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Future trends in designing lightweight components especially for automotive applications increasingly require complex and delicate structures with highest possible level of capacity [1]. The manufacturing of metallic car body components is primarily realized by deep or stretch drawing. The forming process of especially cold rolled and large-sized components is typically characterized by inhomogeneous stress and strain distributions. As a result, the avoidance of undesirable deep drawing effects like earing and local necking is among the greatest challenges in forming complex car body structures [2]. Hence, a novel local laser-treatment approach with the objective of customizing the forming behavior of car body steel sheets is currently explored. [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 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]

Experimental and numerical investigations on the forming limit diagram (FLD) of a ferritic stainless steel were performed in this study. The FLD of this material was obtained by Nakajima tests. Both the Marciniak-Kuczynski (MK) model and the modified maximum force criterion (MMFC) were used for the theoretical prediction of the FLD. From the results of uniaxial tensile tests along different loading directions with respect to the rolling direction, strong anisotropic plastic behaviour was observed in the investigated steel. A recently proposed anisotropic evolving non-associated Hill48 (enHill48) plasticity model, which was developed from the conventional Hill48 model based on the non-associated flow rule with evolving anisotropic parameters, was adopted to describe the anisotropic hardening behaviour of the investigated material. In the previous study, the model was coupled with the MMFC for FLD prediction. In the current study, the enHill48 was further coupled with the MK model. By comparing the predicted forming limit curves with the experimental results, the influences of anisotropy in terms of flow rule and evolving features on the forming limit prediction were revealed and analysed. In addition, the forming limit predictive performances of the MK and the MMFC models in conjunction with the enHill48 plasticity model were compared and evaluated. [ABSTRACT FROM AUTHOR]

During the last decade, the stainless steel market showed a growing volume of 3-5% p.a.. The austenitic grades are losing market shares to ferritic or 200-series grades due to the high nickel price, but still playing the most important role within the stainless steel market. Austenitic stainless steel is characterized by the strain-induced martensite formation, causing the TRIP-effect (Transformation Induced Plasticity) which is responsible for good formability and high strength. The TRIP-effect itself is highly dependent on the forming temperature, the strain as well as the chemical composition which has a direct influence on the stability of the austenite. Today the austenitic stability is usually characterized by the so called Md30-temperature, which was introduced by Angel and enhanced by several researches, particularly Nohara. It is an empirical formula based on the chemical composition and the grain size of a given material, calculating the temperature which is necessary to gain a 50 % martensite formation after 30 % of elongation in a tensile test. A higher Md30-temperature indicates a lower stability and therefore a higher tendency towards martensite formation. The main disadvantage of Md30 -temperature is the fact that it is not based on forming parameters and only describes a single point instead of the whole forming process. In this paper, an experimental set up for measuring martensite and temperature evolution in a non-isothermal tensile test is presented, which is based on works of Hänsel and Schmid. With this set up, the martensite formation rate for different steels of the steel grade EN 1.4301 and EN 1.4310 is measured. Based on these results a new austenitic stability criterion is defined. This criterion and the determined Md30-temperatures are related to the stretch formability of the materials. The results show that the new IFU criterion is with regard to the formability a much more useful characteristic number for metastable austenitic steels than the Md30-temperature. [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]

Forming of automotive sheet metal body panels is a complex process influenced by both the material properties and contact conditions in the forming tooling. Material properties are described by the material constitutive behavior and the material flow into the forming die can be described by the tribological system. This paper investigates the prediction accuracy of the forming process using the Tata Steel state of the art description of the material constitutive behavior in combination with different friction models. A cross-die experiment is used to investigate the accuracy of local deformation modes typically seen in automotive sheet metal forming operations. Results of advanced friction models as well as the classical Coulomb friction description are compared to the experimentally measured strain distribution and material draw-in. Two hot-dip galvanized coated steel forming grades were used for the investigations. The results show that the accuracy of the simulation is not guaranteed by the advanced friction models for the entire investigated blank holder force range, both globally and locally. A measurable difference between the calculated and measured local strains is seen for both studied models even in the case where the global indicator, i.e. the draw-in, is well predicted. [ABSTRACT FROM AUTHOR]

Tube hydroforming is one of the most important manufacturing processes for the production of exhaust systems. Tube hydroforming allows generating parts with highly complex geometries with the forming accuracies needed in the automotive sector. This is possible due to the form-closed nature of the production process. One of the main cost drivers is tool manufacturing, which is expensive and time consuming, especially when forming large parts. To cope with the design trend of individuality, which is gaining more and more importance and leads to a high number of product variants, a new flexible tool design was developed. The designed tool offers a high flexibility in manufacturing different shapes and geometries of tubes with just local alterations and relocation of tool segments. The tolerancing problems that segmented tools from the state of the art have are overcome by an innovative and flexible die holder design. The break-even point of this initially more expensive tool design is already overcome when forming more than 4 different tube shapes. Together with an additionally designed rotary hydraulic tube feeding system, a highly adaptable forming setup is generated. To investigate the performance of the developed tool setup, a study on geometrical and process parameters during forming of a spherical dome was done. Austenitic stainless steel (grade 1.4301) tube with a diameter of 40 mm and a thickness of 1.5 mm was used for the investigations. The experimental analyses were supported by finite element simulations and statistical analyses. The results show that the flexible tool setup can efficiently be used to analyze the interaction of the inner pressure, friction, and the location of the spherical dome and demonstrate the high influence of the feeding rate on the formed part. [ABSTRACT FROM AUTHOR]

Metal/polymer/metal sandwich sheets have recently attracted the interests of industries like automotive industry. These sandwich sheets have superior properties over single-layer metallic sheets including good sound and vibration damping and light weight. However, the formability of these sandwich sheets should be enhanced which requires more research. In this paper, the formability of Bondal sheet (DC06/viscoelastic polymer/DC06 sandwich sheet) was studied through different types of experiments. The mechanical properties of Bondal were determined by uniaxial tensile tests. Hemispherical punch stretching and hydraulic bulge tests were carried out to determine the forming limit diagram (FLD) of Bondal. Furthermore, cylindrical and square cup drawing tests were performed in dry and oil lubricated conditions. These tests were conducted at different blank holding forces (BHFs). An interesting observation about Bondal sheet deep drawing was obtaining of higher drawing depths at dry condition in comparison with oil-lubricated condition. [ABSTRACT FROM AUTHOR]

Complex shaped stainless steel tubes are often required for special purpose biomedical equipment. Nevertheless, traditional manufacturing technologies, such as extrusion, lack the ability to compete in a market of customized complex components because of associated expenses towards tooling and extrusion presses. To rapid manufacture few of such components with low cost and high precision, a new Extrusion based Additive Manufacturing (EAM) process, is proposed in this paper, and as an example, short stainless steel 316L complex shaped and sectioned tubes were prepared by EAM. Several sample parts were produced using this process; the dimensional stability, surface roughness and chemical composition of sintered samples were investigated to prove process competence. The results indicate that feedstock with a 316L particle content of 92.5 wt. % can be prepared with a sigma blade mixing, whose rheological behavior is fit for EAM. The green samples have sufficient strength to handle them for subsequent treatments. The sintered samples considerably shrunk to designed dimensions and have a homogeneous microstructure to impart mechanical strength. Whereas, maintaining comparable dimensional accuracy and chemical composition which are required for biomedical equipment still need iterations, a kinematic correction and modification in debinding cycle was proposed. [ABSTRACT FROM AUTHOR]

As lightweight design as well as crash performance are crucial to future car body design, exact material characterisation is important to use materials at their full potential and reach maximum efficiency. Within the scope of this paper, the potential of newly established bending-tension test procedure to characterise material crashworthiness is investigated. In this test setup for the determination of material failure, a buckling-bending test is coupled with a subsequent tensile test. If prior bending load is critical, tensile strength and elongation in the subsequent tensile test are dramatically reduced. The new test procedure therefore offers an applicable definition of failure as the incapacity of energy consumption in subsequent phases of the crash represents failure of a component. In addition to that, the correlation of loading condition with actual crash scenarios (buckling and free bending) is improved compared to three- point bending test. The potential of newly established bending-tension test procedure to characterise material crashworthiness is investigated in this experimental studys on two aluminium sheet alloys. Experimental results are validated with existing ductility characterisation from edge compression test. [ABSTRACT FROM AUTHOR]

The electron beam additive manufacturing process with wire is a part of global trend to find fast and efficient methods for producing complex shapes elements from costly metal alloys such as stainless steels, nickel alloys, titanium alloys etc. whose production by other conventional technologies is unprofitable or technically impossible. Demand for additive manufacturing is linked to the development of new technologies in the automotive, aerospace and machinery industries. The aim of the presented work was to carried out research on electron beam additive manufacturing with a wire as a deposited (filler) material. The scope of the work was to investigate the influence of selected technological parameters such as: wire feed rate, beam current, travelling speed, acceleration voltage on stability of the deposition process and geometric dimensions of the padding welds. The research revealed that, at low beam currents, the deposition process is unstable. The padding weld reinforcement is non-uniform. Irregularity of the width, height and straightness of the padding welds can be observed. At too high acceleration voltage and beam current, burn-through of plate and excess penetration weld can be revealed. The achieved results and gained knowledge allowed to produce, based on EBAM with wire process, whole structure from stainless steel. [ABSTRACT FROM AUTHOR]

The bending limit or minimum bending radius of sheet metal is conventionally measured in a wiping (swing arm) or in a vee bend test and reported as the minimum radius of the tool over which the sheet can be bent without fracture. Frequently the material kinks while bending so that the actual inner bend radius of the sheet metal is smaller than the tool radius giving rise to inaccuracy in these methods. It has been shown in the previous studies that conventional bend test methods may under-estimate formability in bending dominated processes such as roll forming. A new test procedure is proposed here to improve understanding and measurement of fracture in bending and roll forming. In this study, conventional wiping test and vee bend test have been performed on martensitic steel to determine the minimum bend radius. In addition, the vee bend test is performed in an Erichsen sheet metal tester equipped with the GOM Aramis system to enable strain measurement on the outer surface during bending. The strain measurement before the onset of fracture is then used to determine the minimum bend radius. To compare this result with a technological process, a vee channel is roll formed and in-situ strain measurement carried out with the Vialux Autogrid system. The strain distribution at fracture in the roll forming process is compared with that predicted by the conventional bending tests and by the improved process. It is shown that for this forming operation and material, the improved procedure gives a more accurate prediction of fracture. [ABSTRACT FROM AUTHOR]

Multi-point forming MPF is an innovative technology of manufacturing complex thick sheet metal products without the need for solid tools. The central component of this system is a pair of the desired discrete matrices of punches, and die surface constructed by changing the positions of the tools though CAD and a control system. Because reconfigurable discrete tools are used, part-manufacturing costs are reduced and manufacturing time is shorten substantially. Firstly, in this work we develop constitutive equations which couples isotropic ductile damage into various flow stress based on the Continuum Damage Mechanic theory. The modified Johnson-Cook flow model fully coupled with an isotropic ductile damage is established using the quasi-unilateral damage evolution for considering both the open and the close of micro-cracks. During the forming processes severe mesh distortion of elements occur after a few incremental forming steps. Secondly, we introduce 3D adaptive remeshing procedure based on linear tetrahedral element and geometrical/physical errors estimation to optimize the element quality, to refine the mesh size in the whole model and to adapt the deformed mesh to the tools geometry. Simulation of the MPF process (see Fig. 1) and the unloading spring-back are carried out using adaptive remeshing scheme using the commercial finite element package ABAQUS and OPTIFORM mesher. Subsequently, influencing factors of MPF spring-back are researched to investigate the MPF spring-back tendency with the proposed remeshing procedure. [ABSTRACT FROM AUTHOR]

Processing conditions play a crucial role for the resulting microstructure and properties of the material. In particular, processing materials under non-equilibrium conditions can lead to a remarkable improvement of the final properties [1]. Additive manufacturing represents a specific process example considered in this study. Models for the prediction of residual stresses and microstructure in additive manufacturing processes, such as laser metal deposition, are being developed with huge efforts to support the development of materials and processes as well as to support process design [2-4]. Since the microstructure predicted after each heating and cooling cycle induced by the moving laser source enters the phase transformation kinetics and microstucture evolution of the subsequent heating and cooling cycle, a feed-back loop for the microstructure calculation is created. This calculation loop may become unstable so that the computed microstructure and related properties become very sensitive to small variations in the input parameters, e.g. thermal conductivity. In this paper, a model for phase transformation in Ti-6Al-4V, originally proposed by Charles Murgau et al. [5], is adopted and minimal adjusted concerning the decomposition of the martensite phase are made. This model is subsequently used to study the changes in the predictions of the different phase volume fractions during heating and cooling under the conditions of laser metal deposition with respect to slight variations in the thermal process history. [ABSTRACT FROM AUTHOR]

Curve offsets are utilized in different fields of engineering and science. Additive manufacturing, which lately becomes an explicit requirement in manufacturing industry, utilizes curve offsets widely. One of the necessities of offsetting is for scaling which is required if there is shrinkage after the fabrication or if the surface quality of the resulting part is unacceptable. Therefore, some post-processing is indispensable. But the major application of curve offsets in additive manufacturing processes is for generating head trajectories. In a point-wise AM process, a correct tool-path in each layer can reduce lots of costs and increase the surface quality of the fabricated parts. In this study, different curve offset generation algorithms are analyzed to show their capabilities and disadvantages through some test cases and improvements on their drawbacks are suggested. [ABSTRACT FROM AUTHOR]

The aim of this work is to address a modeling of the SLS process at the scale of the part in PA12 polymer powder bed. The powder bed is considered as a continuous medium with homogenized properties, meanwhile understanding multiple physical phenomena occurring during the process and studying the influence of process parameters on the quality of final product. A thermal model, based on enthalpy approach, will be presented with details on the multiphysical couplings that allow the thermal history: laser absorption, melting, coalescence, densification, volume shrinkage and on numerical implementation using FV method. The simulations were carried out in 3D with an in-house developed FORTRAN code. After validation of the model with comparison to results from literature, a parametric analysis will be proposed. Some original results as densification process and the thermal history with the evolution of the material, from the granular solid state to homogeneous melted state will be discussed with regards to the involved physical phenomena. [ABSTRACT FROM AUTHOR]

3D printing created a totally new manufacturing possibilities. It is possible e.g. to produce closed inner shapes with different geometrical features. Unfortunately traditional methods are not suitable to verify the manufacturing accuracy, because it would be necessary to cut workpieces. In the paper the possibilities of computed tomography (x-ray micro-CT) application for accuracy assessment of inner shapes are presented. This was already reported in some papers. For research works hollow cylindrical samples with 20mm diameter and 300mm length were manufactured by means of FDM. A sphere, cone and cube were put inside these elements. All measurements were made with the application of CT. The measurement results enable us to obtain a full geometrical image of both inner and outer surfaces of a cylinder as well as shapes of inner elements. Additionally, it is possible to inspect the structure of a printed element – size and location of supporting net and all the other supporting elements necessary to hold up the walls created over empty spaces. The results obtained with this method were compared with CAD models which were a source of data for 3D printing. This in turn made it possible to assess the manufacturing accuracy of particular figures inserted into the cylinders. The influence of location of the inner supporting walls on a shape deformation was also investigated. The results obtained with this way show us how important CT can be during the assessment of 3D printing of objects. [ABSTRACT FROM AUTHOR]

This study presents our fundamental study to understand the crystal formation in rapid cooling of cubic crystalline alloys (namely, 316L steel and NiCoCrFeMn) and how crystal microstructure evolves during the repeated deposition of material in powder-bed laser melting. The rapid cooling results in extremely fine rod-like cells. Cells in a fresh meltpool epitaxially grow from existing grains in the substrate (or existing cells in previously solidified meltpools). It is found that the orientation of existing crystals and the thermal gradient are two governing variables for the evolution of cells in meltpools. [ABSTRACT FROM AUTHOR]

Additive-manufacturing technologies have been gaining tremendously in popularity for some years in the production of single-part series with complex, close-to-final-contour geometries and the processing of special or hybrid materials. In principle, the processes can be subdivided into wire-based and powder-based processes in accordance with the Association of German Engineers (VDI) Guideline 3405. A further subdivision is made with respect to the smelting technology. In all of the processes, the base material is applied in layers at the points where it is needed in accordance with the final contour. The process that was investigated was wire-based, multi-pass welding by means of gas–metal arc welding. This was accomplished in the present study by determining the material parameters (thermo-mechanical and thermo-physical characteristics) of the welding filler G3Si1 (material number: 1.5125) that were necessary for the numerical simulation and implementing them in a commercial FE program (MSC Marc Mentat). The focus of this paper was on simulation and validation with respect to geometry and microstructural development in the welding passes. The resulting minimal deviation between reality and simulation was a result of the measurement inertia of the thermocouples. In general, however, the FE model can be used to make a very good predetermination of the cooling behaviour, which affects the microstructural development and thus the mechanical properties of the joining zone, as well as the geometric design of the component (distortion, etc.). [ABSTRACT FROM AUTHOR]

Additive Manufacturing (AM) differs from traditional manufacturing technologies by its ability to handle complex shapes with great design flexibility. These features make the technique suitable to fabricate customized components, particularly answering specific custom needs. Although AM mainly referred to prototyping, nowadays the interest in direct manufacturing of actual parts is growing. This article shows the application of AM within the project 3DP-4H&W (3D Printing for Health & Wealth) which involves engineers and physicians for developing pediatric custom-made medical devices to enhance the fulfilling of the patients specific needs. In the project, two types of devices made of a two-component biocompatible silicone are considered. The first application (dental field) consists in a device for cleft lip and palate. The second one (audiological field) consists in an acoustic prosthesis. The geometries of the devices are based on the anatomy of the patient that is obtained through a 3D body scan process. For both devices, two different approaches were planned, namely direct AM and indirect Rapid Tooling (RT). In particular, direct AM consists in the FDM processing of silicone, while RT consists in molds FDM fabrication followed by silicone casting. This paper presents the results of the RT method that is articulated in different phases: the acquisition of the geometry to be realized, the design of the molds taking into account the casting feasibility (as casting channel, vents, part extraction), the realization of molds produced through AM, molds surface chemical finishing, pouring and curing of the silicone. The fabricated devices were evaluated by the physicians team that confirmed the effectiveness of the proposed procedure in fabricating the desired devices. Moreover, the procedure can be used as a general method to extend the range of applications to any custom-made device for anatomic districts, especially where complex shapes are present (as tracheal or maxillary prostheses). [ABSTRACT FROM AUTHOR]

The paper deals with analysis and selection of parameters of rapid prototyping of gears by selective sintering of metal powders. Presented results show wide spectrum of application of RP systems in manufacturing processes of machine elements, basing on analysis of market in term of application of additive manufacturing technology in different sectors of industry. Considerable growth of these methods over the past years can be observed. The characteristic errors of printed model with respect to ideal one for each technique were pointed out. Special attention was paid to the method of preparation of numerical data CAD/STL/RP. Moreover the analysis of manufacturing processes of gear type elements was presented. The tested gears were modeled with different allowances for final machining and made by DMLS. Metallographic analysis and strength tests on prepared specimens were performed. The above mentioned analysis and tests were used to compare the real properties of material with the nominal ones. To improve the quality of surface after sintering the gears were subjected to final machining. The analysis of geometry of gears after hybrid manufacturing method was performed (fig.1). The manufacturing process was defined in a traditional way as well as with the aid of modern manufacturing techniques. Methodology and obtained results can be used for other machine elements than gears and constitutes the general theory of production processes in rapid prototyping methods as well as in designing and implementation of production. [ABSTRACT FROM AUTHOR]

Additive manufacturing is growing faster and faster. This leads us to study the functionalization of the parts that are produced by these processes. Electron Beam melting (EBM) is one of these technologies. It is a powder based additive manufacturing (AM) method. With this process, it is possible to manufacture high-density metal parts with complex topology. One of the big problems with these technologies is the surface finish. To improve the quality of the surface, some finishing operations are needed. In this study, the focus is set on chemical polishing. The goal is to determine how the chemical etching impacts the dimensional accuracy and the surface roughness of EBM parts. To this end, an experimental campaign was carried out on the most widely used material in EBM, Ti6Al4V. Different exposure times were tested. The impact of these times on surface quality was evaluated. To help predicting the excess thickness to be provided, the dimensional impact of chemical polishing on EBM parts was estimated. 15 parts were measured before and after chemical machining. The improvement of surface quality was also evaluated after each treatment. [ABSTRACT FROM AUTHOR]

Extrusion is one of the oldest manufacturing processes; it is widely used for manufacturing finished and semi-finished products. Moreover, extrusion is also the main process in additive manufacturing technologies such as Fused Filament Fabrication (FFF). In FFF process, the parts are manufactured layer by layer using thermoplastic material. The latter in form of filament, is melted in the liquefier and then it is extruded and deposited on the previous layer. The mechanical properties of the printed parts rely on the coalescence of each extrudate with another one. The coalescence phenomenon is driven by the flow properties of the melted polymer when it comes out the nozzle just before the deposition step. This study aims to master the quality of the printed parts by controlling the effect of the parameters of the extruder on the flow properties in the FFF process. In the current study, numerical simulation of the polymer coming out of the extruder was carried out using Computational Fluid Dynamics (CFD) and two phase flow (TPF) simulation Level Set (LS) method by 2D axisymmetric module of COMSOL Multiphysics software. In order to pair the heat transfer with the flow simulation, an advection-diffusion equation was used. Advection-diffusion equation was implemented as a Partial Differential Equation (PDE) in the software. In order to define the variation of viscosity of the polymer with temperature, the rheological behaviors of two thermoplastics were measured by extensional rheometer and using a parallel-plate configuration of an oscillatory rheometer. The results highlight the influence of the environment temperature and the cooling rate on the temperature and viscosity of the extrudate exiting from the nozzle. Moreover, the temperature and its corresponding viscosity at different times have been determined using numerical simulation. At highest shear rates, the extrudate undergoes deformation from typical cylindrical shape. These results are required to predict the coalescence of filaments, a step towards understanding the mechanical properties of the printed parts. [ABSTRACT FROM AUTHOR]

Direct laser metal deposition is one of the material additive manufacturing processes used to produce complex metallic parts. A thorough understanding of the underlying physical phenomena is required to obtain a high-quality parts. In this work, a mathematical model is presented to simulate the coaxial laser direct deposition process tacking into account of mass addition, heat transfer, and fluid flow with free surface and melting. The fluid flow in the melt pool together with mass and energy balances are solved using the Computational Fluid Dynamics (CFD) software NOGRID-points, based on the meshless Finite Pointset Method (FPM). The basis of the computations is a point cloud, which represents the continuum fluid domain. Each finite point carries all fluid information (density, velocity, pressure and temperature). The dynamic shape of the molten zone is explicitly described by the point cloud. The proposed model is used to simulate a single layer cladding. [ABSTRACT FROM AUTHOR]

Laser additive manufacturing (LAM) has become increasingly popular in industry in recent decades because it enables exceptional degrees of freedom regarding the structural design of lightweight components compared to subtractive manufacturing techniques. Laser metal deposition (LMD) of wire-fed material shows in particular the advantages such as high process velocity and efficient use of material compared to other LAM processes. During wire-based LMD, the material is deposited onto a substrate and supplemented by successive layers allowing a layer-wise production of complex three-dimensional structures. Despite the increased productivity of LMD, regarding the ability to process aluminium alloys, there is still a lack in quality and reproducibility due to the inhomogeneous temperature distribution during the process, leading to undesired residual stresses, distortions and inconsistent layer geometries and poor microstructures. In this study, the aluminium alloy AA5087 as wire and AA5754 as substrate material were utilized for LMD. In order to obtain information about the temperature field during LMD, thermocouple and thermography measurements were performed during the process. The temperature measurements were used to validate a finite element model regarding the heat distribution, which will be further used to investigate the temperature field evolution over time. To consider the continuous addition of material within the FE-model, an inactive/active element approach was chosen, where initially deactivated elements are activated corresponding to the deposition of material. The first results of the simulation and the experiments show good agreement. Therefore, the model can be used in the future for LMD process optimization, e.g., in terms of minimizing local variations of the thermal load for each layer. [ABSTRACT FROM AUTHOR]

Current research activities at the Institute for Metal Forming Technology of the University of Stuttgart are focusing on the manufacturing of hybrid components using semi-solid forming strategies. One process investigated is the joining of different materials in the semi-solid state and is so called “thixojoining”. In this process, metallic inlays are inserted into the semi-solid forming die before the actual forming process and are then joined with a material which was heated up to its semi-solid state. Earlier investigations have shown that using this process a very well-shaped form closure can be produced. Furthermore, it was found that sometimes intermetallic phases are built between the different materials, which decisively influence the part properties of such hybrid components for its future application. Within the framework presented in this paper, inlays made of aluminum, brass and steel were joined with aluminum in the semi-solid state. The aim of the investigations was to create an intermetallic bond between the different materials. For this investigations the liquid phase fraction of the aluminum and the temperature of the inlay were varied in order to determine the influence on the formation of the intermetallic phase. Forming trials were performed using a semi-solid forming die with a disk shaped design. Furthermore, the intermetallic phase built was investigated using microsections. [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]

In the scope of this study, an alternative automated method to the conventional design and fabrication pipeline of 3D printers is developed by using an integrated CAD/CAE/CAM approach. It increases the load carrying capacity of the parts by constructing heterogeneous infill structures. Traditional CAM software of Additive Manufacturing machinery starts with a design model in STL file format which only includes data about the outer boundary in the triangular mesh form. Depending on the given infill percentage, the algorithm running behind constructs the interior of the artifact by using homogeneous infill structures. As opposed to the current CAM software, the proposed method provides a way to construct heterogeneous infill structures with respect to the Von Misses stress field results obtained from a finite element analysis. Throughout the work, Rhinoceros3D is used for the design of the parts along with Grasshopper3D, an algorithmic design tool for Rhinoceros3D. In addition, finite element analyses are performed using Karamba3D, a plug-in for Grasshopper3D. According to the results of the tensile tests, the method offers an improvement of load carrying capacity about 50% compared to traditional slicing algorithms of 3D printing. [ABSTRACT FROM AUTHOR]

Metal-ceramic Interpenetrating Phase Composites (IPC) belong to a special subcategory of composite materials and reveal enhanced properties compared to conventional composite materials. Currently, IPC are produced by infiltration of a ceramic open-pore body with liquid metal applying high pressure and I or high temperature to avoid residual porosity. However, these IPC are not able to gain their complete potential, because of structural damages and interface reactions occurring during the manufacturing process. Compared to this, the manufacturing of IPC using the semi-solid forming technology offers great perspectives due to relative low processing temperatures and reduced mechanical pressure. In this context, this paper is focusing on numerical investigations conducted by using the FLOW-3D software for gaining a deeper understanding of the infiltration of open-pore bodies with semi-solid materials. For flow simulation analysis, a geometric model and different porous media drag models have been used. They have been adjusted and compared to get a precise description of the infiltration process. Based on these fundamental numerical investigations, this paper also shows numerical investigations that were used for basically designing a semi-solid forming tool. Thereby, the development of the flow front and the pressure during the infiltration represent the basis of the evaluation. The use of an open and closed tool cavity combined with various geometries of the upper die shows different results relating to these evaluation arguments. Furthermore, different overflows were designed and its effects on the pressure at the end of the infiltration process were investigated. Thus, this paper provides a general guideline for a tool design for manufacturing of metal-ceramic IPC using semi-solid forming. [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]

Titanium coatings are very attractive to several industrial fields, especially aeronautics, due to the enhanced corrosion resistance and wear properties as well as improved compatibility with carbon fiber reinforced plastic (CFRP) materials. Cold sprayed titanium coatings, among the others deposition processes, are finding a widespread use in high performance applications, whereas post-deposition treatments are often used to modify the microstructure of the cold-sprayed layer. Laser treatments allow one to noticeably increase the superficial properties of titanium coatings when the process parameters are properly set. On the other hand, the high heat input required to melt titanium particles may result in excessive temperature increase even in the substrate. This paper introduces a thermo-mechanical model to simulate the laser treatment effects on a cold sprayed titanium coating as well as the aluminium substrate. The proposed thermo-mechanical finite element model considers the transient temperature field due to the laser source and applied boundary conditions using them as input loads for the subsequent stress-strain analysis. Numerical outcomes highlighted the relevance of thermal gradients and thermally induced stresses and strains in promoting the damage of the coating. [ABSTRACT FROM AUTHOR]

This work illustrates the material characterization to realize of a prototypal polymeric cover of a Digital Optical Module for the Hyper-Kamiokande neutrino experiment. The cover was made of a high transmittance poly-methyl methacrylate (PMMA), used as a glass substitute. The main objective of the present research is to investigate the structural and optical properties of PMMA, evaluating the respect of the project specification. [ABSTRACT FROM AUTHOR]

This work examines the optical properties of polyethylene terephthalate (PET) bottles during the stretch-blow-moulding (SBM) process. PET has a relatively large process window with regards to process parameters, however if the boundaries are pushed, the resultant bottle can become insufficient for consumer requirements. One aspect of this process is the onset of pearlescence in the bottle material, where the bottle becomes opaque due to elevated stress whitening. Experimental trials were carried out using a modified free-stretch-blow machine where the deforming bottle was examined in free air. The strain values of the deformation were measured using digital image correlation (DIC) and the optical properties were measured relative to the initial amorphous PET preform. The results reveal that process parameters can significantly affect pearlescence. The detrimental level of pearlescence may be predicted therefore reducing the probability of poorly formed bottles. [ABSTRACT FROM AUTHOR]

The main objective of the presented work is to evaluate the thermal behavior of Poly-lactic acid (PLA) parts made with a Fused Deposition Modelling (FDM) process. By using a robust framework for the testing sequence of PLA parts, with the aim of establishing a standard testing cycle for the optimization of the part performance and quality. The research involves study the materials before and after 3D printing. Two biodegradable PLA polymers are investigated, characterized by different colors (one black and the other transparent). The study starts with the examination of each polymeric material and measurements of its main thermal properties. [ABSTRACT FROM AUTHOR]

The conventional method of cooling during the rotational moulding process is through the use of forced air. During the cooling phase of a typical rotomoulding cycle, large volumes of high velocity room temperature air are forced across the outside of the rotating rotomoulding tool to encourage cooling of the metal mould and molten polymer. Since no cooling is applied to the inside of the mould, the inner surface of the polymer (polyethylene) cools more slowly and will have a tendency to be more crystalline and the polyethylene will have a higher density in this region. The side that cools more quickly (in contact with the inside mould wall) will be less crystalline, and will therefore have a lower density. The major consequence of this difference in crystallinity will be a buildup of internal stresses producing warpage and excessive shrinkage of the part with subsequent increased levels of scrap. Therefore excessive cooling on the outside of the mould should be avoided. One consequence of this effect is that the cooling time for a standard rotationally moulded part can be quite long and this has an effect on the overall economics of the process in terms of part manufacture. A number of devices are currently on the market to enhance the cooling of rotational moulding by introducing a water spray to the inside of the rotomoulding during cooling. This paper reports on one such device ’Rotocooler’ which during a series of initial industrial trials has been shown to reduce the cycletime by approximately 12 to 16%, with minimal effect on the mechanical properties, leading to a part which has less warpage and shrinkage than a conventionally cooled part. [ABSTRACT FROM AUTHOR]

The thermo-mechanical behavior of polymer matrix materials is strongly dependent on the curing reaction as well as temperature and time. To date, investigations of epoxy resins and their composites mainly focused on the elastic domain because plastic deformation of cross-linked polymer networks was considered as irrelevant or not feasible. This paper presents a novel approach which combines both elastic and plastic domain. Based on an analytical framework describing the storage modulus, analogous parameter combinations are defined in order to reduce complexity when variations in temperature, strain rate and degree of cure are encountered. [ABSTRACT FROM AUTHOR]

In this work, an ultrasound-aided ejection system was designed and tested for different polymers (PS, COC and POM) and mold topographies. The proposed solution aims at reducing the ejection friction by decreasing the adhesion component of the frictional force, which is controlled by the contact area developed during the filling stage of the injection molding process. The experimental results indicate a positive effect of ultrasound vibration on the friction force values, with a maximum reduction of 16. Moreover, it is demonstrated that the ultrasound effect is strictly related to both polymer selection and mold roughness. The combined effect on the ejection force of mold surface roughness, melt viscosity during filling and polymer elastic modulus at ejection was modeled to the experimental data, in order to demonstrate that the effect of ultrasound vibration on the ejection friction reduction is due to the heating of the contact interface and the consequent reduction of the polymer elastic modulus. [ABSTRACT FROM AUTHOR]

Selective Laser Sintering process is one of the additive manufacturing techniques in which parts are manufactured layer by layer. During such process, gas bubbles are formed in the melted polymer due to faster polymer grains coalescence at surface than deeper in the powder bed. Although gas diffusion is possible through the polymer melt, it’s usual that some porosities remain in the final part if their initial sizes are too big and solidification time too short. In this contribution, a bubble dissolution model involving fluid dynamics and mass transport has been developed to study factors affecting porosity resorption kinetic. In this model, gas diffusion follows Fick’s laws and the melted polymer is supposed Newtonian. At the polymer/gas interface, surface tension is considered and Henry’s law is used to relate the partial pressure of gas with its concentration in the fluid. This problem is solved numerically by means of the finite element method in 1D. After validation of the numerical tool, the influence on dissolution time of several parameters (e.g. the initial size and form of gas porosities, the viscosity, the diffusion coefficient, the surface tension constant or the ambient pressure) has been examined. [ABSTRACT FROM AUTHOR]

Boron doped diamond materials, which are generated by Chemical Vapor Deposition (CVD), offer a great potential for the application on highly stressed tools, e. g. in cutting or forming processes. As a result of the CVD process rough surfaces arise, which require a finishing treatment in particular for the application in forming tools. Cutting techniques such as milling and grinding are hardly applicable for the finish machining because of the high strength of diamond. Due to its process principle of ablating material by melting and evaporating, Electrical Discharge Machining (EDM) is independent of hardness, brittleness or toughness of the workpiece material. EDM is a suitable technology for machining and structuring CVD diamond, since boron doped CVD diamond is electrically conductive. In this study the ablation characteristics of boron doped CVD diamond by micro electrical discharge machining are investigated. Experiments were carried out to investigate the influence of different process parameters on the machining result. The impact of tool-polarity, voltage and discharge energy on the resulting erosion geometry and the tool wear was analyzed. A variation in path overlapping during the erosion of planar areas leads to different microstructures. The results show that micro EDM is a suitable technology for finishing of boron doped CVD diamond. [ABSTRACT FROM AUTHOR]

Multi-layer skin-foam and skin-foam-skin sandwich constructions are of increasing interest in the rotational moulding process for two reasons. Firstly, multi-layer constructions can improve the thermal insulation properties of a part. Secondly, foamed polyethylene sandwiched between solid polyethylene skins can increase the mechanical properties of rotationally moulded structural components, in particular increasing flexural properties and impact strength (IS). The processing of multiple layers of polyethylene and polyethylene foam presents unique challenges such as the control of chemical blowing agent decomposition temperature, and the optimisation of cooling rates to prevent destruction of the foam core; therefore, precise temperature control is paramount to success. Long cooling cycle times are associated with the creation of multi-layer foam parts due to their insulative nature; consequently, often making the costs of production prohibitive. Devices such as Rotocooler®, a rapid internal mould water spray cooling system, have been shown to have the potential to significantly decrease cooling times in rotational moulding. It is essential to monitor and control such devices to minimise the warpage associated with the rapid cooling of a moulding from only one side. The work presented here demonstrates the use of threaded thermocouples to monitor the polymer melt in multi-layer sandwich constructions, in order to analyse the cooling cycle of multi-layer foamed structures. A series of polyethylene skin-foam test mouldings were produced, and the effect of cooling medium on foam characteristics, mechanical properties, and process cycle time were investigated. Cooling cycle time reductions of 45%, 26%, and 29% were found for increasing (1%, 2%, and 3%) chemical blowing agent (CBA) amount when using internal water cooling technology from ∼123°C compared with forced air cooling (FAC). Subsequently, a reduction of IS for the same skin-foam parts was found to be 1%, 4%, and 16% compared with FAC. [ABSTRACT FROM AUTHOR]

The great influence of temperature on polymer’s behavior is well known and a 10°C increase can lead to a 10 time reduction of the viscosity for example. The necessity to take into account the self heating phenomena, that may have impact on induced properties, appears to be crucial for thermoforming process simulation and in particular for ISBM of PET. In order to evaluate this self-heating value, preforms have been blown with at different initial temperature followed using a thermal camera. The increase of temperature is determined comparing initial temperature in zone 1-2 with final temperature in zone 3-4. For an identical final volume of the blown preform, the influence of initial temperature on self-heating is discussed. Back to room temperature, induced mechanical properties are determined by two methods: (i) specimens are cut out from the bottle and prepared to be tested on uniaxial tension machine; (ii) bottles are blown under different pressures to follow the strain field using digital image correlation. Coupled with a finite element simulation managed on the bottle, these results allow the identification of the induced mechanical properties. Comparison between the self-heating and the induced modulus is managed and the effect of the self heating on the free blown shapes and induced properties is discussed. [ABSTRACT FROM AUTHOR]

Lightweight construction is an ongoing task in packaging development. Consequently, the stability of packages during transport is gaining importance. This study contributes to the optimization of lightweight packaging concepts regarding their stability. A very widespread packaging concept is the distribution of goods on a pallet whereas a Polyethylene (PE) stretch film stabilizes the lightweight structure during the shipment. Usually, a stretch wrapping machine applies this stretch film to the pallet. The objective of this study is to support packaging development with a method that predicts the result of the wrapping process, based on the mechanical characterization of the stretch film. This result is not only defined by the amount of stretch film, its spatial distribution on the pallet and its internal stresses that result in a containment force. More accurate, this contribution also considers the influence of the deformation history of the stretch film during the wrapping process. By focusing on similarities of stretch wrappers rather than on differences, the influence of generalized process parameters on stretch film mechanics and thereby on pallet stability can be determined experimentally. For a practical use, the predictive method is accumulated in an analytic model of the wrapping process that can be verified experimentally. This paves the way for experimental and numerical approaches regarding the optimization of pallet stability. [ABSTRACT FROM AUTHOR]

Heat transfer during the cooling of a thermoplastic injected part directly affects the solidification of the polymer and consequently the quality of the part in term of mechanical properties, geometric tolerance and surface aspect. This paper proposes to mold designers a methodology based on analytical models to provide quickly the time to reach the ejection temperature depending of the temperature and the position of cooling channels. The obtained cooling time is the first step of the thermal conception of the mold. The presented methodology is dedicated to the determination of solidification time of a semi-crystalline polymer slab. It allows the calculation of the crystallization time of the part and is based on the analytical solution of the Stefan problem in a semi-infinite medium. The crystallization is then considered as a phase change with an effective crystallization temperature, which is obtained from Fast Scanning Calorimetry (FSC) results. The crystallization time is then corrected to take the finite thickness of the part into account. To check the accuracy of such approach, the solidification time is calculated by solving the heat conduction equation coupled to the crystallization kinetics of the polymer. The impact of the nature of the contact between the polymer and the mold is evaluated. The thermal contact resistance (TCR) appears as significant parameter that needs to be taken into account in the cooling time calculation. The results of the simplified model including or not TCR are compared in the case of a polypropylene (PP) with experiments carried out with an instrumented mold. Then, the methodology is applied for a part made with PolyEtherEtherKetone (PEEK). [ABSTRACT FROM AUTHOR]

The purpose of this paper is to develop a cost-effective, efficient and quick to implement experimental optical method in order to predict the optical properties (extinction coefficient) of semi-transparent polymer composites. The extinction coefficient takes into account the effects due to the absorption and the scattering phenomena in a semi-transparent component during the laser processes, i.e. TTLW (through-transmission laser welding). The present method used a laser as light source and a reflex camera equipped with a macro lens as a measurement device and is based on the light transmission measurement through different thickness samples. The interaction between the incident laser beam and the semi-transparent composite is exanimated. The results are presented for the case of a semi-transparent composite reinforced with the unidirectional glass fiber (UD). A numerical method, ray tracing, is used to validate the experimental results. The ray tracing method is appropriate to characterize the light-scattering phenomenon in semi-transparent materials. [ABSTRACT FROM AUTHOR]

Single-screw plastication, used in extrusion and in injection moulding, is a major way of processing commodity thermoplastics. During the plastication phase, the polymeric material is melted by the combined effects of shear-induced self-heating (viscous dissipation) and heat conduction coming from the barrel. In injection moulding, a high level of reliability is usually achieved that makes this process ideally suited to mass market production. Nonetheless, process fluctuations still appear that make moulded part quality control an everyday issue. In this work, we used a combined modelling of plastication, throughput calculation and laminar dispersion, to investigate if, and how, thermal fluctuations could propagate along the screw length and affect the melt homogeneity at the end of the metering section. To do this, we used plastication models to relate changes in processing parameters to changes in the plastication length. Moreover, a simple model of throughput calculation is used to relate the screw geometry, the polymer rheology and the processing parameters to get a good estimate of the mass flow rate. Hence, we found that the typical residence time in a single screw is around one tenth of the thermal diffusion time scale. This residence time is too short for the dispersion coefficient to reach a steady state, but too long to be able to neglect radial thermal diffusion and resort to a purely convective solution. Therefore, a full diffusion/convection problem has to be solved with a base flow described by the classic pressure and drag velocity field. Preliminary results already show the major importance of the processing parameters in the breakthrough curve of an arbitrary temperature fluctuation at the end of the metering section of injection moulding screw. When the flow back-pressure is high, the temperature fluctuation is spread more evenly with time, whereas a pressure drop in the flow will results in a breakthrough curve which presents a larger peak of fluctuation. [ABSTRACT FROM AUTHOR]

The hot embossing process has been widely used in the manufacturing of polymer components, especially for the fabrication of micro or nano components. The significant advantage of the hot embossing process compared to the traditional injection moulding process is the excellent effective filling ratio for the high aspect ratio components and large surface structural components. The lack of material behavior modeling and numerical simulation limits the further development the hot embossing process, especially at the micro and nano scales. In this paper, a visco-elastoplastic behavior law has been proposed to describe the amorphous thermoplastic polymer mechanical properties in the hot embossing processing temperature range, which is lightly above their glass transition temperature. Uniaxial compression tests have been carried out in order to investigate the amorphous thermoplastic polymers properties. The material parameters in the visco-elastoplastic model have been identified according to the experimental results. A 3D numerical model has been created in the simulation software, which is based on the finite element method. The numerical simulation of the filling step of the hot embossing process has been effectuated by taking into account the viscous, elastic and plastic behaviors of thermoplastic polymers. The micro hot embossing process has been carried out using horizontal injection compression moulding equipment. A complete compression mould tool, equipped with the heating system, the cooling system, the ejection system and the vacuum system, has been designed and elaborated for this research work. The microfluidic devices based on the amorphous thermoplastic polymers have been successfully elaborated by hot embossing process. Proper agreement between the numerical simulation and the experimental elaboration has been obtained. [ABSTRACT FROM AUTHOR]

This paper introduces a cost-effective numerical model for infrared (IR) heating of semi-crystalline polymers. For the numerical and experimental studies presented here semi-crystalline polyethylene (PE) was used. The optical properties of PE were experimentally analyzed under varying temperature and the obtained results were used as input in the numerical studies. The model was built based on optically homogeneous medium assumption whereas the strong variation in the thermo-optical properties of semi-crystalline PE under heating was taken into account. Thus, the change in the amount radiative energy absorbed by the PE medium was introduced in the model induced by its temperature-dependent thermo-optical properties. The computational study was carried out considering an iterative closed-loop computation, where the absorbed radiation was computed using an in-house developed radiation heat transfer algorithm -RAYHEAT- and the computed results was transferred into the commercial software -COMSOL Multiphysics- for solving transient heat transfer problem to predict temperature field. The predicted temperature field was used to iterate the thermo-optical properties of PE that varies under heating. In order to analyze the accuracy of the numerical model experimental analyses were carried out performing IR-thermographic measurements during the heating of the PE plate. The applicability of the model in terms of computational cost, number of numerical input and accuracy was highlighted. [ABSTRACT FROM AUTHOR]

This paper focuses on the potential use of stereo-DIC in thermoforming conditions to monitor large deformations of softened thermoplastic sheets posteriori to the sagging phenomenon. The study concerns HIPS sheets which are softened by the radiative heat-transfer mode then stretched by inflation of compressed-air for 1.5 s to form a large and quasi-spherical dome of 250 mm in diameter. While the bubble-inflation operation leads to large deformations of the softened sheet, it shows transitional geometrical instabilities due to the initial surface sagging. When the temperature-induced surface deformations are inaccessible by the stereoscopic system during the heating operation, the geometrical instabilities limit the identification of the reference of displacements which affects the accuracy of results based on image-correlation computations. To compare between the principal strains assessed from bubble-inflation tests conducted at different thermal conditions, a method for filtering these instabilities is developed in this study. [ABSTRACT FROM AUTHOR]

Thermoforming of high impact polystyrene sheets (HIPS) requires technical knowledge on material behavior, mold type, mold material, and process variables. Accurate thermoforming simulations are needed in the optimization process. Determining the behavior of the material under thermoforming conditions is one of the key parameters for an accurate simulation. The aim of this work is to identify the thermomechanical behavior of HIPS in the thermoforming conditions. HIPS behavior is highly dependent on temperature and strain rate. In order to reproduce the behavior of such material, a thermo-elasto-viscoplastic constitutive law was implement in the finite element code ABAQUS. The proposed model parameters are considered as thermo-dependent. The strain-dependence effect is introduced using Prony series. Tensile tests were carried out at different temperatures and strain rates. The material parameters were then identified using a NSGA-II algorithm. To validate the rheological model, experimental blowing tests were carried out on a thermoforming pilot machine. To compare the numerical results with the experimental ones the thickness distribution and the bubble shape were investigated. [ABSTRACT FROM AUTHOR]