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Implementing the ultrasonic vibration-assisted incremental sheet-forming (UISF) process has been proven to significantly reduce the forming force, improve the surface quality, and enhance the accuracy of the sheet-forming process. However, such effectiveness has primarily focused on easily deformable materials (such as AA1050 and AA1060 aluminum alloys) and small step-down sizes (from 0.3 mm to 0.5 mm). To further enhance the process, it is crucial to study larger step-down sizes and harder materials. In this study, a series of UISF experiments were conducted, with step-down sizes ranging from 0.5 mm to 1.5 mm and feed rates ranging from 200 mm/min to 1200 mm/min. The influence of ultrasonic vibration on the effectiveness of force reduction and the optimal operation parameters was experimentally tested. Forming aluminum alloy AA5052, a difficult-to-deform material with two thicknesses of 0.5 mm and 1.0 mm, indicates that the axial force Fz and the tool movement resistance force Fy tend to decrease significantly with ultrasonic vibration assistance. Optimal equations for force reduction Fz and Fy have been developed for plate thickness based on the step-down size and feed rate. The optimal results show that for 1.0 mm thickness, reductions in Fz and Fy can reach 58.73% and 69.17%, respectively, and that of 64.17% and 71.98%, respectively, for 0.5 mm thickness.

Solid-state electrolytes (SSEs) are vital components in solid-state lithium batteries, which hold significant promise for energy storage applications. This review provides an overview of solid-state batteries (SSBs) and discusses the classification of electrolytes, with a focus on the challenges associated with oxide- and sulphide-based SSEs, particularly concerning interfaces and chemical stability. This review also explores methods employed to form and sinter SSEs in large-scale manufacturing, including both established and novel techniques for producing dense oxide- and sulphide-based films. Additionally, the potential application of additive manufacturing (AM) in SSE production is discussed. Lastly, the paper summarises the mass manufacturing of SSEs and provides an outlook for sustainable SSB development goals. The insights presented in this review contribute to the understanding and progress of SSE technology for solid-state lithium batteries

The use of ultra-short pulse lasers in the kW range, combined with an appropriate beam engineering approach, enables the achievement of high-throughput production of laser-functionalised surfaces. However, the manufacturing of complex parts still faces various challenges, such as difficulties in accessing regions with high aspect ratio shapes or intricate profiles, which often leads to the necessity of adapting the laser processing workstation to specific geometries. The forming process is a well-established technique for producing parts of any shape from metallic foils by imposing specific constraints. In this study, we aimed to assess the feasibility of producing laser-functionalised 3D complex products by the forming of laser-treated flat thin metallic sheets. Two-hundred micrometre-thick stainless-steel foils were textured with laser-induced periodic surface structures (LIPSS) through a roll-to-roll pilot line. First, we optimized the morphology of LIPSS. Subsequently, we conducted three types of mechanical tests on both laser-treated and untreated foils: standard tensile tests, fatigue tests, and cruciform specimen tests. We measured and compared parameters such as ultimate tensile strength, breaking strength, maximum elongation, and area reduction between specimens with and without LIPSS, all obtained from the same foil. Additionally, we utilized scanning electron microscopy (SEM) to compare the LIPSS morphology of laser-treated samples before and after mechanical tests. [ABSTRACT FROM AUTHOR]

In order to study the influence of technological factors on the nature of forming and the risk of metal fracture, problems of computer modeling of the process of continuous pipe rolling on the Fine Quality Mill (FQM) are formulated and solved. The solution of the problems has made it possible to assess the nature of the influence of deviation of rolling axes of the continuous mill and the extracting mill. The results of the research have made it possible to formulate and propose technical solutions to minimize the probability of risk defect. [ABSTRACT FROM AUTHOR]

The production of high-performance composite parts with non-crimp fabrics (NCFs) requires a profound understanding of the material’s behavior during draping to prevent forming defects such as wrinkling and gapping. Simulation methods can be used to model the complex material behavior of NCFs and predict their deformation during the draping process. However, NCFs do not intrinsically deform under pure shear like most woven fabrics, but often under superimposed shear, transverse tension and in-plane roving compaction. Therefore, non-standard characterization methods have to be applied besides typical picture frame tests or bias-extension tests. Off-axis-tension tests (OATs) utilize a simple setup to characterize a fabric’s membrane behavior under different ratios of superimposed shear, transverse tension and in-plane compaction. OATs at three different bias angles (30 ∘ , 45 ∘ and 60 ∘ ) are conducted to investigate a unidirectional and a bidirectional NCF. A method is presented to measure the fiber curvatures in addition to the occurring strains. The investigations reveal a relatively symmetrical, shear-dominated behavior with limited roving slippage for the Biax-NCF. The behavior of the UD-NCF strongly depends on the stitching load during tests and is characterized by an asymmetric shear behavior as well as significant roving slippage. The off-axis-tension test results can be used as the basis for the development and validation of new simulation methods to model the complex membrane behavior of NCFs. [ABSTRACT FROM AUTHOR]

In this paper, the influence of ultrasonic vibration on the forming forces and surface quality of products formed using an ultrasonic-assisted incremental sheet forming (UISF) method was investigated and compared with an incremental sheet forming (ISF) method. The elements and parameters used for research include a sheet of Al 5052 aluminum alloy with thickness of 1.0 mm, a lathe with a feed rate of 70-130-225 rpm, and step size of 1.0-1.5-2.0 mm. The results show that ultrasonic vibration significantly reduces the forming forces, of which the main forming force Fzmax is reduced by about 20%. Besides, the results also show that the surface quality of products formed via UISF is significantly improved compared to that formed by ISF. [ABSTRACT FROM AUTHOR]

In scientific studies, sheet metal is usually considered as a two-dimensional body. Thus, it is accepted that material properties are in most cases regarded homogeneous in thickness direction. However, a gradation of certain properties becomes apparent when going beyond the standard characterization methods for sheet metals, which can for example, influence the springback behavior and the thinning of the sheet after forming. Thus, the aim of this work is to further improve the prediction accuracy of springback after forming in simulations, by implementing several inhomogeneous properties over the sheet thickness in an existing material model. For this purpose, the entire procedure from the identification of the inhomogeneous properties for describing the gradation to the implementation in a numerical model and its validation by comparing experimental and simulated bending operations is carried out on a DC04 cold-forming steel in order to prove its influence on the springback behavior. It is shown that including graded material properties in simulations does indeed have an impact on the prediction quality of springback and that the information about inhomogeneous properties can be provided by existing characterization methods with a high local resolution like electron backscatter diffraction or X-ray stress analysis. In a further step, it was possible to validate the improvement in numerical accuracy by comparing the prediction of the springback angle from both the existing and the extended model with experimental bending results. Both the initial model as well as the model supplemented with the 3D properties provide a good prediction accuracy in the solution heat treated material state. For the predeformed material, however, the initial numerical model predicts a springback angle of about 13°, which deviates remarkably from the experimentally obtained mean value of about 17°. The extended model delivers a significantly improved accuracy in springback prediction in relation to the initial prediction (deviation of 4°) with a minor deviation of only about 0.8°, which proves the importance of considering the gradation of material properties in thickness direction for an overall higher dimensional accuracy of sheet metal products. [ABSTRACT FROM AUTHOR]

During the thermoforming of fibre-reinforced thermoplastic (FRTP) organosheets, the desire to minimise tool temperatures leads to non-isothermal temperature profiles through the laminate thickness. The aim of this study was to understand the influence of these non-isothermal conditions on FRTP intra-ply shearing. Novel non-isothermal bias extension tests were conducted, revealing that an average between the isothermal shear curves of both laminate faces approximately represented the respective non-isothermal condition. However, these findings were irrespective of FRTP thickness, and only applied to laminates that wholly remained above the crystallisation onset temperature. Upon the onset of crystallisation in a single ply, the non-isothermal shear resistance skewed heavily towards that (within 5%) of the crystallised ply and inhomogeneous shear angles were observed. Non-isothermal thermoforming validated these findings with the presence of wrinkles on non-isothermal hemispheres in which a single ply had reached crystallisation. This reaffirms the importance of accurate thermal monitoring during FRTP processing. [ABSTRACT FROM AUTHOR]

This study presents an experimental investigation on Al matrix composites (AMCs) reinforced titanium carbide (TiC) nano-particles produced by five accumulative roll bonding cycles and three cryorolling (CR) cycles. The microstructures and mechanical properties of composites were studied. The results exhibited consequentially improved mechanical properties for processed Al/TiC AMCs as the number of rolling cycles increased. The presence of TiC in Al matrix showed the combination of elastic modulus, hardness, yield, and ultimate tensile stress of 84 ± 2GPa, 86 ± 3HV, 240 ± 12MPa, and 308 ± 15MPa, respectively. The dispersion of TiC particles was improved with increasing in the number of rolling cycles, resulting in a decrease in porosity between the matrix and reinforcement. This phenomenon was attributed to the breakup of particle clusters and their subsequent uniform dispersion within the Al matrix under CR. The composite microstructure shows uniform TiC particle distribution and grain refinement in the Al matrix, which all contribute to the enhanced mechanical properties. [ABSTRACT FROM AUTHOR]

Fatigue of cold formed parts is an important consideration especially in the automotive industry. Methods exist for predicting the fatigue of parts where the plastic deformation during forming is less than the uniform elongation. Nevertheless, many stamped parts include areas where forming strain exceeds uniform elongation. These areas are also very important in terms of high cyclic fatigue. Fatigue tests were carried out on these highly formed bodies. The results are presented in this paper. Also, a simple method is proposed for avoiding some common mistakes in fatigue evaluation. [ABSTRACT FROM AUTHOR]

Copyright of Electroplating & Finishing is the property of Electroplating & Finishing Editorial Office and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

Understanding the thermoforming process for thermoplastic composites is of great importance to ensure the quality of the composite product but is difficult because of the complex material constitutive models and thermo-mechanical coupling in the thermoforming process. In this study, a woven fabric thermoplastic composite consisting of glass fiber and polyetherimide resin was thermoformed under one-sided cooling conditions. After the effective material properties are homogenized with newly developed, two-step asymptotic homogenization methods, and the temperature and pressure boundary conditions are measured experimentally, a 3D composite laminate sandwiched by interfacial layers and metal molds was finite element simulated in the macroscale. The simulated warpage, which was caused by the in-plane residual stresses, was consistent with the experimental results when reasonable tool–part interactions were considered. Subsequently, the temperature, displacement, strain, and stress were comprehensively discussed in terms of their spatial distribution, temporal evolution, and correlations with the others. [ABSTRACT FROM AUTHOR]

The demands on joining technology are constantly increasing due to the consistent lightweight construction and the associated increasing material mix. To meet these requirements, the adaptability of the joining processes must be improved to be able to process different material combinations and to react to challenges caused by deviations in the process chain. One example of a highly adaptable process due to the two-step process sequence is thermomechanical joining with Friction Spun Joint Connectors (FSJCs) that can be individually adapted to the joint. In this paper, the potentials of the adaption in the two-stage joining process with aluminium auxiliary joining elements are investigated. To this end, it is first investigated whether a thermomechanical forming process can be used to achieve a uniform and controlled manufacturing regarding the process variable of the temperature as well as the geometry of the FSJC. Based on the successful proof of the high and good repeatability in the FSJC manufacturing, possibilities, and potentials for the targeted influencing of the process and FSJC geometry are shown, based on an extensive variation of the process input variables (delivery condition and thus mechanical properties of the raw parts as well as the process parameters of rotational speed and feed rate). Here it can be shown that above all, the feed rate of the final forming process has the strongest influence on the process and thus also offers the strongest possibilities for influencing it. [ABSTRACT FROM AUTHOR]

According to the need of a certain gas transmission pipeline project, a Φ610 mmxl8 mm L290M SAWH pipe with ultra large SDR is researched and developed by a certain domestic company. Described here in the paper are the difficulties as concerned with the formation and welding operations which are encountered during the trial production process of the said SAWH pipe, and relevant adjustment and control measures as taken. Also analyzed are the physiochemical properties, the welding quality and the welding difficulties, etc. of the pipe. The results of the tests and inspections as made to the pipe show that all the technical indexes of the pipe are up to the applicable technical requirements. [ABSTRACT FROM AUTHOR]

Significant fluid–structure interaction is present in fiber metal laminate forming with a low viscous matrix. A modular, process-inspired test setup is presented for one-dimensional saturated and unsaturated infiltration experiments for fiber metal laminates. Permeability measurements for different fabric orientations, fabric layers, and fiber volume contents show low scatter and good repeatability for fiber volume contents up to 65%. Fiber metal laminate specimens were formed by exchanging the mid-segment of the test setup with a punch and die. The stiffness differences between metal and fabric lead to remarkably high compactions in the bending radii, significantly reducing the flow during infiltration. Contrary to resin transfer molding processes, no formation of resin-rich zones along bending edges occurs due to the high normal pressures from metal forming. A numerical forming simulation was developed to predict the local fiber volume content. Comparing the experimental results with the numerical simulation shows that the high fiber volume content in the radii almost exclusively impacts the overall permeability. Implications for fiber metal laminate processing and modeling are outlined. [ABSTRACT FROM AUTHOR]

The design of structures using advanced composite materials such as fiber metal laminate requires an in‐depth understanding of their deformation behavior and response to the discontinuities in the structures. In the present study, a GLARE kind of fiber metal laminate in 2/1 configuration was fabricated in the form of conical frustum. Three cut‐outs of two different shapes such as circular and square were intentionally made at the center of the frustum at an angular distance of 120°. The quasi‐static compression test was conducted to determine the crashworthiness characteristics of laminate frustums with cut‐out and the results were compared with perfect frustum. The study showed that the laminate with cut‐out undergone for inward buckling near the discontinuities. Apart from that, the delamination and outward buckling were noted in the edges of the cut‐outs. The energy absorption of laminate frustum with circular cut‐outs was observed to be better than square cut‐outs. The performance of laminate frustums with cut‐outs was ranked using Technique for Order Preference by Similarity to an Ideal Solution technique. A finite element analysis was carried out to simulate the deformation behavior of laminate frustum with cut‐outs and the numerical results of deformation mode closely represented the experimental results. [ABSTRACT FROM AUTHOR]

In this work, an innovative manufacturing approach that includes a fully linked and integrated manufacturing system consisting of a laser-based directed energy deposition (DED-LB/M) module and a forming press is presented. The alternating additive manufacturing (AM) process is based on a combination of a DED-LB/M process using a laser power of 600 W and a feed rate of 400 mm/min and a subsequent forming process, in which the structure is upset with a hydraulic press using a constant forming force of 500 kN in order to smooth the surface and influence the accuracy of the components. For the generation of a fundamental process understanding, a cuboid, basic shape was chosen as geometry for the investigations. The aim is to improve part properties by applying the process steps to generate part properties, which are superior to solely additive manufactured material. It is shown that the geometry of additive manufactured structures can be adapted, and the top surface can be smoothed due to the forming operation. The mean roughness value Rz decreases up to 50% after the forming operation. The hardness can be increased by work hardening. Of special interest is that the higher hardness can be kept up even though a further DED-LB/M process step and forming operation are applied to the additively manufactured and formed structure again. Finally, an analysis of the new manufacturing approach regarding its potential is given. [ABSTRACT FROM AUTHOR]

In this work, a new welding method, AC-DC hybrid TIG welding, is used to weld 304 stainless steel. Research on the formation, microstructure, and properties of 304 stainless-steel welded joints are studied by using optical microscope and microhardness. The results show that the weld with AC/DC hybrid welding is a fish-scale pattern, and the density of the fish-scale pattern increases with the increase of AC proportion. Both the weld penetration and the ratio of weld penetration to weld width are the highest when AC accounts for 30%. At this point, the weld penetration is 0.83 mm larger than DC mode, an increase of 93.26%, and the ratio of weld penetration to weld width is 1.6, which is 76.19% higher than DC mode. When the proportion of AC is increased, the microstructure of the weld is equiaxed or columnar, and the microstructure of the heat-affected zone is ferrite in the form of lath. The hardness of the weld is greater than that of the base metal, and the hardness of the heat-affected zone is the lowest. The microhardness distribution of the weld with AC 50% is the most uniform. When AC accounts for 20% and 30%, the average weld hardness is the highest, which are 196.7 HV and 198.1 HV, respectively. [ABSTRACT FROM AUTHOR]

A vacuum-assisted sheet former was used for analyzing water removal from refined bleached hardwood kraft pulp furnishes. The Schopper Riegler (SR) values of the studied furnishes ranged from 43 to 97. Water removal time increased significantly with increasing SR value; the water removal time for SR97 furnish was two orders of magnitude longer than for SR43. Retention behaved differently with different SR levels. Retention was approximately constant for SR43 and SR72, for SR85 retention was initially slightly lower, and for SR97 retention was initially very low. The clogging of the wire due to the fines was very strong for SR97. A simple model of flow resistance of the filtered sheet worked very well for SR43 and SR72, and the model worked reasonably well for SR85. However, for higher SR levels, a retention model is needed to predict accurately the water removal in real-life applications.

Drawing operations are commonly used to shape metallic thin-walled products for variety of industries – automotive, aerospace, household appliances etc. The basic indicator characterizing cold drawing process is possibility to decrease weight of a product, while at the same time increasing its stiffness in comparison to other conventional manufacturing technologies such as casting, forging or machining. In this research authors presented results of a numerical study on the influence of parameters such as blankholder pressure, forming force, tooling shape and part shape design on the success in manufacturing a part of complicated shape designed as an element of a phase change material heat accumulator. The subject of wrinkling (first and second degree of buckling) was discussed, and the research presented the manufacturing process design which allowed manufacturing discussed drawpiece without defects and within dimensional tolerances. The paper analyzes the phenomenon of drawpiece folding during the forming process for various groups of materials. Experimental research was carried out on a prototype tool for stainless steel (X5CrNi18-10), aluminum alloy (AW-5754) and copper alloy (CW024A).

Bio Forming in Nature to Create Textile Printing Design for Hospitalization HouseResearch SummaryThe vast universe around us always pushes us to think, contemplate and learn. Nature is the basis on which all sciences and arts are based, and from this standpoint, the inspiration the structural and forming systems of all the vital forms of living creatures around us will enrich the field of textile printing design, especially if our destination is design for psychological support and resisting the repercussions of disease for the recovered and sick to improve their visual environment in the places of receiving treatment ( hospitalization) by applying the requirements of the healing environment and resisting disease through communicating with nature and its aesthetic values, which are derived and inspired by micro and ultrafine morphological details of cells of living organismswith interest in using color that has a positive impact on Human health to design psychologically which supports recoverees from illness . The design aims to meet all human requirements, which vary between functional and psychological requirements, and ignoring one of these requirements is a deficiency in the design process itself. The research problem is summarized in the use of the biological structure of living organisms to find innovative design solutions for textile printing fabrics for hospitalization rooms, which in turn contribute to Psychological support for recovered and sick people.The importance of the research is summarized in the development of a methodology to take advantage of the aesthetic values of biological forms under the microscope as one of the sources of creativity and psychological support for the recovered and sick people, inspiration for the biosynthesis of nature is an important moral message for the recovered and the sick. It is also an important trend for a textile printing designer, in-depth study enables us to understand the laws and relationships that are govern the natural systems around us, so attention must be paid to the designer's role towards his community in its various categories with attention to the psychological aspect of the users and the need to study in depth the modern trends of design and combine them with the design of textile printing.Key words : Bio formation - Hospitalization House

This paper is focused on investigating the mechanisms associated with different failure modes of copper (C101) sandwich panels with honeycomb cores of different heights subjected to flexural loading. Honeycomb core is made up of copper strips which were formed to required shapes using Dies fabricated by Electric Discharge Wire cut machining technique. All the joints in the sandwich panel were established through Brazing technique. Three-point bending test was conducted as per ASTM standard C-393. It was observed that increase in height of the core resulted in panels with higher strength to weight ratio. It also exhibited higher stiffness to weight ratio and very high strain energy absorption ability. An increase in flexural strength was reported with a maximum of 43% improvement for 10.9 mm core compared to 6.9 mm core. Further, 81.75% increase in absorbed strain energy was reported for 10.9 mm thick panel compared to 6.9 mm. The Optical and scanning electron microscope (SEM) analysis confirmed the establishment of good bonding between the filler and the substrate. Energy-dispersive Spectroscopic (EDS) analysis revealed the presence of Cu, Al, Zn, SiO2 and CaCO3 in the substrate. Further it also revealed the presence of Cu, CaCO3 and GaP in the filler material. The failure mode map was constructed which can be used for predicting different types of failures more likely to occur for specific parameters of copper sandwich panel. The dominant failures occurred during testing was in good agreement with the prediction done through failure mode map. The appreciable results in the proposed research may be supportive in construction of cooling system. The structure development and process control are convenient in mass production in automobile industries.

This study reports a counterintuitive antisymmetric deformation behavior during the electrohydraulic sheet-forming process, which is induced by the positional eccentricity of the electrical explosion. The novelty lies in the antisymmetry between the explosion eccentricity and the position of maximum deformation. When the explosion position is eccentric, the sheet metal becomes naturally eccentric; however, herein the position of maximum deformation was found to be far away from the position of the eccentric explosion, instead of being close to it. Herein, a series of simulations was performed to understand the dynamics involved in such behavior. It was found that the shockwave pressure and the inertial force of water medium are two dominant mechanisms for such an antisymmetric phenomenon. The former tends to accelerate the explosion-side sheet region, and the latter tends to accelerate the explosion-opposite-side sheet region. The much longer duration of the inertial force of water finally results in the observed antisymmetric phenomenon. The experimental results of the high-velocity deformation process obtained by using a high-speed camera confirmed the abovementioned findings. This study may aid in better understanding of the process dynamics in the eccentric explosion electrohydraulic forming, and may also help in the process and equipment design. [ABSTRACT FROM AUTHOR]

Flanging is sheet metal forming process which has high-end applications from automobile industry to aircraft industry. Straight, stretch, shrink and hole-flanging are the variations of flanging process flange types. It is found that that market share (revenue) of flanging process in stamping industry will increase by nearly 4 billion USD during the decade of 2013–2024. Coventional stamping, incremental forming, rubber forming, fluid forming, electromagnetic forming are the technologies utilized till date for the formation of flanges. Hole-flanging is the most widely used/applied form of flanging process. Besides this, shrink flanging process finds its applications in automobile and aircraft parts. The objective of the present study deals with critical review and analysis of sheet metal shrink flanging process. Aluminum alloys were used for manufacturing aircraft parts, whereas steel alloys were used for manufacturing car body parts in the making shrink flanged parts. Strain-based models were majorly used in mathematical analysis of shrink flanging process. Shell-based elements were utilized for meshing of sheet metal for FEM analysis of shrink flanging process. Rubber forming was found to be most efficient forming technique for the formation of shrink flange portion parts. Blank shape optimization is carried out by employing FEM simulation topology optimization for shrink flanging process. [ABSTRACT FROM AUTHOR]

The automotive industry has undergone significant advancements and changes over time, resulting in the use of more complex parts in modern vehicles. As a consequence, the parts used in the manufacturing process are subject to higher stress levels, which reduce their service life. To mitigate this issue, surface treatments can be applied to improve the mechanical properties of the tools. In this study, we examined the impact of surface treatments on reducing tool stress during a cold forming process. The process involved reducing the thickness of a sheet from 6 mm to 2.5 mm, which generated high stresses in the tooling. We used finite element stress calculations to analyze the process and found that by reducing the friction coefficient to 0.1, tool stresses can be reduced by 20%, leading to an increase in tool life. Moreover, the press force and tool wear were also reduced by 18%. To validate the theoretical calculations, we performed field tests in a real manufacturing process. [ABSTRACT FROM AUTHOR]

Sheet-metal forming is one of the most important manufacturing processes in the automotive industry. This study proposes a multiobjective optimisation scheme that controls both sheet-metal formability and springback. First, the mechanical properties of DP590 steel were characterised to obtain the mechanical parameters and forming limit diagram (FLD) of DP590. Then, the FLD, thinning rate, and average springback were selected as forming quality evaluation indices. Response surface tests were then conducted for different process parameters for the A-pillar side-stiffener drawing process to analyse the DP590 steel's formability and springback. The optimal process parameters for the drawing process were obtained using a multiobjective optimisation algorithm based on an improved particle swarm method. Finally, a springback compensation scheme was proposed based on the results of the multiprocess simulation. The scheme was applied experimentally to the A-pillar side-stiffener drawing process, and the formability and springback compensation performances verified that the scheme successfully and efficiently eliminated springback and rupture in formed DP590 steel. [ABSTRACT FROM AUTHOR]

This study discusses the development of a numerical simulation model to predict press force and final deformation induced by welding-to-forming process chain with experimental validation. The numerical models of welding and forming were developed in sequence by utilizing two specialized virtual manufacturing software family namely Simufact.Welding (SW) and Simufact.Forming (SF). In the non-linear thermomechanical simulation, the GMAW process was firstly executed on a butt joint of mild steel S235 with thickness of 2 mm followed by bending process whereby the plate and dies geometry were modelled based on the actual dimension and the weld bead geometry was modelled by means of simplified shape. The result of transient welding simulation was transferred to forming which considers the final deformation and effective stress. For achieving realistic transient temperature distribution, the heat transfer coefficients during the welding process were calibrated on specific points measured by using thermocouple with data logger. For verification purpose, a series of comprehensive welding experiments was executed using robotic system followed by the metal bending process using hydraulic press machine. It can be observed at the final deformation results that the difference between simulation using SF-SW and experiment showed an acceptable error percentage within the range of 4 to 12% on each measurement point and up to 7% in average. The press force prediction showed an error percentage of up to 10% at lower-to-medium and up to 17% at high stroke section. Hence, by referring to the results, this study can be applied to select a suitable press machine for this specific coupled process based on estimated load range. [ABSTRACT FROM AUTHOR]

Copyright of Al-Academy is the property of Republic of Iraq Ministry of Higher Education & Scientific Research (MOHESR) and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

Copyright of FORMakademisk is the property of FORMakademisk and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

Abstract—The results of studying the influence of pipe forming on the mechanical properties (ultimate tensile strength, yield strength) of the base metal of large diameter pipes of strength classes K52–K65 (X56–X80) are analyzed. The differences in the properties determined by testing longitudinal and transverse standard cylindrical and full-thickness specimens cut from both a sheet and the finished pipe and plate specimens cut at various distances from the pipe surface (from different layers) are analyzed. The relation between the state of stress in pipe steel at various stages of pipe forming and its mechanical properties is considered. [ABSTRACT FROM AUTHOR]

The main idea behind “Quilted Stratum Process” (QSP®) is to create a flat blank made of unidirectional/woven thermoplastic prepreg patches instead of using uniformly shaped prepreg stack as is the case with standard thermostamping process. Thus, using QSP®; one can manufacture components with complex geometries by using nearly rectangular patches while still maintaining a short cycle time similar to the standard thermostamping process. The use of near-rectangular patches results in a significant material saving which is a necessity for a sustainable product development. During standard thermostamping and/or QSP®; the consolidation phase plays a key role in the strength and quality of the final product. This becomes even more important in the case of unidirectional thermoplastic prepregs where mechanisms such as transverse squeeze flow can impact not only the in-plane dimensions of the prepreg but also the fibre orientations within the prepreg. This work presents a unified modeling approach that combines a novel pinching shell element, a new elasto-plastic constitutive model for pinching shell in order to provide a unified solution to simulate both forming and consolidation-flow using a shell-based approach. This unique unified approach of simulating forming and consolidation provides a set of additional outputs such as the through-thickness stress, final deformed shape of the plies including the squeeze flow effect and the changes in the orientation of fibres within the plies during and after the process. This work finally demonstrates how this information can help the manufacturers to design better tooling based on the outcomes of the numerical process simulation in order to achieve a desired product quality. Additionally, one can also steer the final fibre orientation which results from the initial position of the patch, its forming and squeeze flow.

In the aluminum industry, forming is an important process step that introduces dislocations in the material. To investigate the effect of dislocation retention after ageing on 6xxx-series alloys, a non-heat-treatable 5005 alloy was selected to measure the change in mechanical properties due to dislocation annihilation during dynamic recovery. However, the isothermal ageing treatment led to an unexpected and significant increase in mechanical properties after deformation. Increases in yield strength of 120% and tensile strength of 50% compared with the as-received material were achieved. However, this caused a significant decrease in elongation properties. The deformation start temperature did not have any impact on the final mechanical properties. TEM analysis attributed the increase in mechanical properties to an increased precipitation and dislocation density compared with the undeformed reference material. The precipitates are located along dislocation lines, showing that the solute elements are preferentially segregating to dislocations and precipitating. The precipitates were typical for the Al–Mg–Si(–Cu) system; therefore, the low amounts of Si and, to a lesser extent, Cu were responsible for the precipitation hardening in the 5005 alloy.

This article provides an overview of the latest developments in the field of hybrid additive manufacturing of metal parts. The concept and various kinds of additive manufacturing are discussed. Special attention is paid to hybridization of additive technologies and various processes of forming: die forging, deep drawing, and others. The background and significance of the technologies, as well as their applicability in production are presented. The combination of additive manufacturing with forming processes is carried out with a dual purpose: to expand the area of application of additive manufacturing and overcome its limitations associated with low productivity, metallurgical defects, surface roughness and lack of dimensional accuracy; new application of traditional forming processes.

Additive Manufacturing (AM) offers great potentialities in the medical sector, particularly when part customization is sought after. Maxillofacial surgery has to deal with complex bone fractures and facial reconstructions, hence the need of metallic prostheses to help in the process of bone growth and fracture healing. Commercial prostheses, even if available in different sizes, might not fit the patient's anatomy, and thus should be adapted directly in the operating room. This paper provides an insight on how AM approach, by designing and producing customized prosthesis from computer tomography scan data, can lead to predictable and reliable results reducing the stress on both surgeons and patients. [ABSTRACT FROM AUTHOR]

The pressure fields generated by two simultaneous discharges have not been investigated on any notable scale for the electrohydraulic impulse forming method. In this study, the synchronicity of two discharges is ensured by the sequential connection of two wires mounted in two spark gaps in a common volume of liquid. The objective is to experimentally confirm the equilibrium of the energies evolved in two spark gaps by means of pressure measurements. In addition, multipoint membrane pressure gauges demonstrated the feasibility of easily recording detailed pressure maps. Based on the membrane deformation mechanism and material strengthening under static and impulse conditions, the processing procedure is further developed so as to achieve better accuracy in the determination of pressure field parameters. The practical equality of the pressure fields on the left and right halves of the flat-loaded area confirms the equality of energies evolved in the two spark gaps. The direct shock waves create zones with the most intensive loading. These results provide a basis for the development of new electrohydraulic technologies involving the application of two simultaneous discharges with equal energy and pressure parameters. [ABSTRACT FROM AUTHOR]

Information is presented on the conceptualization, experimental study, and numerical process simulation of tailor heat treated aluminum alloy blanks. This concept is intended to improve the forming behavior of aluminum parts in challenging conditions. The implementation requires precise control of laser heat treatment parameters within a suitable industrial framework. The study details material properties, heat treatment parameters, and experimental results for the strength and elongation properties of an AA6063-T6 aluminum alloy. Constitutive modeling is applied using the Hocket–Sherby equation, which allowed us to establish a correlation between laser heat treatment maximum temperature and the corresponding material softening degree. Based on the generated flow stress–strain curves, a numerical simulation of a representative case study was performed with Abaqus finite element software highlighting potential improvements of tailor heat treated blanks (THTB). The influence and effectiveness of heat-affected zone (HAZ) dimensions and material softening were analyzed. [ABSTRACT FROM AUTHOR]

In the present work, the elevated-temperature deformation characteristics and microstructural evolution of a Ti-5V-5Mo-5Cr-4Al alloy in solution-treatment conditions were studied under a tensile load at temperatures in the range of 25 to 550 °C and strain rates between 0.001 and 0.1 s−1. The results obtained indicated that, essentially, dynamic recovery (DRV) was the dominant softening mechanism in the case of the regimes considered. An analysis based on transmission electron microscopy (TEM) and the assessment of the mechanical behavior of the solution-heat-treated Ti-5V-5Mo-5Cr-4Al alloy revealed that dynamic precipitation (DPN) only took place at a strain rate of 0.001 s−1 and at temperatures of 450 °C and 500 °C. Void coalescence occurred upon an increase in the deformation temperature and a decrease in the strain rate due to a higher rate of diffusion and the provision of sufficient time for growth, respectively. The results obtained in the present study pave the way for the robust processing of this novel β titanium alloy. Depending on the deformation parameters, the deformation characteristics can be governed by either DRV (at moderate temperatures) or DPN (at moderate temperatures and at low rates of deformation). [ABSTRACT FROM AUTHOR]

Multi-point forming (MPF) is an advanced and flexible method to form sheet metal workpieces. Although there are studies investigating different aspects of this method, the studies on the effects of pin diameter on sheet and pin contact on MPF are insufficient. In this study, pins with diameters of 10, 12, and 14 mm were used to investigate the damage factor, effective stress distribution, and required forming loads of three forms of aluminum 1100 parts in finite element simulations. In addition, experimental works were conducted for the 12 mm pin and the forming loads and the thinning on the contact points of pin and formed sheet metal parts were compared with the simulations. The 14 mm pin forming provided the highest effective stress distributions and the damage factors of 0.448, 0.770, and 0.329 were obtained for form1, form2, and form3, respectively. The percentage errors between experimental works and simulations using 12 mm pin forming were calculated as 7.4, 5.1, and 2.4% for all forms 1 to 3. In conclusion, pin diameter was shown to have significant effects on the MPF process. Larger diameter pins resulted in higher loads and tearing of sheet metal. [ABSTRACT FROM AUTHOR]

The study considers a method for forming stiffened monolithic panels by local deformation of the panel ribs. The local deformation is caused by bending moments along the rib towards each other. The goal of the study is to numerically model the forming process of the stiffened monolithic panel utilizing the designed local-impact tool and analyze its effects on the panel, obtaining which experimentally is challenging. The finite element method (FEM) modeling is performed in ANSYS and validated by the experimental forming of a panel made of an aluminum alloy analogous to Al 2024. Simulation results provide deformation, stress, and strain distributions along the panel in loaded and unloaded states for various study cases. Furthermore, the effects of finite panel length, width, and forming process parameters such as applied force couples and single versus successive deformation are numerically investigated and discussed. Performed modeling demonstrates the advantages of the forming with the designed tool in terms of low residual stresses and their distribution. Finally, the analysis suggests future modification of the tool, particularly the shape of its grips, to minimize local residual stress concentrations. [ABSTRACT FROM AUTHOR]