International Journal of Material Forming最新文献

{"title":"The influence and analysis of shot peening sequence on the strengthening performance of complex aviation components","authors":"Long Li,&nbsp;Luteng Liu,&nbsp;Shihong Lu","doi":"10.1007/s12289-025-01910-x","DOIUrl":"10.1007/s12289-025-01910-x","url":null,"abstract":"<div><p>Different shot peening sequences can affect the effectiveness of shot peening definitely. To comprehensively investigate the ramifications of different shot peening sequences on the structural integrity of aviation components, this study formulates a shot peening sequence model tailored to the cross-sectional features of H-shaped slide rails commonly found in aircraft, leveraging Abaqus and Python. Combining numerical simulations and experimental data, we utilize the Euclidean distance to assess the similarity of residual stress distribution curves. Effects of six different shot peening surface strengthening sequences on the residual stress distribution and deformation across each surface of the aircraft slide rail’s typical cross-section are analyzed. Results indicate that variability exists in the similarity of maximum residual stress distribution among surfaces subjected to different shot peening sequences. Notably, the fully symmetric strengthening sequence S4 yields the highest similarity in the residual stress distribution curve. Moreover, the maximum deformation of the workpiece groove exhibits a 26.3% disparity under various shot peening strengthening sequences. This indicates that an appropriately selected shot peening sequence can mitigate size errors arising from the strengthening process. This implies that a judiciously chosen shot peening strengthening sequence could enhance the overall shot peening quality of the component.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"18 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2025-05-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143908646","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":"Metamodel-based control algorithms for the correction of bending angle after springback in an industrial U-Bending process","authors":"L. Muñiz,&nbsp;L. Galdos,&nbsp;J. Trinidad","doi":"10.1007/s12289-025-01906-7","DOIUrl":"10.1007/s12289-025-01906-7","url":null,"abstract":"<div><p>The increased complexity of geometries and the improved properties of sheet metal components result in narrower process windows, highlighting the need for better process control to minimize deviations and to ensure the production of high-quality parts. In this context, this study focuses on controlling the bending angle of a seat rail component manufactured by a renowned TIER1 company. This angle changes due to material, process fluctuations and post-forming springback. Two types of material, a cold-rolled Dual Phase DP980 steel and a Complex Phase CP980 high-strength steel, are both employed interchangeably when manufacturing this component. Variations in the mechanical properties and thickness of these two materials result in significant differences in post-springback bending angle. To tackle this challenge, various control strategies have been developed including a classical controller and a controller enhanced with a metamodel-based feedforward term. For the latter, two approaches were used: a simulation-based metamodel and an experimental data-based metamodel. Heuristic-based disturbances, reflecting both material variability and process changes (tool mounting variations, tool wear, gap changes and temperature variations), have been considered. To calibrate the new controller parameters and gains, a constrained-based genetic algorithm approach has been utilized together with a numerical virtualization of the process. After this virtual set-up, the new controllers have been tested experimentally in a real environment, using an industrial U-bending tool and a 4000 kN servomechanical press. The new controllers have proven to be an efficient method for enhancing the process robustness. A classical controller, employing a feedback control system, enabled consideration of part-to-part variations. On the other hand, the addition of a metamodel-based feedforward term facilitated anticipation of material properties and sheet thickness changes, thereby preventing scrap production.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"18 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2025-05-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s12289-025-01906-7.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143908645","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":"Plastic strain related tensile-compressive asymmetric yield behavior of pulse current assisted AZ31B magnesium alloy forming","authors":"Yu Yan,&nbsp;Yuxuan Wang,&nbsp;Haibo Wang,&nbsp;Gence Fan","doi":"10.1007/s12289-025-01909-4","DOIUrl":"10.1007/s12289-025-01909-4","url":null,"abstract":"<div><p>To effectively predict the deformation behavior of AZ31B magnesium alloy (Mg alloy) in plastic forming assisted by pulse current, the influences of different pulse currents’ frequencies on the flow stress of Mg alloy were studied. The Voce and Hockett-Sherby constitutive models were modified to include the influence of frequencies, and the parameters of the constitutive models were calibrated based on the experimental data. The Cazacu 2004 yield criterion was improved to describe the yield behavior under the action of pulse current, in which the tensile-compressive asymmetry keeps changing with the increase of plastic strain. The three-point bending tests of AZ31B Mg alloy assisted by different frequency pulse currents were carried out. The improved constitutive model and yield criterion were embedded in ABAQUS using user material subroutine VUMAT for the corresponding three-point bending simulation. It is found that the improved constitutive model and yield criterion considering the current frequencies and tensile-compressive asymmetry can obviously improve the simulation accuracy.</p><h3>Graphical Abstract</h3>\u0000<div><figure><div><div><picture><source><img></source></picture></div></div></figure></div></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"18 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2025-04-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143892596","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":"Recent advances in the remelting process for recycling aluminium alloy chips: a critical review","authors":"Xin Chen,&nbsp;Mariem Ben Saada,&nbsp;Bruno Lavisse,&nbsp;Amine Ammar","doi":"10.1007/s12289-025-01904-9","DOIUrl":"10.1007/s12289-025-01904-9","url":null,"abstract":"<div><p>This critical review examines advances in preprocessing and remelting processes for aluminium alloy chip recycling, emphasizing pre-treatment and remelting techniques that improve both resource recovery and material quality. Pre-treatment strategies, particularly cleaning methods and compaction are critically evaluated. Various cleaning methods, including centrifugation, ultrasonic solvent washing, extraction, and distillation are compared based on their ability to remove residual cutting fluids. Cold compaction, which augments chip density to approximately 2.5 g/cm³, significantly curtails oxidation losses and enhances metal recovery. During remelting, NaCl-KCl-based fluxes with limited fluoride additions (e.g., 3–7 wt% Na₃AlF₆) disrupt oxide networks but require careful dosage control to minimize furnace corrosion and environmental hazards. Moreover, mechanical stirring combined with suitable melting temperatures reduces porosity while enhancing melt purity. Future research should prioritize the development of low-energy cleaning methods, flux composition optimization, and scalable production techniques to further advance sustainable aluminium recycling.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"18 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2025-04-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s12289-025-01904-9.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143865443","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 simulation study on T2/Q235 composite impact welded with various thickness of Zn interlayer","authors":"Xingxing Cheng,&nbsp;Bing Xue,&nbsp;Jiangliang Li,&nbsp;Moujin Lin,&nbsp;Junqi Zhou,&nbsp;Lu Zhang,&nbsp;Jichun Wang,&nbsp;Pengfei Gao","doi":"10.1007/s12289-025-01903-w","DOIUrl":"10.1007/s12289-025-01903-w","url":null,"abstract":"<div><p>The single-stage light gas gun has been employed to drive the T2 copper welding on Q235 carbon steel. The effect of the Zn interlayer on the microstructure at the interface of impact welded the T2 copper/Q235 carbon steel composite has been studied by both experiment and numerical simulation. The simulation results are mainly consistent with the results of the experiment. The 100 µm Zn interlayer can broaden the lower limit of the T2/Q235 weld window, resulting in a 3.11% reduction in energy dissipation during the impact welding. While the 25 µm Zn interlayer achieves a reduction of up to 11.6%. As the thickness of the Zn interlayer diminishes, the plastic strain, pressure, and temperature of the flyer plate gradually increase, allowing for the modulation of welding parameters through varying Zn interlayer thicknesses.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"18 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2025-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143861259","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":"Microstructure and mechanical properties study of friction stir processed GH4169 via laser deposition manufacturing","authors":"Changfu Li,&nbsp;Bin Yu,&nbsp;Siyu Zhou,&nbsp;Yuhang Ren,&nbsp;Dezhi Wang,&nbsp;Guang Yang","doi":"10.1007/s12289-025-01900-z","DOIUrl":"10.1007/s12289-025-01900-z","url":null,"abstract":"<div><p>The coarse columnar crystals and inter-dendritic Laves phases of laser deposition manufactured (LDM) GH4169 are the two the primary reasons for the undesirable strength and plasticity compatibility and anisotropy of the alloy. In this study, we used friction stir processing (FSP) on LDMed GH4169 samples, the microstructure difference between the FSP zone and the LDM zone were compared, the microstructure refinement process in the FSP zone were analyzed, and the mechanism of microstructure refinement and its influence on the properties of the room-temperature tensile properties were proposed. The results show that fine equiaxed grains with an average grain size of ~ 3.13 μm were obtained in the stir zone (SZ) due to intense plastic deformation and recrystallization processes.The size and shape of the Laves phase changed significantly after FSP, the Laves phase fragmented in the thermo-mechanically affected zone (TMAZ), distributed in long strips along the rotational direction of the tool, and distributed as small particles in the SZ; while the MC-type carbides precipitation exhibited no significant change.The strength and plasticity of the FSP samples were significantly improved relative to the LDM samples, the yield strength and tensile strength reached 546 MPa and 1063 MPa, respectively, and the elongation reached 43%. Numerous strengthening mechanisms to increase the yield strength of the materials are analyzed and calculated in detail.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"18 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2025-04-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143856510","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":"Automatic quality assessment of FE draping simulation results","authors":"Sophia Keller,&nbsp;Franz Maier,&nbsp;Anna Trauth,&nbsp;Markus G. R. Sause,&nbsp;Roland M. Hinterhoelzl","doi":"10.1007/s12289-025-01896-6","DOIUrl":"10.1007/s12289-025-01896-6","url":null,"abstract":"<div><p>Developing and optimizing manufacturing processes for composite components is commonly supported by finite element (FE) simulations. Initial concepts are modeled and parametric studies are conducted to determine optimum process parameters. Built-in application programming interfaces (APIs) typically allow for a script-based automation of systematic model modifications for many FE solvers. However, the evaluation of simulation results typically depends on a manual inspection by experts, despite its repetitive nature. This study aims to use APIs to develop a fully-automated method for identifying and evaluating critical features and thus, the quality of draping simulations. The focus thereby lies on providing a validated framework for the automated evaluation of draping simulation results, rather than claiming perfect virtual representation of experimental draping. Three different metrics (deviations of fiber angles, the boundary contour and topological defects) are used to determine the overall draping quality of simulation results. With the developed routine, all quality metrics can be estimated quite well for simulation results. The routine is designed to be extended for the use with experimental data for a reliable real-life quality assessment.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"18 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143830682","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":"The effect of post-weld heat treatment on the formability of aluminum to steel friction stir welded blanks","authors":"Muhamad Zulkhairi Rizlan,&nbsp;Ahmad Baharuddin Abdullah,&nbsp;Zuhailawati Hussain","doi":"10.1007/s12289-025-01898-4","DOIUrl":"10.1007/s12289-025-01898-4","url":null,"abstract":"<div><p>Formability is the ability of a material to undergo plastic deformation without being damaged. In sheet metal forming, materials are known to experience deformation in biaxial stretch mode. In order to simulate the common failure strains in sheet metal forming process, numerous formability test methods can be used. A material’s formability can be altered in several ways, one of which is post-weld heat treatment. In this study, the effect of post-weld heat treatment on the formability of aluminum alloy 6061 and SAE1020 mild steel tailor welded blanks fabricated by friction stir welding was evaluated using limiting dome height test. It was found that the specimens which underwent post-weld heat treatment recorded a lower springback and higher value of plane strain, indicating a better formability. The improved formability is attributed to microstructural homogenization, defects elimination, residual stresses relieve and IMC layer growth control from the post-weld heat treatment process.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"18 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2025-04-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143809104","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":"In-plane torsion test – Analysis and design of the clamps","authors":"Fabian Stiebert,&nbsp;Heinrich Traphöner,&nbsp;A. Erman Tekkaya","doi":"10.1007/s12289-025-01901-y","DOIUrl":"10.1007/s12289-025-01901-y","url":null,"abstract":"<div><p>The objective of the paper is to analyze the fundamental influence of the tool design on the in-plane torsion test in order to create a common basis for carrying out tests that enable the characterization of comparable material parameters between various test setups. The clamps have a major influence on the process limits wrinkling and slippage of the in-plane torsion test. The size and the surface structure of the clamping on the process limit of slipping and wrinkling is investigated. Results show that a ring-shaped clamping surface can transmit up to 50% more torque at the same clamping force compared to a full-circle clamping surface. Investigations show that torque transmission through plain clamping surfaces is not possible for thin sheets (<i>t</i> = 0.5 to 3.0 mm). In order to enable torque transmission in spite of this, the structuring of the clamping surface is necessary. Therefore, radial serrations are well suited, to ensure a homogenous torque transmission over the circumference. An analytical approach was developed and numerically validated, that can determine the indentation depth, the maximum transmittable torque and the necessary clamping force for radial serrations. The geometrical and material specific influence on the process boundary of wrinkling was analyzed and a material independent recommendation for the geometrical shape of the clamps was proposed. This publication is an extended version of the paper “In-Plane Torsion Test—Analysis of the Tool Design”, which was published in the Proceedings of the 14th International Conference on the Technology of Plasticity—Current Trends in the Technology of Plasticity (ISBN 978–3-031–41022-2).</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"18 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2025-04-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s12289-025-01901-y.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143793136","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":"Combined rotary draw tube bending and hydroforming: thickness recovery and defect optimization","authors":"Ruan Shangwen,&nbsp;Hamza Blala,&nbsp;Cheng Pengzhi,&nbsp;Zhang Shenglun,&nbsp;Cheng Gang,&nbsp;Meng Zhang","doi":"10.1007/s12289-025-01902-x","DOIUrl":"10.1007/s12289-025-01902-x","url":null,"abstract":"<div><p>The demand for bent hollow parts, particularly those with larger diameters and smaller bending radii, has significantly increased in industries such as automotive, energy, and aerospace. However, manufacturing these components presents substantial challenges, primarily due to the risk of defects such as wrinkling or cracking caused by excessive wall thinning. This study investigates the combined manufacturing process of Rotary Draw Tube Bending (RDTB) followed by Tube Hydroforming (THF) to address these challenges. Through numerical simulations and experimental validation, the process parameters of both forming techniques, as well as key defects including wrinkling, wall thickness reduction, and die filling rate, were thoroughly examined. The findings reveal that excessive thinning in the extrados during RDTB is mitigated during the subsequent THF operation. Similarly, excessive thickening in the intrados during RDTB is counteracted by the stretching and thinning effects of THF. The results demonstrate that the proposed process, with optimized parameters, enables the production of high-quality elbow parts, confirming the method's effectiveness and its potential as a reliable manufacturing solution for complex elbow geometries.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"18 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2025-04-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143786653","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}