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In the last decades, the development of new, flexible manufacturing processes caused the increase of the demands for highly customized complex functional parts in many industrial fields. The peculiar design of these components often overcome conventional sheet metal and bulk metal forming processes capabilities. In order to face this issue, new hybrid techniques, capable of exploit key advantages of different processes, have to be developed. In this paper, a novel approach based on the Linear Friction Welding process is proposed to obtain sheet-bulk joints. The feasibility of the technique on high specific strength alloys is investigated through an experimental campaign. [ABSTRACT FROM AUTHOR]

In this paper a isotropic criterion expressed in terms of both invariants of the stress deviator, J2 and J3 is proposed. This criterion involves a unique parameter, α, which depends only on the ratio between the yield stresses in uniaxial tension and pure shear. If this parameter is zero, the von Mises yield criterion is recovered; if a is positive the yield surface is interior to the von Mises yield surface whereas when a is negative, the new yield surface is exterior to it. Comparison with polycrystalline calculations using Taylor-Bishop-Hill model [1] for randomly oriented face-centered (FCC) polycrystalline metallic materials show that this new criterion captures well the numerical yield points. Furthermore, the criterion reproduces well yielding under combined tension-shear loadings for a variety of isotropic materials. An extension of this isotropic yield criterion such as to account for orthotropy in yielding is developed using the generalized invariants approach of Cazacu and Barlat [2]. This new orthotropic criterion is general and applicable to three-dimensional stress states. The procedure for the identification of the material parameters is outlined. Illustration of the predictive capabilities of the new orthotropic is demonstrated through comparison between the model predictions and data on aluminum sheet samples. [ABSTRACT FROM AUTHOR]

Cold spray technology is a relatively new additive process allowing to create high quality metallic coatings, on both metallic and non-metallic substrates, without extensive heating of the powders sprayed. Upon impact with a target surface, conversion of kinetic energy to plastic deformation occurs, the solid particles deform and bond together. The actual bonding mechanism for cold spray particles is still not well understood, a high number of works has been carried out during the past two decades, several theories have been proposed to explain the adhesion/rebound mechanisms making the system ineffective for industrial applications. Therefore, the aim of this research activity is to better explain the complex adhesion/rebound phenomena into cold spray impact processes through numerical simulations; for this purpose, on the base of simplified hypothesis and results found in literature, an original 3D Finite Element Method (FEM) model of an aluminium particle impacting on an aluminium substrate was proposed. A cohesive behaviour algorithm was implemented in the particle-substrate contact regions aiming to simulate the bonding between the impacting particle and the substrate under specific working conditions. A rebound coefficient was also defined representing the particle residual energy. Different simulations were performed using a range of impact velocities and varying the interfacial cohesive strength. It was shown that at low impact velocities the rebound phenomenon is governed by the elastic energy stored in the system, meanwhile at high impact velocities, the rebound phenomenon is mainly due to the strain rate effects making the system mechanically stronger; therefore, a specific range of bonding velocities depending on substrate-particle contact area were found. [ABSTRACT FROM AUTHOR]

The use of ultrasonic assistance in microforming is becoming more and more popular. Mainly due to the beneficial effect of vibrations on the flow of plastic deformation reported already in the 50s of the last century. The influence is of two types: surface and volume. The surface effect is mainly the reduction of friction forces, and volumetric is the impact on the dislocation movement and even on phase transitions. The work focuses on the dynamic aspect of vibration assisted microforming. The use of ultrasonic vibrations at a frequency of 20 kHz and an amplitude of 16 µm, in the micro-upsetting process of an aluminum sample resulted in a high concentration of strain on both ends of the sample - at 14% of the height on both sides. There was observed (in relation to deformations of the sample without vibrations) 150-250% increase and a 50% decrease in strain in the center of the sample. At the same time, the larger deformations occurred from the impact side of the punch. Analyzing the course of forces of the upsetting process in the loading and unloading phase as well as the process of breaking glass samples, the spring deflections of key system elements and their natural frequencies were determined or calculated. Based on the determined or calculated parameters of the test stand, it was shown that during the micro-upsetting process the punch may detach from the sample surface and this is the main reason for the phenomena occurring. Detach of the punch is also the cause of the observed instability of the measurement of force, which should be considered unbelievable in such a situation. [ABSTRACT FROM AUTHOR]

Large amount of strengthening can be achieved by equal channel angular pressing (ECAP), by the applied severe plastic deformation during the processing. For pure metals, this high strength is accompanied with low thermal stability due to the large activation energy for recrystallization. In the present paper, the chosen technological route was elevated temperature single pass ECAP processing of copper, and its effect on the thermal behavior during the restoration processes of the deformed samples was studied. [ABSTRACT FROM AUTHOR]

Cold extrusion processes are distinguished by their low material usage as well as great efficiency in the production of mid-range and large component series. Although majority of the cold extruded parts are produced using die systems containing multiple forming stages, this subject has rarely been investigated so far. Therefore, the characteristics of multi-stage cold forward rod extrusion is studied in the current work using thermo-mechanically coupled finite element (FE) analysis. A case hardening steel, 16MnCr5 (1.7131) was used as experimental material. Its strain, strain rate and temperature dependent mechanical characteristics were determined using compression testing and modeled in FE simulations via a Johnson-Cook material model. Friction coefficients for the same material while in contact with a tool steel (1.2379) were determined dependent on temperature and contact pressure using sliding compression test (SCT) and modeled by an adaptive friction model developed by the author. In the first set of simulations, rod material with a diameter of 14.9 mm was extruded down to a diameter of 9.6 mm in a single step using three different die opening angles (2α); 20°, 40° and 60°. In the second set of investigations, the same rod was reduced first to 12 mm and then to 9.6 mm in two steps within the same forming die. Press forces, contact normal stresses between extruded material and forming die, material temperature and axial stresses are compared in these two set of simulations and the differences are discussed. [ABSTRACT FROM AUTHOR]

The Tailor Made Blank concept is widely accepted in the production of sheet metal parts. By joining, adding and subtracting materials, and sometimes even applying different alloys, parts can be produced more efficiently by cost and/or weight, and new design options have been discovered. This paper is about the manufacture of press formed parts of Fibre Reinforced Thermoplastics and the evaluation whether the Tailoring concept, though adapted to the material behavior of FRTP, can be applied to these composites as well. From research, the first results and ideas are presented. One of the ideas is the multistep forming process, creating parts with thickness variations and combinations of fibre orientations that are usually not feasible using common press forming strategies. Another idea is the blending of different prepreg materials in one component. This might be useful in case of specific details, like for areas of mechanical fastening or to avoid carbon/metal contact, otherwise resulting in severe corrosion. In a brief overview, future perspectives of the potential of the Tailoring concept are presented. [ABSTRACT FROM AUTHOR]

At grain scale, polycrystalline materials develop heterogeneous plastic deformation fields, localizations and stress concentrations due to variation of grain orientations, geometries and defects. Development of inter-granular stresses due to misorientation are crucial for a range of grain boundary (GB) related failure mechanisms, such as stress corrosion cracking (SCC) and fatigue cracking. Local crystal plasticity finite element modelling of polycrystalline metals at micron scale results in stress jumps at the grain boundaries. Moreover, the concepts such as the transmission of dislocations between grains and strength of the grain boundaries are not included in the modelling. The higher order strain gradient crystal plasticity modelling approaches offer the possibility of defining grain boundary conditions. However, these conditions are mostly not dependent on misorientation of grains and can define only extreme cases. For a proper definition of grain boundary behavior in plasticity, a model for grain boundary behavior should be incorporated into the plasticity framework. In this context, a particular grain boundary model ([l]) is incorporated into a strain gradient crystal plasticity framework ([2]). In a 3-D setting, both bulk and grain boundary models are implemented as user-defined elements in Abaqus. The strain gradient crystal plasticity model works in the bulk elements and considers displacements and plastic slips as degree of freedoms. Interface elements model the plastic slip behavior, yet they do not possess any kind of mechanical cohesive behavior. The physical aspects of grain boundaries and the performance of the model are addressed through numerical examples. [ABSTRACT FROM AUTHOR]

In the presented work an experimental simple shear device for cutting cylindrical rods was used to obtain force-displacement data for a low-carbon steel. In addition, and FEM 3D-simulation was applied to obtain internal shear stress and strain maps for this material. The experimental longitudinal grid patterns and force-displacement curve were compared with numerical simulation results. Many aspects of the elastic and plastic deformations were described. It was found that bending reduces the shear yield stress of the rod material. Shearing starts on top and bottom die-workpiece contact lines evolving in an arc-shaped area. Due to this geometry, stress concentrates on the surface of the rod until the level of damage reaches the critical value and the fracture starts here. The volume of material in the plastic zone subjected to shearing stress has a very complex shape and is function of a dimensionless geometrical parameter. Expressions to calculate the true shear stress τ and strain γ from the experimental force-displacement data were proposed. The equations’ constants are determined by fitting the experimental curve with the stress τ and strain γ simulation point tracked data. [ABSTRACT FROM AUTHOR]

Tungsten is a promising material for plasma facing components in future nuclear fusion reactors. In the present work, we numerically investigate the deformation behavior of unirradiated tungsten (a body-centered cubic (bcc) single crystal) underneath nanoindents. A finite element (FE) model is presented to simulate wedge indentation. Crystal plasticity finite element (CPFE) simulations were performed for face-centered and body-centered single crystals accounting for the slip system family {110} 〈111〉 in the bcc crystal system and the {111} 〈110〉 slip family in the fcc system. The 90° wedge indenter was aligned parallel to the [ 1 ¯ 01 ] -direction and indented the crystal in the [ 0 1 ¯ 0 ] -direction up to a maximum indentation depth of 2 µm. In both, the fcc and bcc single crystals, the activity of slip systems was investigated and compared. Good agreement with the results from former investigations on fcc single crystals was observed. Furthermore, the in-plane lattice rotation in the material underneath an indent was determined and compared for the fcc and bcc single crystals. [ABSTRACT FROM AUTHOR]

This paper is based on the hypothesis that introducing distribution of mechanical properties is beneficial for modeling all kinds of mechanical behavior, even of ordinary metallic materials. To bring proof of its admissibility, it has to be first shown that modeling based on this assertion is able to efficiently describe standard mechanical behavior of materials. Searching for typical study case, it has been assessed that at a low scale, yield stresses could be strongly distributed in ultrathin aluminum foils used in packaging industry, offering opportunities to identifying their distribution and showing its role on the mechanical properties. Considering initially reduced modeling allow to establish a valuable connection between the hardening curve and the distribution of local yield stresses. This serves for finding initial value of distribution parameters in a more sophisticated identification procedure. With finally limited number of representative classes of local yield stresses, concretely 3 is enough, it is shown that a 3D finite element simulation involving limited numbers of elements returns realistic behavior of an ultrathin aluminum foil exerted to tensile test, in reference to experimental results. This gives way to large possibilities in modeling in order to give back complex experimental evidence. [ABSTRACT FROM AUTHOR]

The Flow forming process is a tube spinning process where the thickness of a tube is reduced with the help of spinning roller/s by keeping the internal diameter unchanged. A 3-D Finite element model for the flow-formability test has been developed by using Abaqus/explicit software. A coupled damage criterion based on continuum damage mechanics (CDM) has been studied in this research. The damage model is introduced by using FORTRAN based VUMAT subroutine which is developed through a stress integration algorithm. Further, the effect of reduction angle, friction coefficient, and coolant heat transfer coefficient on fracture has been studied. The results show that the formability improves with increase in reduction angle. Both, equivalent plastic strain and damage variable increases from inner to outer surface of flow formed tube. [ABSTRACT FROM AUTHOR]

Steel has been used in vehicles from the automotive industry’s inception. Different steel grades are continually being developed in order to satisfy new fuel economy requirements. For example, advanced high strength steel grades (AHSS) are widely used due to their good strength/weight ratio. Because each steel grade has a different microstructure composition and hardness, they show different behaviors when they are subjected to different strain paths. Similarly, the friction behavior when using different contact pressures is considerably altered. In the present paper, four different steel grades, ZSt380, DP600, DP780 and Fortiform 1050 materials are deeply characterized using uniaxial and cyclic tension-compression tests. Coefficient of friction (COF) is also obtained using strip drawing tests. These results have been used to calibrate mixed kinematic-hardening material models as well as pressure dependent friction models. Finally, the geometrical accuracy of the different material and friction models has been evaluated by comparing the numerical predictions with experimental demonstrators obtained using a U-Drawing tester. [ABSTRACT FROM AUTHOR]

Hot forming processes are widely used in deep drawing applications due to the ability of metallic materials to sustain large deformations. The optimization of such forming processes often requires the mechanical behavior to be accurately described. In this study, the hot temperature behavior of a 5383 aluminum alloy is investigated. In this perspective, different uniaxial tension tests have been carried out on dog-bone shaped specimens using a specific experimental device. The temperature and strain rate ranges of interest are 623∼723 K and 0.0001∼0.1 s-1, respectively. An inverse method has been used to determine the flow curves from the experimental force-displacement data. The material exhibits a slight flow stress increase beyond the yield point for most configurations. Softening phenomenon exists at high strain rates and high temperatures. A new model based on the modification of a modified Zerilli-Armstrong model is proposed to describe the stress-strain responses. Genetic algorithm optimization method is used for the identification of parameters for the new model. It is found that the new model has a good predictability under the experimental conditions. The application of this model is validated by shear and notched tension tests. [ABSTRACT FROM AUTHOR]

Hexagonal close-packed (HCP) metals have quite different mechanical behaviours in comparison to conventional cubic metals such as steels and aluminum alloys [1, 2]. They exhibit a significant tension-compression asymmetry in initial yielding and subsequent plastic hardening. The reason for this unique behaviour can be attributed to their limited symmetric crystal structure, which leads to twining deformation [3-5]. This unique behaviour strongly influences sheet metal forming of such metals, especially for roll forming, in which the bending is dominant. Hence, it is crucial to represent constitutive relations of HCP metals for accurate estimation of bending moment-curvature behaviours. In this paper, an analytical model for asymmetric elastoplastic pure bending with an application of Cazacu-Barlat asymmetric yield function [6] is presented. This yield function considers the asymmetrical tension-compression behaviour of HCP metals by using second and third invariants of the stress deviator tensor and a specified constant, which can be expressed in terms of uniaxial yield stresses in tension and compression. As a case study, the analytical model is applied to predict the moment-curvature behaviours of AZ31B magnesium alloy sheets under uniaxial loading condition. Furthermore, the analytical model is implemented as a user-defined material through the UMAT interface in Abaqus [7, 8] for conducting pure bending simulations. The results show that the analytical model can reasonably capture the asymmetric tension-compression behaviour of the magnesium alloy. The predicted moment-curvature behaviour has good agreement with the experimental results. Furthermore, numerical results show a better accuracy by the application of the Cazacu-Barlat yield function than those using the von-Mises yield function, which are more conservative than analytical results. [ABSTRACT FROM AUTHOR]

In this work, a characterisation method involving a deep-notched specimen subjected to a tensile loading is introduced. This specimen leads to heterogeneous states of stress and strain, the latter being measured using a stereo DIC system (MatchID). This heterogeneity enables the identification of multiple material parameters in a single test. In order to identify material parameters from the DIC data, an inverse method called the Virtual Fields Method is employed. The method combined with recently developed sensitivity-based virtual fields allows to optimally locate areas in the test where information about each material parameter is encoded, improving accuracy of the identification over the traditional user-defined virtual fields. It is shown that a single test performed at 45° to the rolling direction is sufficient to obtain all anisotropic plastic parameters, thus reducing experimental effort involved in characterisation. The paper presents the methodology and some numerical validation. [ABSTRACT FROM AUTHOR]

This paper presents a comparison of two criteria of strain localization in experimental research and numerical simulation of sheet metal forming. The first criterion is based on the analysis of the through-thickness thinning (through-thickness strain) and its first time derivative in the most strained zone. The limit strain in the second method is determined by the maximum of the strain acceleration. Experimental and numerical investigation have been carried out for the Nakajima test performed for different specimens of the DC04 grade steel sheet. The strain localization has been identified by analysis of experimental and numerical curves showing the evolution of strains and their derivatives in failure zones. The numerical and experimental limit strains calculated from both criteria have been compared with the experimental FLC evaluated according to the ISO 12004-2 norm. It has been shown that the first method predicts formability limits closer to the experimental FLC. The second criterion predicts values of strains higher than FLC determined according to ISO norm. These values are closer to the strains corresponding to the fracture limit. The results show that analysis of strain evolution allows us to determine strain localization in numerical simulation and experimental studies. [ABSTRACT FROM AUTHOR]

The anisotropic deformation of Aluminum alloys at micron scale exhibits localized deformation, which has negative implications on the macroscale mechanical and forming behavior. The scope of this work is twofold. Firstly, micro-scale deformation heterogeneities affecting forming behavior of aluminum alloys is investigated through experimental microstructure analysis at large strains and various strain paths. The effects of initial texture, local grain misorientation, and strain paths on the strain localizations are established. In addition to uniaxial tension condition, deformation heterogeneities are also investigated under equibiaxial tension condition to determine the strain path effects on the localization behavior. Secondly, the morphology and the crystallographic data obtained from the experiments is transferred to Abaqus software, in order to predict both macroscopic response and the microstructure evolution though crystal plasticity finite element simulations. The model parameters are identified through the comparison with experiments and the capability of the model to capture real material response is discussed as well. [ABSTRACT FROM AUTHOR]

In the past, the selection of suitable steels has been carried out primarily based on the mechanical properties of different steels. One of these properties is the resistance against crack propagation. For many constructions, this value plays an important role, because it can compare the impact toughness of different steel grades easily and gives information about the loading capacity of the specific materials. For thin sheets, impact toughness properties were usually not considered. One of the reasons for this is that the Charpy-impact test is not applicable for sheets with thicknesses below 2 mm. For a long time, this was not relevant because conventional steels had a sufficient impact toughness in a wide temperature range. However, since new multiphase steel grades with improved mechanical property exploitations are available, it turned out that impact toughness properties need to be considered during the component design phase, as the activation of the cleavage fracture mechanism is observed under challenging loading conditions. Therefore, this work aims to provide a new and practical testing procedure for sheet material or thin walled structures. The new testing procedure is based on tensile tests conducted in an impact pendulum similar to the Charpy impact hammer. A new standard geometry is provided, which enables a comparison between different steels or steel grades. A connection to the conventional Charpy test is presented using a damage mechanics model, which predicts material failure with consideration of to the stress state at various temperatures. Different specimen geometries are analysed to cover manifold stress states. A special advantage of the damage mechanics model is also the possibility to predict the materials behaviour in the transition area. To verify the method a conventional steel was tested in Charpy tests as well as in the new tensile impact test. [ABSTRACT FROM AUTHOR]

Large-scale advanced high strength steel (AHSS) sheet specimens were deformed in uniaxial tension, using a novel grip system mounted on a MTS universal tension machine. After pre-strain, they were used as a pre-strained material to examine the anisotropic response in the biaxial tension tests with various load ratios, and orthogonal tension tests at 45° and 90° from the pre-strain axis. The flow curve and the instantaneous r-value of the pre-strained steel in each of the aforementioned uniaxial testing conditions were also measured and compared with those of the undeformed steel. Furthermore, an exhaustive analysis of the yield surface was also conducted and the results, prior and post-prestrain were represented and compared. The homogeneous anisotropic hardening (HAH) model [1] was employed to predict the behavior of the pre-strained material. It was found that the HAH-predicted flow curves after non-linear strain path change and the yield loci after uniaxial pre-strain were in good agreement with the experiments, while the r-value evolution after strain path change was qualitatively well predicted. [ABSTRACT FROM AUTHOR]

In the production of semi-finished metal products, hot forming is used to eliminate the pores and voids from the casting process under compressive stresses and to modify the microstructure for further processing. In the case of caliber and flat rolling processes, tensile stresses occur at certain roll gap ratios which promote pore formation on nonmetallic inclusion. The formation of new pores contributes to ductile damage and reduces the load carrying capacity of the material. In the literature, the damage nucleation and growth during the hot forming process are not comprehensively described. The aim of this study is to understand the damage initiation and growth mechanism during hot forming processes. Hot tensile tests are performed at different temperatures and strain rates for 16MnCrS5 steel. To investigate the influence of geometrical variations on the damage mechanism, specimens with different stress triaxiality ratios are used. Finite element simulations using the Gurson-Tvergaard-Needleman (GTN) damage model are performed to estimate the critical void fraction for the damage initiation and the evolution of the void volume fraction. The results showed that the GTN model underestimates the softening of the material due to the independence of the temperature and the strain rate. [ABSTRACT FROM AUTHOR]

In modeling of hot rolling pass schedules the heat transfer phenomena have to be known. Radiation to ambient, between rolls and a steel slab as well as heat transfer in contacts must be considered to achieve accurate temperature distribution and thereby accurate material behavior in simulations. Additional heat is generated by friction between the slab and the work roll and by plastic deformation. These phenomena must be taken into account when the effective heat transfer coefficient is determined from experimental data. In this paper we determine the effective heat transfer coefficient at the contact interface and emissivity factor of slab surface for 1100MPa strength carbon steel for hot rolling simulations. Experimental pilot rolling test were carried out and slab temperatures gathered right below the interface and at the mid thickness of the slab. Emissivity factor tests were carried out in the same manner but without rolling. Experimental data is utilized to derive contact heat transfer coefficient at the interface and emissivity factor of slab surface. Pilot rolling test is reproduced in FE-analysis to further refine the heat transfer coefficient and emissivity factor. Material mechanical properties at rolling temperatures were determined by Gleeble™ thermo-mechanical simulator and IDS thermodynamic-kinetic-empirical software. [ABSTRACT FROM AUTHOR]

Magnesium based alloys are yet to fill a greater niche especially in the automotive and aeronautical industry. In fact, such alloys have a big weight saving potential, together with good damping characteristics. However, nowadays about 90% of Magnesium products are produced by casting, mainly using two alloy systems, namely Mg-Al-Zn (AZ91D) and Mg-Al (AM50, AM60). Now the emphasis, especially after having achieved considerable success in creep resistance and understanding of the deformation behaviour of Magnesium, has been shifted towards wrought alloys; AZ31, in this case, is the most popular. In this work a multi-element Magnesium alloy, developed to improve the deformation capacity of such a lightweight material, has been investigated and compared to a commercial AZ31B. The possibility of adopting such a multi-element Magnesium alloy for manufacturing components via unconventional sheet forming (such as superplastic forming, warm hydroforming, incremental forming) has been proved in the present work focusing the attention on the superplastic field. Free inflation tests were thus conducted at 450°C setting constant pressure to investigate the superplastic behaviour (in terms of dome height and strain rate sensitivity index) of both the multi-element Magnesium alloy (Mg-2Zn-Ce) and the commercial one (AZ31B). To enhance information on the thickness distribution and investigate the microstructure evolution, metallographic analyses on the samples used to carry out free inflation tests were also performed. The developed ternary alloy manifested quite a good deformation behaviour (high strain rate sensitivity index), even being tested in the as cast condition; in addition a limited grain coarsening was observed in the specimens after deformation. [ABSTRACT FROM AUTHOR]

Hot work tools are subjected to complex thermal and mechanical loads during hot forming processes. Locally, the stresses can exceed the material’s yield strength in highly loaded areas as e.g. in small radii in die cavities. To sustain the high loads, the hot forming tools are typically made of martensitic hot work steels. While temperatures for annealing of the tool steels usually lie in the range between 400 and 600 °C, the steels may experience even higher temperatures during hot forming, resulting in softening of the material due to coarsening of strengthening particles. In this paper, a temperature dependent cyclic plasticity model for the martensitic hot work tool steel 1.2367 (X38CrMoV5-3) is presented that includes softening due to particle coarsening and that can be applied in finite-element calculations to assess the effect of softening on the thermomechanical fatigue life of hot work tools. To this end, a kinetic model for the evolution of the mean size of secondary carbides based on Ostwald ripening is coupled with a cyclic plasticity model with kinematic hardening. Mechanism-based relations are developed to describe the dependency of the mechanical properties on carbide size and temperature. The material properties of the mechanical and kinetic model are determined on the basis of tempering hardness curves as well as monotonic and cyclic tests. [ABSTRACT FROM AUTHOR]

The production of Nickel-based high-temperature components is of great importance for the transport and energy sector. Forging of high-temperature alloys often requires expensive dies, multiple forming steps and leads to forged parts with tolerances that require machining to create the final shape and a large amount of scrap. Additive manufacturing offers the possibility to print the desired shapes directly as net-shape components, requiring only little additional effort in machining. Especially for high-temperature alloys carrying a large amount of energy per unit mass, additive manufacturing could be more energy-efficient than forging if the energy contained in the machining scrap exceeds the energy needed for powder production and laser processing. However, the microstructure and performance of 3d-printed parts will not reach the level of forged material unless further expensive processes such as hot-isostatic pressing are used. Using the design freedom and possibilities to locally engineer material, additive manufacturing could be combined with forging operations to novel process chains, offering the possibility to reduce the number of forging steps and to create near-net shape forgings with desired local properties. Some innovative process chains combining additive manufacturing and forging have been patented recently, but almost no scientific knowledge on the workability of 3D printed preforms exists. The present study investigates the flow stress and microstructure evolution during hot working of pre-forms produced by laser powder deposition and selective laser melting (Figure 1) and puts forward a model for the flow stress. [ABSTRACT FROM AUTHOR]

The tendency to a higher variety of products requires economical manufacturing processes suitable for the production of prototypes and small batches. In the case of complex hollow-shaped parts, single point incremental forming (SPIF) represents a highly flexible process. The flexibility of this process comes along with a very long process time. To decrease the process time, a new incremental forming approach with multiple forming tools is investigated. The influence of two incremental forming tools on the resulting mechanical and geometrical component properties compared to SPIF is presented. Sheets made of EN AW-1050A were formed to frustums of a pyramid using different tool-path strategies. Furthermore, several variations of the tool-path strategy are analyzed. A time saving between 40% and 60% was observed depending on the tool-path and the radii of the forming tools while the mechanical properties remained unchanged. This knowledge can increase the cost efficiency of incremental forming processes. [ABSTRACT FROM AUTHOR]

Ti6Al4V sheets are usually difficult-to-form at room temperature as a consequence of their strong basal texture and hcp crystal lattice. The heating of the alloy below the beta transus temperature is recognized to enhance its formability, reducing the flow stress and increasing the ductility. However, the influence of the sheet anisotropy on the material failure hasn’t been studied yet. To this aim, the paper presents the anisotropy influence on the failure characteristics of Ti6Al4V titanium alloy sheets making use of tensile tests carried out at room temperature and 600°C on smooth, notched and shear samples in order to have various stress states. The fracture strain is measured and the effect of the sample orientation and stress state is identified. To determine the actual stress state for each sample geometry, a numerical model is set up and calibrated using elasto-plastic data from uni-axial tensile tests on smooth samples. Finally, the fracture surfaces are observed through SEM analysis to explain the failure characteristics. [ABSTRACT FROM AUTHOR]

Inhomogeneous strain and sheet thickness distributions can be observed in complex sheet metal parts manufactured by stretch forming. In literature, this problem is solved by flexible clampings adapted to the part geometry. In this paper, an approach, which does not rely on extensive tooling, is presented. The strain distribution in the sheet is influenced by means of hole patterns. Holes are introduced into the sheet area between clamping and part next to areas where high strains are expected. When deforming the sheet, high strains are shifted out of the part area. In a local area around the holes, high strains concentrate perpendicular to the drawing direction. Thus, high strains in the part area are reduced and the strain distribution is homogenised. To verify this approach, an FE-model of a stretch forming process of a conical part is implemented in LS-Dyna. The model is validated by corresponding experiments. In the first step, the positioning of the holes is applied manually based on the numerically determined strain distribution and experience. In order to automate the positioning of the holes, an optimisation method is applied in a second step. The presented approach implemented in LS-OPT uses the response surface method to identify the positioning and radius of the holes homogenising the strain in a defined area of the sheet. Due to nonlinear increase of computational complexity with increasing number of holes, the maximum number of holes is set to three. With both, the manual and the automated method, hole patterns were found which allow for a relative reduction of maximum strains and for a homogenisation of the strain distribution. Comparing the manual and automated positioning of holes, the pattern determined by automated optimisation shows better results in terms of homogenising the strain distribution. [ABSTRACT FROM AUTHOR]

New technological challenges like electro-mobility pose an increasing demand for cost-efficient processes for the production of product variants. This demand opens the possibility to combine established die-based manufacturing methods and innovative, dieless technologies like additive manufacturing [1, 2]. In this context, additive manufacturing technologies allow for the weight-efficient local reinforcement of parts before and after forming, enabling manufacturers to produce product variants from series parts [3]. Previous work by the authors shows that the optimal shape of the reinforcing structure can be determined using sizing optimization. Sheet metal parts can then be reinforced using laser metal deposition. The material used is a pearlite-reduced, micro-alloyed steel (ZE 630). The aim of this paper is to determine the effect of the additive manufacturing process on the material behavior and the mechanical properties of the base material and the resulting composite material. The parameters of the AM process are optimized to reach similar material properties in the base material and the build-up volume. A metallographic analysis of the parts is presented, where the additive layers, the base material and also the bonding between the additive layers and the base material are analyzed. The paper shows the feasibility of the approach and details the resulting mechanical properties and performance. [ABSTRACT FROM AUTHOR]

In the field of production systems, globalization and technological progress lead to increasing requirements regarding part quality, delivery time and costs. Hence, today’s production is challenged much more than a few years ago: it has to be very flexible and produce economically small batch sizes to satisfy consumer’s demands and avoid unnecessary stock. Furthermore, a trend towards increasing functional integration continues to lead to an ongoing miniaturization of sheet metal components. In the industry of electric connectivity for example, the miniaturized connectors are manufactured by progressive tools, which are usually used for very large batches. These tools are installed in mechanical presses and then set up by a technician, who has to manually adjust a wide range of punch-bending operations. Disturbances like material thickness, temperatures, lubrication or tool wear complicate the setup procedure. In prospect of the increasing demand of production flexibility, this time-consuming process has to be handled more and more often. In this paper, a new approach for a model-based setup assistant is proposed as a solution, which is exemplarily applied in combination with a progressive tool. First, progressive tools, more specifically, their setup process is described and based on that, the challenges are pointed out. As a result, a systematic process to set up the machines is introduced. Following, the process is investigated with an FE-Analysis regarding the effects of the disturbances. In the next step, design of experiments is used to systematically develop a regression model of the system’s behaviour. This model is integrated within an optimization in order to calculate optimal machine parameters and the following necessary adjustment of the progressive tool due to the disturbances. Finally, the assistant is tested in a production environment and the results are discussed. [ABSTRACT FROM AUTHOR]

Cranial implants are custom prostheses characterized by quite high geometrical complexity and small thickness; at the same time aesthetic and mechanical requirements have to be met. Titanium alloys are largely adopted for such prostheses, as they can be processed via different manufacturing technologies. In the present work cranial prostheses have been manufactured by Super Plastic Forming (SPF) and Single Point Incremental Forming (SPIF). In order to assess the mechanical performance of the cranial prostheses, drop tests under different load conditions were conducted on flat samples to investigate the effect of the blank thickness. Numerical simulations were also run for comparison purposes. The mechanical performance of the cranial implants manufactured by SPF and SPIF could be predicted using drop test data and information about the thickness evolution of the formed parts: the SPIFed prosthesis revealed to have a lower maximum deflection and a higher maximum force, while the SPFed prostheses showed a lower absorbed energy. [ABSTRACT FROM AUTHOR]

As a result from the ever increasing demand to produce lighter vehicles, more and more advanced high-strength materials are used in automotive industry. Focusing on sheet metal cold forming processes, these materials require high pressing forces and exhibit large springback after forming. Due to the high pressing forces deformations occur in the tooling geometry, introducing dimensional inaccuracies in the blank and potentially impact the final springback behavior. As a result the tool deformations can have an impact on the final assembly or introduce cosmetic defects. Often several iterations are required in try-out to obtain the required tolerances, with costs going up to as much as 30% of the entire product development cost. To investigate the sheet metal part feasibility and quality, in automotive industry CAE tools are widely used. However, in current practice the influence of the tool deformations on the final part quality is generally neglected and simulations are carried out with rigid tools to avoid drastically increased calculation times. If the tool deformation is analyzed through simulation it is normally done at the end of the drawing prosses, when contact conditions are mapped on the die structure and a static analysis is performed to check the deflections of the tool. But this method does not predict the influence of these deflections on the final quality of the part. In order to take tool deformations into account during drawing simulations, ESI has developed the ability to couple solvers efficiently in a way the tool deformations can be real-time included in the drawing simulation without high increase in simulation time compared to simulations with rigid tools. In this paper a study will be presented which demonstrates the effect of tool deformations on the final part quality. [ABSTRACT FROM AUTHOR]

An axisymmetric dome of 70 mm in diameter and 35 mm in depth was formed using the ISF process using varying proportions (25, 50 and 75%) of spiral (S) and helical (H) tool path combinations as a single tool path strategy, on a 2 mm thickness commercially pure aluminium sheets. A maximum forming depth of ∼30 mm was observed on all the components, irrespective of the different tool path combinations employed. None of the components were fractured for the different tool path combinations used. The springback was also same and uniform for all the tool path combinations employed, except for the 75S25H which showed slightly larger springback. The wall thickness reduced drastically up to a certain forming depth and increased with the increase in forming depth for all the tool path combinations. The maximum thinning occurred near the maximum wall angle region for all the components. The wall thickness improved significantly (around 10-15%) near the maximum wall angle region for the 25S75H combination than that of the complete spiral and other tool path strategies. It is speculated that this improvement in wall thickness may be mainly due to the combined contribution of the simple shear and uniaxial dilatation deformation modes of the helical tool path strategy in the 25S75H combination. This increase in wall thickness will greatly help in reducing the plastic instability and postpone the early failure of the component. [ABSTRACT FROM AUTHOR]

The incremental tube forming (ITF) is a process combination of the kinematic tube bending and spinning to shape high strength and tailored tubes with variable diameters and thicknesses. In contrast to conventional bending methods, the compressive stress superposition by the spinning process facilitates low bending stresses, so that geometrical errors are avoided and the shape accuracy is improved. The study reveals the interaction of plastic strains of the rolling and bending process through an explicit FEM investigation. For this purpose, the three-dimensional machine set-up is discretized and modeled in terms of the fully disclosed spinning process during the gradual deflection of the tube end for bending. The analysis shows that, depending on the forming tool shape, the stress superposition is accompanied by high plastic strains. Furthermore, this phenomenon is explained by the three dimensional normal and shear strains during the incremental spinning. Analyzing the strains history also shows a nonlinearity between the strains by bending and spinning. It is also shown that process parameters like rotational velocity of the spinning rolls have a huge influence on the deformation pattern. Finally, the method is used for the manufacturing of an example product, which reveals the high process flexibility. In one clamp a component with a graded wall thickness and outside diameter along the longitudinal axis is produced. [ABSTRACT FROM AUTHOR]

To encounter trends regarding an efficient production of complex functional components in forming technology, the process class of sheet-bulk metal forming (SBMF) can be applied. SBMF is characterized by the application of bulk forming operations on sheet metal, often in combination with sheet forming operations [1]. The combination of these conventional process classes leads to locally varying load conditions. The resulting load conditions cause high tool loads, which lead to a reduced tool life, and an uncontrolled material flow. Several studies have shown that locally modified tool surfaces, so-called tailored surfaces, have the potential to control the material flow and thus to increase the die filling of functional elements [2]. A combination of these modified tool surfaces and high tool loads in SBMF is furthermore critical for the tool life and leads to fatigue. Tool fatigue is hardly predictable and due to a lack of data [3], a challenge in tool design. Thus, it is necessary to provide such data for tool steels used in SBMF. The aim of this study is the investigation of the influence of tailored surfaces on the fatigue strength of the powder metallurgical tool steel ASP2023 (1.3344, AISI M3:2), which is typically used in cold forging applications, with a hardness 60 HRC ± 1 HRC. To conduct this investigation, the rotating bending test is chosen. As tailored surfaces, a DLC-coating and a surface manufactured by a high-feed-milling process are chosen. As reference a polished surface which is typical for cold forging tools is used. Before the rotating bending test, the surface integrity is characterized by measuring topography and residual stresses. After testing, the determined values of the surface integrity are correlated with the reached fracture load cycle to derive functional relations. Based on the gained results the investigated tailored surfaces are evaluated regarding their feasibility to modify tool surfaces within SBMF. [ABSTRACT FROM AUTHOR]

Reducing dimensional variations in the extrusion process without increasing cost is challenging due to the nature of the process itself. An alternative approach—also from a cost perspective—is using extruded profiles with standard tolerances and utilize downstream processes, and thus calibrate the part within tolerance limits that are not achievable directly from the extrusion process. In this paper, two mechanical calibration strategies for the extruded product are investigated, utilizing the forming lines of the manufacturer. The first calibration strategy is based on global, longitudinal stretching in combination with local bending, while the second strategy utilizes the principle of transversal stretching and local bending of the cross-section. An extruded U-profile is used to make a comparison between the two methods using numerical analyses. To provide response surfaces with the FEA program, ABAQUS is used in combination with Design of Experiment (DOE). DOE is conducted with a two-level fractional factorial design to collect the appropriate data. The aim is to find the main factors affecting the dimension accuracy of the final part obtained by the two calibration methods. The results show that both calibration strategies have proven to reduce cross-sectional variations effectively form standard extrusion tolerances. It is concluded that mechanical calibration is a viable, low-cost alternative for aluminium parts that demand high dimensional accuracy, e.g. due to fit-up or welding requirements. [ABSTRACT FROM AUTHOR]

Exhaust gas components of automobiles are often produced in ferritic stainless steel 1.4509 due to the low thermal expansion coefficient and the low material price. Until now, components of the stainless steel with complex geometries have been produced in series by means of multi-stage hydroforming at room temperature with intermediate annealing operations. The application of a single-stage hot-forming process, also referred to as hot metal gas forming (HMGF), offers great potential to significantly reduce the production costs of such components. The article describes a novel process chain for the HMGF process. Therefore the tube is heated in two steps. After pre-heating of the semi-finished product outside the press, the tube is heated up to forming start temperature by means of a tool-integrated conductive heating before forming. For the tube of a demonstrator geometry, a simulation model for the conduction heating was set up. In addition to the tool development for this process, experimental results are also described for the production of the demonstrator geometry. [ABSTRACT FROM AUTHOR]

Fuel efficiency requirements demand lightweight construction of vehicle body parts. The usage of advanced high strength steels permits a reduction of sheet thickness while still maintaining the overall strength required for crash safety. However, damage, internal defects (voids, inclusions, micro fractures), microstructural defects (varying grain size distribution, precipitates on grain boundaries, anisotropy) and surface defects (micro fractures, grooves) act as a concentration point for stress and consequently as an initiation point for failure both during deep drawing and in service. Considering damage evolution in the design of car body deep drawing processes allows for a further reduction in material usage and therefore body weight. Preliminary research has shown that a modification of load paths in forming processes can help mitigate the effects of damage on the material. This paper investigates the load paths in Nakajima tests of a DP800 dual phase steel to research damage in deep drawing processes. Investigation is done via a finite element model using experimentally validated material data for a DP800 dual phase steel. Numerical simulation allows for the investigation of load paths with respect to stress states, strain rates and temperature evolution, which cannot be easily observed in physical experiments. Stress triaxiality and the Lode parameter are used to describe the stress states. Their evolution during the Nakajima tests serves as an indicator for damage evolution. The large variety of sheet metal forming specific load paths in Nakajima tests allows a comprehensive evaluation of damage for deep drawing. The results of the numerical simulation conducted in this project and further physical experiments will later be used to calibrate a damage model for simulation of deep drawing processes. [ABSTRACT FROM AUTHOR]

The applications of Advanced High-Strength Steels (AHSS) in the automotive industry are rapidly increasing due to a demand for a lightweight material that significantly reduces fuel consumption without compromising passenger safety. Automotive industries and material suppliers are expected by consumers to deliver reliable and affordable products, thus stimulating these manufacturers to research solutions to meet these customer requirements. The primary advantage of AHSS is its extremely high strength to weight ratio, an ideal material for the automotive industry. However, its low ductility is a major disadvantage, in particular, when using traditional cold forming processes such as roll forming and deep drawing process to form profiles. Consequently, AHSS parts frequently fail to form. Thereby, in order to improve quality and reliability on manufacturing AHSS products, a recently-developed incremental cold sheet metal forming technology called Chain-die Forming (CDF) is recognised as a potential solution to the forming process of AHSS. The typical CDF process is a combination of bending and roll forming processes which is equivalent to a roll with a large deforming radius, and incrementally forms the desired shape with split die and segments. This study focuses on manufacturing an AHSS top-hat section with minimum passes without geometrical or surface defects by using finite element modelling and simulations. The developed numerical simulation is employed to investigate the influences on the main control parameter of the CDF process while forming AHSS products and further develop new die-punch sets of compensation design via a numerical optimal process. In addition, the study focuses on the tool design to compensate spring-back and reduce friction between tooling and sheet-metal. This reduces the number of passes, thereby improving productivity and reducing energy consumption and material waste. This numerical study reveals that CDF forms AHSS products of complex profiles with much less residual stress, low spring back, low strain and of higher geometrical accuracy compared to other traditional manufacturing processes. [ABSTRACT FROM AUTHOR]

The need to increase the safety and decrease the weight of the car body-in-white has determined the success of the direct hot stamping process as a primary technology for the automotive sector. Thanks to this process, parts with high strength-to-weight ratio can be obtained along with high stiffness and increase of the crashworthiness properties. Moreover, the thinner metal sheets used to manufacture the pieces lead to a decrease of the total weight of the car body-in-white, with a consequent reduction of the CO2 emissions. The direct hot stamping process is becoming the key to obtain pieces with high mechanical properties, thanks to the quenching stage that allows the manufacture of complex shapes characterized by a fully martensitic structure, thanks to the forming stage at elevated temperature and subsequent hardening inside the cooled dies. The aim of this paper is the investigation of the influence that the forming temperature may have on the formability of 22MnB5 steel sheets, commonly used in the hot stamping process of automotive components. Nakajima tests were carried out at different temperatures and the Forming Limit Diagrams (FLDs) at rupture were obtained and analysed. The temperature influenced both the major and the minor strain at which the sheet failed, indicating that not only the formability increased at increasing temperature, but there was also a modification of the strain path, which means a modification of the strain states through which the part passes during the deformation process. Moreover, the influence of friction is studied using a model developed in the LS-Dyna FEM environment. The obtained data are of great importance for an accurate calibration of Finite Element (FE) models of the hot stamping of real components in order to get optimal process parameters to obtain defects-free pieces. [ABSTRACT FROM AUTHOR]

Zinc alloys are used in a wide range of application such as electronics, automotive and building construction. Their various shapes are generally obtained by metal forming operation such as stamping. Therefore, it is important to characterize the material with adequate characterization tests. Sheet Bulging Test (SBT) is well recognized in the metal forming community. Different theoretical models of the literature for the evaluation of thickness and radius of the deformed sheet in SBT have been studied in order to get the hardening curve of different materials. These theoretical models present the advantage that the experimental procedure is very simple. But Koç et al. showed their limitation, since the combination of thickness and radius evaluations depend on the material. As Zinc alloys are strongly anisotropic with a special crystalline structure, a procedure is adopted for characterizing the hardening curve of a Zinc alloy. The anisotropy is first studied with tensile test, and SBT with elliptical dies is also investigated. Parallel to this, Digital Image Correlation (DIC) measures are carried out. The results obtained from theoretical models and DIC measures are compared. Measures done on post-mortem specimens complete the comparisons. Finally, DIC measures give better results and the resulting hardening curve of the studied zinc alloy is provided. [ABSTRACT FROM AUTHOR]

The aim of this work was the characterization of the newly developed press hardening sheet alloys 1800 PHS and 2000 PHS developed by SSAB with regard to their hot forming behavior on the basis of the experimental determination of relevant mechanical and technological properties. For this purpose conventional and non-conventional sheet metal testing methods were used. To determine the friction coefficient, the strip drawing test was applied, while the deep drawing cup test was used to determine the maximum draw depth. Finally, a V-bending test was carried out to evaluate the springback behavior of the investigated alloys by varying the blank temperature and quenching media. This work provides a technological guideline for the production of press hardened sheet parts made of these investigated sheet metals. [ABSTRACT FROM AUTHOR]

Globalisation is forcing many sectors to be more cost-effective due to the low manpower cost of developing countries. This, in combination with European trends of green production and reduction of emissions, enhances the necessity of advanced technologies to remain at the forefront of the market. It is precisely in this field where the Semisolid forming (SSF) exhibits a great potential. In Mondragon Unibertsitatea, it has been demonstrated the capability of producing sound components of 42CrMo4 and S48C steels by saving material, energy and attaining as hot forged properties. To make the process even more cost-effective, it has also been proved the capacity of SSF 44MnSiV6 microalloyed steel that enables the striking of the post processing heat treatment. [ABSTRACT FROM AUTHOR]

The biaxial tensile properties of thin poly-ether-ether-ketone (PEEK) films are presented. Investigation into the biaxial mechanical behaviour of PEEK films will provide a preliminary insight into the anticipated stress/strain response, and potential suitability, to the possible fabrication of thin walled parts through stretch blow moulding and thermoforming processes – with the multi-axial state of strain imposed onto the heated thermoplastic sheet representative of the expected strain history experienced during these material forming processes. Following identification of the prospective forming temperature window, the biaxial mechanical behaviour of the material is characterized under differing modes of deformation, at a nominal strain rate of 1 s−1. The temperature dependence is outlined within – with an appreciable increase in flow behaviour correlated with specimen temperature exceeding its glass transition temperature (Tg). [ABSTRACT FROM AUTHOR]

The mechanical properties of formed metal components are highly affected by the prevailing residual stress state. A selective induction of residual compressive stresses in the component, can improve the product properties such as the fatigue strength. By means of single point incremental forming (SPIF), the residual stress state can be influenced by adjusting the process parameters during the manufacturing process. To achieve a fundamental understanding of the residual stress formation caused by the SPIF process, a valid numerical process model is essential. Within the scope of this paper the significance of kinematic hardening effects on the determined residual stress state is presented based on numerical simulations. The effect of the unclamping step after the manufacturing process is also analyzed. An average deviation of the residual stress amplitudes in the clamped and unclamped condition of 18 % reveals, that the unclamping step needs to be considered to reach a high numerical prediction quality. [ABSTRACT FROM AUTHOR]

Incremental forming processes (i.e., spinning) of sheet metal blanks into cylindrical cups are suitable for lower lot sizes. The produced cups were frequently used as preforms to produce workpieces in further forming steps with additional functions like profiled hollow parts [1]. The incremental forming process radial-rotation profile forming has been developed to enable the production of profiled hollow parts with low sheet thinning and good geometrical accuracy. The two principal forming steps are the production of the preform by rotational swing-folding [2] and the subsequent radial profiling of the hollow part in one clamping position. The rotational swing-folding process is based on a combination of conventional spinning and swing-folding. Therefore, a round blank rotates on a profiled mandrel and due to the swinging of a cylindrical forming tool, the blank is formed to a cup with low sheet thinning. In addition, thickening results at the edge of the blank and wrinkling occurs. However, the wrinkles are formed into the indentation of the profiled mandrel and can be reshaped as an advantage in the second process step, the radial profiling. Due to the rotation and continuous radial feed of a profiled forming tool to the profiled mandrel, the axial profile is formed in the second process step. Because of the minor relative movement in axial direction between tool and blank, low sheet thinning occurs. This is an advantage of the principle of the process. [ABSTRACT FROM AUTHOR]