International Journal of Material Forming最新文献_第6页

Stamping process analysis in an industrial plant and its limitations to obtain an industrializable Continuous Twin 工业厂房中的冲压工艺分析及其在获得可工业化的连续孪晶方面的局限性

IF 2.4 3区材料科学

International Journal of Material Forming Pub Date : 2024-01-10 DOI: 10.1007/s12289-023-01808-6

Ivan Peinado-Asensi, Nicolás Montés, Eduardo García

{"title":"Stamping process analysis in an industrial plant and its limitations to obtain an industrializable Continuous Twin","authors":"Ivan Peinado-Asensi, Nicolás Montés, Eduardo García","doi":"10.1007/s12289-023-01808-6","DOIUrl":"10.1007/s12289-023-01808-6","url":null,"abstract":"<div><p>This article aims to define the problem of the development of a “Continuous Twin” in any stamping process installed in an industry. A “Continuous Twin” is a modeling concept using the information available in both worlds, the virtual twin (simulation) and the digital twin (real-time data) of the process. There is currently a trend in the industry related to IIoT (Industrial Internet of Things) and linked to Industry 4.0. IIoT is the collection of sensors, instruments and autonomous devices connected through the internet to industrial applications. However, filling with sensors the entire industry and channelling all that information through industrial networks is a utopia. In our previous works, a new concept for generating industrializable IIoT applications has been presented, <i>Industrializable Industrial Internet of Things</i> (<i>I3oT</i>). The purpose of the <i>I3oT</i> is using the installations available in factories to develop IIoT applications from them. This article aims to analyse all available and accessible information from the parameters accessible from the stamping process PLC, material properties, FLD, to the measurement of the operators corrections after detecting part failures. This is information that could be included in the model in order to develop an industrializable “Continuous Twin”.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"17 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-01-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139414245","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}

引用次数: 0

Finite difference based stress integration algorithm for crystal plasticity finite element method 基于有限差分的晶体塑性有限元法应力积分算法

IF 2.4 3区材料科学

International Journal of Material Forming Pub Date : 2024-01-04 DOI: 10.1007/s12289-023-01806-8

Donghwan Noh, Jeong Whan Yoon

{"title":"Finite difference based stress integration algorithm for crystal plasticity finite element method","authors":"Donghwan Noh, Jeong Whan Yoon","doi":"10.1007/s12289-023-01806-8","DOIUrl":"10.1007/s12289-023-01806-8","url":null,"abstract":"<div><p>In this study, we present a Finite Difference Method (FDM)-based stress integration algorithm for Crystal Plasticity Finite Element Method (CPFEM). It addresses the complexity of computing the first derivative of resolved shear stress in the Euler backward stress integration algorithm with Newton-Raphson method. The proposed FDM-based model was verified by evaluating its accuracy, convergence and computational efficiency through single-element simulations. The developed FDM-based model can be easily applied to various constitutive models for CPFEM, overcoming the problem of deriving complex derivative regardless of constitutive models. Additionally, the proposed FDM-based model was validated with the reduced texture approach using AA 2090-T3. Specific parameters including crystallographic orientations were calibrated and the plastic anisotropy was successfully described. In addition, the earing profiles were compared using various stress integration methods. As a result, the proposed FDM-based model can be used as an alternative to the Euler backward method using analytic derivatives with the compatible accuracy, convergence, computational efficiency along with easy implementation within the CPFEM framework.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"17 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-01-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s12289-023-01806-8.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139103171","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}

引用次数: 0

Development of a plane strain tensile test to characterize the formability of 5xxx and 6xxx aluminium alloys 开发平面应变拉伸试验，鉴定 5xxx 和 6xxx 铝合金的可成形性

IF 2.4 3区材料科学

International Journal of Material Forming Pub Date : 2024-01-02 DOI: 10.1007/s12289-023-01805-9

Maryse Gille, Fanny Mas, Jean-Christophe Ehrström, Dominique Daniel

{"title":"Development of a plane strain tensile test to characterize the formability of 5xxx and 6xxx aluminium alloys","authors":"Maryse Gille, Fanny Mas, Jean-Christophe Ehrström, Dominique Daniel","doi":"10.1007/s12289-023-01805-9","DOIUrl":"10.1007/s12289-023-01805-9","url":null,"abstract":"<div><p>This article presents the development of a plane strain tensile test aiming at an easy classification of aluminium automotive alloys according to their formability in prototyping steps. A parametric study with finite element method is performed on three different designs inspired by literature. It is found that, due to plastic anisotropy, specimens designed for steel are not suited for aluminium alloys. One optimized specimen geometry, ensuring near plane strain state on a large zone all along the deformation range up to failure, is selected. On this geometry, tensile tests instrumented by Digital Image Correlation are performed for five different aluminium alloys (5xxx and 6xxx) in three different directions of the metal sheet (rolling, diagonal and transverse). From Digital Image Correlation analysis, necking limits are evaluated and their relevance for the ranking of alloys according to their formability is discussed in comparison with a standard formability test, namely the Limiting Dome Height test.</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":"17 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-01-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139078586","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}

引用次数: 0

Identification of material parameters in low-data limit: application to gradient-enhanced continua 低数据极限下的材料参数识别：梯度增强连续体的应用

IF 2.4 3区材料科学

International Journal of Material Forming Pub Date : 2024-01-02 DOI: 10.1007/s12289-023-01807-7

Duc-Vinh Nguyen, Mohamed Jebahi, Victor Champaney, Francisco Chinesta

{"title":"Identification of material parameters in low-data limit: application to gradient-enhanced continua","authors":"Duc-Vinh Nguyen, Mohamed Jebahi, Victor Champaney, Francisco Chinesta","doi":"10.1007/s12289-023-01807-7","DOIUrl":"10.1007/s12289-023-01807-7","url":null,"abstract":"<div><p>Due to the growing trend towards miniaturization, small-scale manufacturing processes have become widely used in various engineering fields to manufacture miniaturized products. These processes generally exhibit complex size effects, making the behavior of materials highly dependent on their geometric dimensions. As a result, accurate understanding and modeling of such effects are crucial for optimizing manufacturing outcomes and achieving high-performance final products. To this end, advanced gradient-enhanced plasticity theories have emerged as powerful tools for capturing these complex phenomena, offering a level of accuracy significantly greater than that provided by classical plasticity approaches. However, these advanced theories often require the identification of a large number of material parameters, which poses a significant challenge due to limited experimental data at small scales and high computation costs. The present paper aims at evaluating and comparing the effectiveness of various optimization techniques, including evolutionary algorithm, response surface methodology and Bayesian optimization, in identifying the material parameter of a recent flexible gradient-enhanced plasticity model developed by the authors. The paper findings represent an attempt to bridge the gap between advanced material behavior theories and their practical industrial applications, by offering insights into efficient and reliable material parameter identification procedures.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"17 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-01-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139080221","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}

引用次数: 0

Inline closed-loop control of bending angles with machine learning supported springback compensation 利用机器学习支持回弹补偿的内联闭环控制弯曲角

IF 2.4 3区材料科学

International Journal of Material Forming Pub Date : 2023-12-13 DOI: 10.1007/s12289-023-01802-y

Dirk Alexander Molitor, Viktor Arne, Christian Kubik, Gabriel Noemark, Peter Groche

{"title":"Inline closed-loop control of bending angles with machine learning supported springback compensation","authors":"Dirk Alexander Molitor, Viktor Arne, Christian Kubik, Gabriel Noemark, Peter Groche","doi":"10.1007/s12289-023-01802-y","DOIUrl":"10.1007/s12289-023-01802-y","url":null,"abstract":"<div><p>Closed-loop control of product properties is becoming increasingly important in forming technology research and enables users to counteract unavoidable uncertainties in semi-finished product properties and process environments. Therefore, closed-loop controlled forming processes are considered to have the potential to reduce tolerances on desired product properties, resulting in consistent qualities. The achievement of associated increases in robustness and reliability is linked to enormous requirements, which in particular include the inline recording of the product properties to be controlled and the subsequent adaptation of the process control through the targeted derivation of manipulated variables. The present paper uses the example of an air bending process to show how the bending angle can be controlled camera-based and how springback can be compensated within a stroke by recording force signals and subsequently predicting the loaded bending angle using machine learning algorithms. The results show that the combined application of camera-based control and machine learning assisted springback compensation leads to highly accurate bending angles, whereby the results strongly depend on the machine learning algorithms and associated data transformation processes used.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"17 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2023-12-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s12289-023-01802-y.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"138578053","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}

引用次数: 0

Predictive control for a single-blow cold upsetting using surrogate modeling for a digital twin 利用数字孪生模型的代理模型对单次冷镦进行预测控制

IF 2.4 3区材料科学

International Journal of Material Forming Pub Date : 2023-12-04 DOI: 10.1007/s12289-023-01803-x

David Uribe, Cyrille Baudouin, Camille Durand, Régis Bigot

{"title":"Predictive control for a single-blow cold upsetting using surrogate modeling for a digital twin","authors":"David Uribe, Cyrille Baudouin, Camille Durand, Régis Bigot","doi":"10.1007/s12289-023-01803-x","DOIUrl":"10.1007/s12289-023-01803-x","url":null,"abstract":"<div><p>In the realm of forging processes, the challenge of real-time process control amid inherent variabilities is prominent. To tackle this challenge, this article introduces a Proper Orthogonal Decomposition (POD)-based surrogate model for a one-blow cold upsetting process in copper billets. This model effectively addresses the issue by accurately forecasting energy setpoints, billet geometry changes, and deformation fields following a single forging operation. It utilizes Bézier curves to parametrically capture billet geometries and employs POD for concise deformation field representation. With a substantial database of 36,000 entries from 60 predictive numerical simulations using FORGE® software, the surrogate model is trained using a multilayer perceptron artificial neural network (MLP ANN) featuring 300 neurons across 3 hidden layers using the Keras API within the TensorFlow framework in Python. Model validation against experimental and numerical data underscores its precision in predicting energy setpoints, geometry changes, and deformation fields. This advancement holds the potential for enhancing real-time process control and optimization, facilitating the development of a digital twin for the process.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"17 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2023-12-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"138485101","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}

引用次数: 0

Rapid multi-material joining via flow drill screw process: experiment and FE analysis using the coupled Eulerian‒Lagrangian method 流钻螺杆快速多材料连接:欧拉-拉格朗日耦合法试验与有限元分析

IF 2.4 3区材料科学

International Journal of Material Forming Pub Date : 2023-11-30 DOI: 10.1007/s12289-023-01800-0

Minki Kim, Sungho Kim, Namsu Park

{"title":"Rapid multi-material joining via flow drill screw process: experiment and FE analysis using the coupled Eulerian‒Lagrangian method","authors":"Minki Kim, Sungho Kim, Namsu Park","doi":"10.1007/s12289-023-01800-0","DOIUrl":"10.1007/s12289-023-01800-0","url":null,"abstract":"<div><p>This paper is concerned with experiments and finite element (FE) simulations using the coupled Eulerian‒Lagrangian (CEL) method for multi-material joining by the flow drill screw (FDS) process. The FDS joining experiments involved various combinations of aluminum alloys (Al6061-T6 2.0t and Al6063-T6 2.0t), and steel (SPRC45E 1.6t) sheets. During the FDS joining, thermocouples and a thermal imaging camera, FLIR, were used to measure the elevated temperature near the joint. Cross-sections of the multi-material joint specimens were prepared to check the joining quality and the deformed shape of the materials. To consider the complexity of the joining process and convergence issue of numerical simulation, the FE modeling approach for the FDS joining was constructed based on the CEL method using the ABAQUS/Explicit, considering the strain rate and thermal softening dependent strain hardening of each material. From the comparison of experimental and FE simulation results, the reliability of the FE modeling was validated, revealing the predictability of the deformed shape was 90% or more, especially in terms of the bushing length. Furthermore, it was confirmed that the proposed modeling approach can accurately describe the temperature history and peak values during rapid joining.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"17 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2023-11-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"138468355","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}

引用次数: 0

High-reduction radial shear rolling of aluminum alloy bars using custom-calibrated rolls 使用定制校准的轧辊对铝合金棒材进行高减径径向剪切轧制

IF 2.4 3区材料科学

International Journal of Material Forming Pub Date : 2023-11-28 DOI: 10.1007/s12289-023-01801-z

Yu V. Gamin, S. P. Galkin, A. N. Koshmin, A. Mahmoud Alhaj Ali, X. D. Nguyen, I. S. ELDeeb

{"title":"High-reduction radial shear rolling of aluminum alloy bars using custom-calibrated rolls","authors":"Yu V. Gamin, S. P. Galkin, A. N. Koshmin, A. Mahmoud Alhaj Ali, X. D. Nguyen, I. S. ELDeeb","doi":"10.1007/s12289-023-01801-z","DOIUrl":"10.1007/s12289-023-01801-z","url":null,"abstract":"<div><p>The article presents a novel technique for performing high reduction radial shear rolling (HRRSR) of aluminum alloy bars. For this purpose, rolls with a special calibration were developed, including a high reduction section and a roll feed angle of 20°. The proposed process was investigated using FEM simulation, first. The temperature, stress-strain state, and force parameters analysis showed that the proposed method can produce defect-free bars with a natural gradient microstructure. Afterward, the experimental alloy Al-3Ca-2La-1Mn (wt%), was processed by a single-pass HRRSR process, resulting in a bar with an elongation ratio of 5. High compression and shear strains provide severe deformation of the initial cast microstructure and form a uniform distribution of small eutectic inclusions of the Al4(Ca, La) phase in the aluminum matrix. The obtained results, indicate the possibility of severe deformation of aluminum alloys using the radial shear rolling method. The proposed method of deformation can be the basis for an effective technology for obtaining bulk, long-length bars from various aluminum alloys, with a high reduction in a single pass.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"17 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2023-11-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"138468320","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}

引用次数: 0

Polymer extrusion die design using a data-driven autoencoders technique 基于数据驱动的自编码器技术的聚合物挤出模具设计

IF 2.4 3区材料科学

International Journal of Material Forming Pub Date : 2023-11-14 DOI: 10.1007/s12289-023-01796-7

Chady Ghnatios, Eloi Gravot, Victor Champaney, Nicolas Verdon, Nicolas Hascoët, Francisco Chinesta

引用次数: 0

Experimental and numerical study of the closure of voids with different size and various locations in the three-dimensional cogging process 三维开槽过程中不同尺寸、不同位置孔洞闭合的实验与数值研究

IF 2.4 3区材料科学

International Journal of Material Forming Pub Date : 2023-11-14 DOI: 10.1007/s12289-023-01798-5

Marcin Kukuryk

{"title":"Experimental and numerical study of the closure of voids with different size and various locations in the three-dimensional cogging process","authors":"Marcin Kukuryk","doi":"10.1007/s12289-023-01798-5","DOIUrl":"10.1007/s12289-023-01798-5","url":null,"abstract":"<div><p>In this paper, a new forging system was developed and a new complex methodology was tested for the analysis of the closure of voids. The effective geometric shapes of anvils and optimal the forging parameters has been determined. A new cogging process provided a complete closure of voids, which was confirmed by experimental tests. The effect of the reduction ratio, original anvil shape, forging ratio and the location and size of introduced voids on the efficiency of void closure during the multi-transition cogging process was assessed. Moreover, the following were used for the evaluation of void closure: the hydrostatic stress around voids, stress triaxiality, effective strain around voids, and the critical reduction ratio. Numerical examinations were performed using the finite element method (FEM) for the three-dimensional forging process at elevated temperature. Computer simulations of the cogging process under investigation were carried out using a program DEFORM-3D, and selected simulation results were compared with experimental test results. Void reduction predictions obtained from the FEM analysis were in good agreement with the experimental findings. The test results are supplemented with the prediction of crack formation in the zone of existing voids and within the forging volume during the multi-transition cogging process.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"17 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2023-11-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134796630","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}

引用次数: 0