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In this study, different contents (0.0, 0.1, 0.2, and 0.4 wt.%) of Zr55Cu30Al10Ni5 amorphous alloys (Zr-AA) are used to manipulate hypereutectic Al-Si alloys. The edge-to-edge model shows that there is a perfect lattice matching between the crystallized phases and α-Al and Si phases. The thermal analysis of solidification behavior of hypereutectic Al-Si alloys unmanipulated and manipulated by Zr-AA, indicates that the addition of Zr-AA greatly promotes the nucleation of primary Si and significantly accelerates the process of eutectic reaction. When manipulated by the optimal content of 0.2 wt.% Zr-AA, the sizes of α-Al dendrites and primary Si decrease from 212.46 μm and 19.24 μm to 143.39 μm and 16.47 μm, respectively. The eutectic Si changes from needle-like to rod-like and exhibits a mean size decrease from 20.21 μm to 11.69 μm. Meanwhile, alloys exhibit ultimate tensile strength of 362 MPa and fraction strain of 2.21% after 0.2 wt.% Zr-AA manipulation, which are 23% and 37% higher than those of the unmanipulated alloy (295 MPa and 1.61%). The strengthening mechanisms of hypereutectic Al-Si alloys manipulated by in situ nanocrystals crystallized in the melt are mainly attributed to the fine grain strengthening effect and precipitation strengthening effect. The increase in plasticity is due to the refinement and morphology improvement of Si phases.

In this study, the thermal stability of Ni–Nb–Ti metallic glasses was investigated under isothermal and non-isothermal conditions. The effectiveness of NiTi phases, one of the nanosized crystallized phases, as grain refiners for Al–Cu alloys was also investigated from a crystallographic point of view using the edge-to-edge matching (E2EM) model. Thermal analysis showed that NiTi phases promote solidification of α-Al, and these nanocrystalline phases also promote an Al–Cu eutectic reaction and inhibit the growth of eutectic phases. A significant refining effect of α-Al grains from 402.7 μm to 69.1 μm was achieved with 0.05 wt.% nanocrystalline phases. Simultaneously, values for yield strength, ultimate tensile strength and fracture strain of inoculated Al–Cu alloys were increased by 18%, 13% and 78% to 363.2 MPa, 534.3 MPa and 11.92%, respectively, when compared with those of uninoculated Al–Cu alloys. Strengthening mechanisms of Al–Cu alloys manipulated by the nanocrystalline phases are grain boundary strengthening and precipitation strengthening.

The finite element model of flexible clamp multi-point stretch forming (FCMPSF) was set up, and extensive contradistinctive analysis of forming limit and forming accuracy between FCMPSF and RCMPSF were done. The results show that under the same forming conditions, spherical part formed by FCMPSF is not easy to fracturing, dimpling and springback, and is easy to fit the die. The reason for this was analysed. The non-fracturing limited graph, the non-dimpling limited diagram and the average springback value of spherical parts formed by FCMPSF and RCMPSF were obtained. Finally, the forming experiment and error analysis of spherical part formed by FCMPSF were done, the results indicate that 3D parts with large transversal curvature can be shaped by FCMPSF and the forming quality was guaranteed.

Multi-point holder forming (MPHF) adopts series of coupled holder punches, arranged between forming punches, to clamp the whole sheet in the forming zone. The multi-point holder forming processes of spherical parts of titanium mesh plate were simulated by finite element code, and the results were compared with those of multi-point die forming (MPDF). The influence of holder punch load on the deformation of spherical part in multi-point holder forming was investigated. The shape error analysis of titanium mesh formed by MPHF was performed in finial. The results showed that the spherical part had more excellent performance in multi-point holder forming, and the more deformation the titanium mesh was, the larger force of holder punch would be needed. In addition, there was a small shape error for titanium mesh part formed by MPHF before springback.

Flexible DCSF technology was put forward, and its forming character was described. The flexible DCSF machine was developed and related stretching experiment were carried out. The experimental photos show the DCSF technology is feasible and the DCSF machine is practicable. The FE model of flexible DCSF was set up, and extensive numerical simulations for spherical parts, saddle parts and S-type parts were carried out by Abaqus. The numerical results show that the longer the transitional length is, the more homogeneous the stretching strain and the thickness become. The smaller the friction coefficient is, the more homogeneous the stretching strain and the thickness become. The larger the clamp number is, the better the fit degree becomes. This work may provide useful guidance on the flexible DCSF process.

Although multi-point forming (MPF) is an advanced processing technique and has been investigated comprehensively as a metal working operation, there are few papers published to deal with MPF of polymers. The present paper reviews the features of MPF and evaluates the possibility of producing polymer components by means of MPF. The experimental research work makes use of PC sheets with a thickness of 3.82 mm. Numerical simulations were performed with the software ABAQUS, then spherical and saddle-shaped components were manufactured by MPF. The geometrical deviations between shaped components and their original CAD/CAM models were obtained to investigate the forming accuracy. The results confirm that MPF of PC sheet has potential for the manufacture of complex components.

Flexible-gripper stretch forming is a new flexible manufacturing process of sheet metal. Four numerical simulation models of discrete grippers were established using finite element method, the effect of the numbers of grippers on stress distribution, thickness distribution and gripping surface shape of the spherical parts were studied. The results show that the clamped edge of the spherical parts formed by using integral grippers is straight，the tensile stress distribution is uneven and the thickness is obviously reduced. However, the stress distribution on the parts formed by using discrete grippers stretch forming is relatively uniform, with the increase in the numbers of grippers, the thickness increases, and the more gripping surface curvature of the parts is close to the curvature of die, the better forming quality of the parts is.

A new type of discrete clamp stretch forming machine based on flexible holding technology was developed to improve the performance of traditional rigid clamp stretch forming machine used for double-curvature metal sheet forming, and its forming characters were illuminated simply. The FE model of flexible discrete clamp stretch forming was set up, and extensive numerical simulations of spherical parts for both the flexible holding mode and the rigid holding mode were carried out by dynamic explicit finite element analysis. The numerical results show that the distribution of stress, strain and thickness were well-proportioned in the flexible holding mode. The larger the spherical radius is, the smaller the minimum transitional length of sheet metal is. The transitional length of 60mm is suitable for flexible discrete clamp stretch forming in the case of considering the forming quality and material utilization. Then, the stretch forming experiment proves that the flexible holding technology is feasible, and the error contrast illustrates the new type of discrete clamp stretch forming machine is practicable.

In order to improve the performance of back drawing type of flexible multi-gripper stretch forming machine used for double-curvature metal sheet forming, back and down drawing type of flexible multi-gripper stretch forming machine was designed by finite element method (FEM), which has simple structure and cheap cost. The FE model of flexible multi-gripper stretch forming was established, and extensive numerical simulations of spherical parts for two kinds of flexible stretch forming machines were carried out. The variations of stress, strain, thickness and springback value of spherical parts for two kinds of drawing modes were analyzed. The numerical results show that the quality of spherical parts formed by the back and down drawing type of stretch forming machine is better than that by the back drawing type of stretch forming machine. This work provides a machine for developing the technology of stretch forming.