reduction resulting from intense stress concentration. Among the three modes, the shear failure mode exhibited the smallest bulging depth and thickness reduction ratio, indicating that a large <i>d</i>/<i>D</i> ratio or an excessively high forming velocity is unfavorable in laser shock bulging.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 3","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-07-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148614697","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":"From mechanism to application: microstructure modeling of 42CrMo steel during hot deformation and its implementation in profiled grooved ring rolling","authors":"Tingting Pan,&nbsp;Xiaoqing Chen,&nbsp;Xuechao Li,&nbsp;Fei Li,&nbsp;Shijian Zou,&nbsp;Xiao Li","doi":"10.1007/s12289-026-02063-1","DOIUrl":"10.1007/s12289-026-02063-1","url":null,"abstract":"<div><p>A microstructure prediction model for 42CrMo steel during hot deformation was developed and applied to the profiled ring rolling process. Hot compression experiments on a Gleeble simulator were carried out in the deformation range of 0.01–10 s⁻¹ and 1073–1473 K, and the dynamic recrystallization (DRX) mechanism was analyzed by metallography and EBSD. The results showed that, under three representative deformation states, namely partial recrystallization, complete recrystallization, and unstable deformation, the DRX volume fractions were 83.14%, 100%, and 91%, respectively, and the corresponding average grain sizes were 5.09 μm, 6.82 μm, and 5.57 μm. Based on the work hardening rate theory, the average deformation activation energy was determined as 410.723 kJ/mol. A DRX kinetic model and a grain size evolution model coupled with the Zener-Hollomon parameter were then established. The validation results showed that the average relative error of grain size prediction was 8.96%. Furthermore, the developed model was implemented into the finite element model of profiled ring rolling via a VUMAT subroutine, enabling prediction of the DRX volume fraction and grain size evolution in the ring. The results indicate that finer grains formed on the inner and outer surfaces of the profiled ring, whereas coarser grains appeared at the corners, mainly owing to the non-uniform temperature and strain distributions arising from variations in roll-ring contact and overall heat transfer conditions.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 3","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-07-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148614557","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 sheet thickness on forming limit curves: review and assessment of predictive models","authors":"Grégoire Mainguy,&nbsp;Tudor Balan,&nbsp;Xavier Lemoine,&nbsp;Dorel Banabic","doi":"10.1007/s12289-026-02067-x","DOIUrl":"10.1007/s12289-026-02067-x","url":null,"abstract":"<div><p>The influence of sheet thickness on forming limit curves (FLCs) remains insufficiently understood, despite its well-documented experimental significance. While most classical forming limit prediction models are inherently thickness-independent, industrial applications increasingly require reliable predictions outside the standard thickness range (0.5–2.5<i> mm</i>). This work presents a critical review and comparison of existing modelling approaches accounting for thickness effects on forming limits. Two representative approaches, the extended Modified Maximum Force Criterion (eMMFC) and a thickness-dependent Marciniak–Kuczyński (MK) model, are further applied to low-carbon and high-strength low-alloy steels. A physically motivated definition of the initial imperfection based on void distribution is proposed, leading to an explicit dependence on sheet thickness. Both models predict a non-linear increase in forming limits with thickness. However, significant discrepancies remain depending on the underlying assumptions. The study highlights the lack of a unified theoretical framework and emphasizes the need for physically grounded models to better capture thickness effects across a wide range of materials and geometries.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 3","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-07-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148838103","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":"An AI-augmented tribo-plasticity analysis of severe plastic deformation by low-speed high-die-angle wire drawing: thermal mixed lubrication and a novel constitutive-geometric strain redundancy factor","authors":"Behrouz Asadzadeh Totonchi,&nbsp;Koosha Aghazadeh,&nbsp;Iliya Attarnejad,&nbsp;Reza Attarnejad","doi":"10.1007/s12289-026-02061-3","DOIUrl":"10.1007/s12289-026-02061-3","url":null,"abstract":"<div><p>In alloys susceptible to Strain-Induced Martensitic Transformation (SIMT) such as metastable austenitic steels, the extensive shearing imposed during Severe Plastic Deformation (SPD) processes accelerates transformation kinetics and enhances material strength. However, compressive mean stress inherent to such processes acts detrimentally to the transformation. The present study investigated the potential of Low-Speed High-Die-Angle (LSHDA) wire drawing as an SPD process for manufacturing ultra-high strength 304 L steel wires by leveraging a controlled state of positive mean stress using atypically high die semi-angles (20<span>(:^circ:)</span> to 40<span>(:^circ:)</span>). The tribo-plasticity analysis of this process was conducted using slab method combined with a physically-based, regime-switching Thermal Mixed Lubrication (TML) model capable of predicting the onset of local lubrication breakdown under extremely high die pressures. Furthermore, a novel constitutive-geometric redundancy factor was proposed to accurately capture the coupled effects of highly localized deformation geometry and material strain hardening on the extent of redundant shearing. The theoretical framework was augmented with a Particle Swarm Optimization (PSO) scheme for inverse calibration of constitutive parameters of the proposed friction model and the redundancy coefficient against experimental measurements. The framework demonstrated high fidelity in deriving governing parameters of the frictional model, accurately predicting the onset of surface scoring due to high die pressure. Moreover, the calibrated redundancy factor provided new insights into the extreme inhomogeneous deformation caused by unconventionally high die angles. Experiments confirmed that maintaining low drawing speeds and efficient lubrication entirely prevented central bursting and surface defects, enabling the successful manufacture of defect-free, high-strength products via LSHDA wire drawing.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 3","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-07-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148613622","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 and experimental investigation of internal thread cold extrusion using specially shaped preformed holes","authors":"Hong-Ling Hou,&nbsp;Jia-Le Dong,&nbsp;Zhao-Le Yu,&nbsp;Xi-Xin Wang,&nbsp;Tao Yan,&nbsp;Jing Liu,&nbsp;Yong-Qiang Zhao,&nbsp;Jian-Qiang Jin","doi":"10.1007/s12289-026-02056-0","DOIUrl":"10.1007/s12289-026-02056-0","url":null,"abstract":"<div><p>To address the problems of high forming torque, severe tap wear, and tap fracture during cold extrusion of large-diameter internal threads in high-strength materials, this study proposes a novel internal thread cold extrusion method using specially shaped preformed holes. An M20 × 2.5 internal thread made of Ti-6Al-4V titanium alloy was selected as a representative case. Considering material plasticity, frictional behavior, and strain hardening, a mathematical model of extrusion torque was established to clarify the torque generation mechanism and its dominant influencing factors. Based on this model, several preformed-hole geometries were designed, and finite element simulations were performed to investigate the effects of preformed-hole geometry on extrusion torque, forming temperature, axial load-bearing capacity, and tap wear. The results show that specially shaped preformed holes can effectively modify material flow behavior and the tap–workpiece contact state, thereby reducing extrusion torque and tap wear. By comprehensively considering forming difficulty, thread mechanical performance, tap wear, and manufacturing feasibility, the keyway-shaped preformed hole was identified as the optimal design. Compared with the conventional circular preformed hole, the keyway-shaped preformed hole reduced the extrusion torque, forming temperature, and tap wear by 14.79%, 4.43%, and 12.93%, respectively, while the axial load-bearing capacity decreased by only 10.22%. Experimental validation showed that the relative errors between the experimental and simulated results for extrusion torque, forming temperature, and thread height were 2.80%, 7.73%, and 8.18%, respectively, indicating that the finite element model has good predictive accuracy. The proposed method provides a theoretical basis and practical process reference for the cold extrusion of large-diameter internal threads in high-strength materials.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 3","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-07-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148613512","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":"Tool wear effects on surface morphology and topography during aisi 304 l machining under various cooling and lubrication conditions","authors":"Amirhossein Ranjbar,&nbsp;Behzad Jabbaripour,&nbsp;Andrzej Kurek","doi":"10.1007/s12289-026-02059-x","DOIUrl":"10.1007/s12289-026-02059-x","url":null,"abstract":"<div><p>Many machining parameters are directly influenced by tool wear and tool geometry evolution. In conventional tool condition assessment, the wear criterion <span>({V}_{b})</span> is commonly employed. However, this criterion merely reflects the flank wear width on the main flank face. This study aims to propose a novel methodology based on the integration of microscopic imaging and CAD technology. This approach enables the evaluation of the total flank wear area over the entire flank face, including the tool nose region. Notably, the tool nose accounts for approximately 30% of the total wear area. The output of this measurement provides a comprehensive indicator of how various machining parameters, such as tool orientation angle and depth of cut, influence the process. In the present work, the combined influence of this parameter on surface topography and surface morphology is investigated qualitatively. The study also explains its relationship with tool wear and the defects imprinted on the cutting tools. In addition, the role of machining environments under critical cutting conditions is examined. The results show that cryogenic machining, under the most severe conditions performed in this research (v_c = 150 m/min and a_p = 2.5 mm), reduced the flank face wear area by 69.26%, 21.64% and 37.78% compared to dry, wet, and minimum quantity lubrication environments, respectively. This improvement is attributed to the preservation of tool hardness and coating stability. Although cryogenic cooling effectively limited thermal softening, the MQL condition showed superior protection of the rake surface due to reduced friction and the presence of a lubricating oil film.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 3","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-07-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148613712","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":"Isothermal hot compression deformation behavior and interfacial bonding criteria of Al/Mg dissimilar materials","authors":"Wenjie Ji,&nbsp;Ruibin Mei,&nbsp;Xiong Xiong,&nbsp;Xiaobin Lu,&nbsp;Li Bao","doi":"10.1007/s12289-026-02060-4","DOIUrl":"10.1007/s12289-026-02060-4","url":null,"abstract":"<div><p>Based on the analysis of the interfacial bonding state of industrially hot-rolled 1060 Al/AZ31 Mg laminated composites, isothermal hot-compression experiments were designed to simulate the rolling bonding process of Al/Mg and to investigate the interfacial bonding criteria for dissimilar metals. A thermo–mechanical coupled finite element method was employed to analyze the upsetting hot deformation behavior of Al/Mg composites under different processing parameters. By integrating the experimental results with numerical simulations, a novel interfacial bonding criterion for Al/Mg composites based on the coupled response of stress and strain was proposed. The results indicate that increasing temperature and deformation promotes interfacial bonding and improves overall deformation uniformity. Complete interfacial bonding was achieved at 250 °C/60%, 300 °C/50%, 350 °C/50%, and 400 °C/30%. At 400 °C, oxide phases Al₂O₃ and MgO formed at the interface. The strain dispersion coefficients reached 0.485 and 0.457 at 350 °C/70% and 400 °C/50%, respectively, indicating improved deformation uniformity. Stress–strain state analysis at typical locations during Al/Mg upsetting deformation was conducted, and four characteristic deformation regions were defined. Interfacial bonding criterion coefficients (<span>({C}_{varepsilon })</span>,<span>({C}_{sigma })</span>) based on strain and stress fields were established and validated through hot-compression experiments, providing a new approach for studying interfacial bonding criteria in dissimilar layered metals.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 3","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-07-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148466234","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}