International Journal of Material Forming最新文献_第9页

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

Bending behavior of structured steel sheets with undercuts for interlocking with Al die-cast metal 与铝压铸金属联锁用带凹口的结构钢薄板的弯曲性能

IF 2.4 3区材料科学

International Journal of Material Forming Pub Date : 2023-11-09 DOI: 10.1007/s12289-023-01797-6

Aron Ringel, Gerhard Hirt

{"title":"Bending behavior of structured steel sheets with undercuts for interlocking with Al die-cast metal","authors":"Aron Ringel, Gerhard Hirt","doi":"10.1007/s12289-023-01797-6","DOIUrl":"10.1007/s12289-023-01797-6","url":null,"abstract":"<div><p>Due to the current changes in mobility, lightweight design concepts continue to be of particular interest to the automotive industry. One form is the multi-material design, in which the advantageous properties of different materials are combined in one component. In this work, a component made of a steel sheet with stiffening structures of cast aluminum is considered. The joint is created by channel structures with undercuts on the surface of the steel sheet, into which the molten aluminum can flow. After solidification, an interlocking connection is created. The aim of this work is to investigate the influence of a bending operation on the surface structure before the die casting process. Numerical simulations and experimental validations were performed with different bending angles and radii as well as orientations between the channel structure and the punch. The results show that the undercuts on the outer radius are reduced by up to 75% by the bending operation, thus weakening the resulting joint. On the inner radius, the channel opening width narrows by up to 73% and can thus impede the filling with the melt.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"17 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2023-11-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s12289-023-01797-6.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134795858","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

Unified thermomechanical model of Ti-6Al-4V titanium alloy considering microstructure evolution and damage fracture under different stress state 考虑不同应力状态下组织演变和损伤断裂的Ti-6Al-4V钛合金统一热机械模型

IF 2.4 3区材料科学

International Journal of Material Forming Pub Date : 2023-11-08 DOI: 10.1007/s12289-023-01799-4

Rui Feng, Minghe Chen, Lansheng Xie

{"title":"Unified thermomechanical model of Ti-6Al-4V titanium alloy considering microstructure evolution and damage fracture under different stress state","authors":"Rui Feng, Minghe Chen, Lansheng Xie","doi":"10.1007/s12289-023-01799-4","DOIUrl":"10.1007/s12289-023-01799-4","url":null,"abstract":"<div><p>Establishing a unified constitutive model to simulate the hot deformation behaviors, microstructure evolution and fracture behaviors under different stress states during the hot forming of titanium alloy is indispensable. The high temperature tensile tests were first carried out on different stress states of forged Ti-6Al-4 V alloy specimens to analyze the flow behaviors, microstructure evolution and fracture mechanism. The results show that the effect of temperature on fracture elongation is more significant than strain rate. High temperature and low strain rate will increase the dynamic recrystallization (DRX) volume fraction and softening effect, which inhibits the nucleation and growth of voids, thereby enhancing the plastic deformation ability of the alloy. The DRX volume fraction, grain size and stress triaxiality were introduced into the unified Gurson-Tvergaard-Needleman (GTN) damage model using the internal state variables. The parameters of GTN model were modified by the Response Surface Method (RSM) and compared with the high temperature tension. Finally, the established GTN damage model was successfully applied to finite element (FE) simulation under different stress states. The correlation coefficient <i>R</i> of predicted stress is 0.989, and the maximum errors of DRX volume fraction and grain size are 9.86% and 6.54%. The research results can provide a basis for the performance control in hot working of titanium alloy.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"17 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2023-11-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"71909639","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

The adaption, evaluation and application of a semi-empirical bond strength model for the simulations of multi-pass hot roll bonding of aluminium alloys 半经验结合强度模型在铝合金多道次热轧结合过程模拟中的应用及评价

IF 2.4 3区材料科学

International Journal of Material Forming Pub Date : 2023-11-03 DOI: 10.1007/s12289-023-01795-8

Zhao Liu, Alexander Krämer, Johannes Lohmar, Holger Aretz, Kai Karhausen, David Bailly, Gerhard Hirt, Marco Teller

{"title":"The adaption, evaluation and application of a semi-empirical bond strength model for the simulations of multi-pass hot roll bonding of aluminium alloys","authors":"Zhao Liu, Alexander Krämer, Johannes Lohmar, Holger Aretz, Kai Karhausen, David Bailly, Gerhard Hirt, Marco Teller","doi":"10.1007/s12289-023-01795-8","DOIUrl":"10.1007/s12289-023-01795-8","url":null,"abstract":"<div><p>Nowadays, the requirements on metallic materials have become more comprehensive, which gradually exceed the capability of monolithic metals. One of the solutions is the composite metal, where different properties of the constituents are integrated as one. In industrial practice, hot roll bonding has been frequently employed to produce laminated composite metals thanks to its high adaptivity. However, the bonding mechanism and the bond strength models have not been thoroughly investigated and parametrized. In a recent publication, a semi-empirical bond strength model has been developed, which quantitatively considers the influence of various influencing factors on the bond strength.</p><p>In this paper, this new model is applied in FE simulations of lab-scale hot roll bonding of multiple passes to achieve a better understanding of the process and the bonding behaviours. Firstly, this new model is adapted for macroscopic process simulations, implemented in FE environment via Abaqus subroutines, and evaluated by the simulations of the truncated-cone experiments. Secondly, the FE setup is applied in the process simulation of hot roll bonding. Eight roll bonding passes are simulatively reproduced and good accordance with experiment is achieved. The strain distribution in thickness, evolution of temperature and bond strength, bonding status and cause of local temporary de-bonding are analysed by this simulation. Finally, the influences of the thickness ratio of metallic plates, height reduction, rolling velocity, and material combination with different bonding properties are tested in simulative studies. The process simulations provide a promising way to facilitate the design and optimization of hot roll bonding by FE simulations.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"16 6","pages":""},"PeriodicalIF":2.4,"publicationDate":"2023-11-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s12289-023-01795-8.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134795498","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