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Metals
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Analysis and Design of Metal-Forming Processes
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Analysis and Design of Metal-Forming Processes

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: closed (31 December 2020) | Viewed by 26964

Special Issue Editor

Prof. Dr. Sergei Alexandrov

E-Mail Website1 Website2
Guest Editor
1. Laboratory of Technological Processes, Ishlinsky Institute for Problems in Mechanics of the Russian Academy of Sciences, 119526 Moscow, Russia
2. School of Mechanical Engineering and Automation, Beihang University, Beijing 100191, China
Interests: plasticity theory; fracture mechanics; metal forming; structural mechanics
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Large-scale bulk-forming processes are widely used for the processing of materials. The analysis and design of such processes requires accurate constitutive equations and boundary conditions. The constitutive equations should account for the material response under conditions that occur in real forming processes. It is evident that standard tests are not capable of reproducing all possible conditions. Therefore, new experimental techniques are needed for developing accurate constitutive equations during large strains. Of special importance are the constitutive equations for prediction of the evolution of ductile damage and plastic anisotropy. Friction has a great effect on material flow in forming processes. Therefore, the friction law is one of the most important boundary conditions, and experimental determination of the friction stress is an extremely difficult task. Hence, the development of new friction tests is a vital aspect in the successful analysis and design of material-forming processes. On the other hand, fast computational methods are needed for solving boundary value problems, especially when the calculations are to be performed in real time. Moreover, the development of analytic methods is useful for understanding some general tendencies in solution behavior and for verifying numerical solutions.

In this Special Issue, we seek to provide a wide set of articles on various aspects of bulk-forming processes. Articles devoted to different materials (traditional metals, powders, composites, etc.) are desired. We would like articles devoted to both experimental and theoretical (analytical and numerical) approaches, as well as those that consider a combination of these approaches.

Prof. Sergei Alexandrov
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • Bulk forming
  • Constitutive equations
  • Ductile fracture
  • Friction
  • Design.

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Related Special Issue

Published Papers (7 papers)

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Research

16 pages, 6177 KiB  
Article
Interface Quality Indices of Al–10Si–Mg Aluminum Alloy and Cr18–Ni10–Ti Stainless-Steel Bimetal Fabricated via Selective Laser Melting
by Alexander Khaimovich, Yaroslav Erisov, Vitaliy Smelov, Anton Agapovichev, Ilia Petrov, Vasilii Razhivin, Igor Bobrovskij, Viktoriya Kokareva and Alexander Kuzin
Metals 2021, 11(1), 172; https://doi.org/10.3390/met11010172 - 19 Jan 2021
Cited by 12 | Viewed by 2717
Abstract
Bimetallic materials are important in many industries (aerospace, medicine, etc.) since they allow the creation of constructions that combine specific functional properties, for example, low density (aluminum alloy) and high corrosion resistance (stainless steel), due to layering fabrication of the bimetallic joint. On [...] Read more.
Bimetallic materials are important in many industries (aerospace, medicine, etc.) since they allow the creation of constructions that combine specific functional properties, for example, low density (aluminum alloy) and high corrosion resistance (stainless steel), due to layering fabrication of the bimetallic joint. On the other hand, the difference in thermophysical properties of the dissimilar material layers leads to residual stresses, which cause deformation and destruction of such a bimetallic joint produced via the methods of surfacing or additive technologies. This article discusses the methods based on the gray relational analysis and generalized desirability function for the quality assessment of Al–10Si–Mg aluminum alloy and Cr18–Ni10–Ti stainless-steel bimetal fabricated via selective laser melting (SLM). There are four main parameters (quality indices) of the quality generalized assessment, which determine the degree of Al penetration into the steel substrate and Fe into the deposited layer, the difference in microhardness values on both sides of the interface boundary, and the resistance to mechanical destruction of the bimetallic joint. According to the results obtained, the best set of quality indices corresponds to the SLM technological modes with an energy density of 105 and 147 J/mm3. The greatest functionality of the bimetals is determined by the quality index associated with its strength. Therefore, methods of gray relational analysis and desirability function make it possible to form a generalized assessment for the bimetallic joint quality and, consequently, to select the best technological mode. Full article
(This article belongs to the Special Issue Analysis and Design of Metal-Forming Processes)
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9 pages, 5402 KiB  
Article
Effect of Die Angle and Frictional Conditions on Fine Grain Layer Generation in Multipass Drawing of High Carbon Steel Wire
by Alexey Stolyarov, Marina Polyakova, Guzel Atangulova and Sergei Alexandrov
Metals 2020, 10(11), 1462; https://doi.org/10.3390/met10111462 - 31 Oct 2020
Cited by 12 | Viewed by 2173
Abstract
Fine grain layers that generate near frictional interfaces in metal forming processes affect the quality of products. The present paper aims to contribute to the continuum-mechanics-based phenomenological approach for predicting such layers’ properties. In particular, it studies the generation of fine grain layers [...] Read more.
Fine grain layers that generate near frictional interfaces in metal forming processes affect the quality of products. The present paper aims to contribute to the continuum-mechanics-based phenomenological approach for predicting such layers’ properties. In particular, it studies the generation of fine grain layers in the process of multipass drawing of thin high carbon steel wires experimentally. The wires are drawn in three passes under different friction conditions. All three dies in each multipass process have the same semiangle. In total, two die semiangles are used, 4° and 5°. The effects of such processing conditions as the die semiangle, the number of passes, and the friction conditions on the thickness of fine grain layers are observed and discussed. The criterion for determining this thickness is based on the coefficient of anisotropy. Under soft friction conditions, the fine grain layer’s thickness decrease occurs during the consequential passes independently of the die semiangle. On the other hand, in the case of hard friction conditions, the thickness may or may not be a monotonic function of the number of passes, and its general qualitative behavior depends on the die semiangle. Full article
(This article belongs to the Special Issue Analysis and Design of Metal-Forming Processes)
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14 pages, 3673 KiB  
Article
A Constitutive Model for Yield Strength and Work Hardening Behaviour of Aluminium Alloys during Artificial Ageing
by Kang Ji, Guanfeng Li, Yongbao Sun, Jia Xu, Hui Chen, Kaiyan Chen, Yan Zhu and Yong Li
Metals 2020, 10(8), 1094; https://doi.org/10.3390/met10081094 - 13 Aug 2020
Cited by 6 | Viewed by 2947
Abstract
In this study, a unified constitutive model has been developed for both yield strength and work hardening behaviour prediction of aluminium alloys with different types of precipitates during and after artificial ageing. The different type and dimensions of general precipitate shapes (sphere, plate, [...] Read more.
In this study, a unified constitutive model has been developed for both yield strength and work hardening behaviour prediction of aluminium alloys with different types of precipitates during and after artificial ageing. The different type and dimensions of general precipitate shapes (sphere, plate, rod) have been classified and modelled by a primary dimension and aspect ratio, with which a general set of equations has been utilised to model the precipitates evolutions during ageing of various aluminium alloys. In addition, the effects of main microstructures on not only yield strength but also work-hardening behaviour of artificially aged aluminium alloys have been considered and modelled, based on which, a whole set of unified constitutive model considering both micro- and macro-properties for long-term artificial ageing of aluminium alloys has been proposed. Artificial ageing of two representative aluminium alloys (an Al-Mg-Si alloy AA6063 and an Al-Cu-Li alloy AA2198) has been adopted to show the capability and effectiveness of the developed model. The results show that the model can successfully predict the microstructures, yield strength and work hardening behaviour of various aluminium alloys with different precipitate types after long-term artificial ageing process, e.g., from 0 h to 500 h. It is believed that the model can be used for ageing of other aluminium alloys with dominant sphere, plate or rod-shaped precipitates. Full article
(This article belongs to the Special Issue Analysis and Design of Metal-Forming Processes)
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21 pages, 13116 KiB  
Article
Sheet Metal Forming Optimization Methodology for Servo Press Process Control Improvement
by Antonio Del Prete and Teresa Primo
Metals 2020, 10(2), 271; https://doi.org/10.3390/met10020271 - 19 Feb 2020
Cited by 12 | Viewed by 6287
Abstract
In sheet metal forming manufacturing operations the use of servo presses is gaining more interest due to the opportunity to improve process performance (quality, productivity, cost reduction, etc.). It is not yet clear how to proceed in the engineering process when this type [...] Read more.
In sheet metal forming manufacturing operations the use of servo presses is gaining more interest due to the opportunity to improve process performance (quality, productivity, cost reduction, etc.). It is not yet clear how to proceed in the engineering process when this type of operating machine is used to achieve the maximum possible potential of this technology. Recently, several press builders have developed gap- and straight-sided metal forming presses adopting the mechanical servo-drive technology. The mechanical servo-drive press offers the flexibility of a hydraulic press with the speed, accuracy and reliability of a mechanical press. Servo drive presses give the opportunity to improve the productivity of process conditions and improve the quality of stamped parts. Forming simulation and numerical optimization can be useful tools to define beforehand the optimal process parameter set-up in terms of servo press downward curve properties. This is done by carrying out a sensitivity analysis of the forming parameters having influence on said curve. The authors have developed a numerical methodology able to analyze the influence factors, for comparison with the degrees of freedom made available by the usage of a servo press, in terms of stroke profile management, to obtain an optimized process parameters combination. Full article
(This article belongs to the Special Issue Analysis and Design of Metal-Forming Processes)
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14 pages, 5417 KiB  
Article
Determination of Wide Burnishing Energy-Force Parameters based on Constructing the Kinematically Admissible Velocity Field
by Igor Bobrovskij, Alexander Khaimovich, Nikolaj Bobrovskij and Aleksander D’yakonov
Metals 2020, 10(1), 46; https://doi.org/10.3390/met10010046 - 25 Dec 2019
Cited by 4 | Viewed by 2860
Abstract
Processing technology using productive surface plastic deformation (SPD) was developed and is known as “wide burnishing” (WB). The mechanics of new WB technology differs from classic SPD technologies (rolling or burnishing). For example, force, applied during burnishing, is equal to 150–300 N, but [...] Read more.
Processing technology using productive surface plastic deformation (SPD) was developed and is known as “wide burnishing” (WB). The mechanics of new WB technology differs from classic SPD technologies (rolling or burnishing). For example, force, applied during burnishing, is equal to 150–300 N, but for WB it is equal to 2500–5000 N due to implementing this process in mass production, characterized with limited processing time (3–4 turns of the work piece). WB also has a high degree of deformation due to a multiple deformation passes. An analytical study of burnishing with the upper bound approach method energy-force parameters was carried out. Its results were compared with the results of finite elements analysis in Deform 2D and with experimental data. Field of reasonable burnishing parameters, assuring minimum surface roughness, was determined experimentally. Full article
(This article belongs to the Special Issue Analysis and Design of Metal-Forming Processes)
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17 pages, 6466 KiB  
Article
Analysis, Validation and Optimization of the Multi-Stage Sequential Wiredrawing Process of EN AW-1370 Aluminium
by Óscar Rodríguez-Alabanda, Pablo E. Romero, Esther Molero and Guillermo Guerrero-Vaca
Metals 2019, 9(9), 1021; https://doi.org/10.3390/met9091021 - 19 Sep 2019
Cited by 6 | Viewed by 4368
Abstract
For the wiredrawing of aluminium, the initial wire rod is obtained by continuous inverted casting. The raw geometry is industrially processed in a linear multi-step wiredrawing sequence to obtain a wire that is commonly used for the manufacture of electrical conductors. In the [...] Read more.
For the wiredrawing of aluminium, the initial wire rod is obtained by continuous inverted casting. The raw geometry is industrially processed in a linear multi-step wiredrawing sequence to obtain a wire that is commonly used for the manufacture of electrical conductors. In the present work a complete study of the material has been made. The experimental procedure consisted in the realization of a sequence of section reduction stages in the laboratory, a sequence designed following the technological criteria recommended by the manufacturer of the drawing machine in which the industrial process will be implemented. From the specimens corresponding to each reduction step, it has been possible to know the evolution of the main mechanical properties when this pure aluminium is processed by wiredrawing. This information has led to establish the hardening law by which it is possible characterize the plastic behaviour of this pure metal when it is transformed by this specific sequential process of cold forming. The strain hardening law has been implemented in a numerical simulation software application and the experimental setup has been simulated for its validation. Finally, the classic analytical solution founded in the “slab method” has been applied for the design of a proposal for the optimization of the industrial wiredrawing process. Full article
(This article belongs to the Special Issue Analysis and Design of Metal-Forming Processes)
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Graphical abstract

13 pages, 3903 KiB  
Article
Study on Multi-Step Creep Aging Behavior of Al-Li-S4 Alloy
by Yunlong Ma, Feng Xia, Lihua Zhan and Yongqian Xu
Metals 2019, 9(7), 807; https://doi.org/10.3390/met9070807 - 22 Jul 2019
Cited by 5 | Viewed by 4081
Abstract
Creep age forming (CAF) is a new technology developed for manufacturing large aluminum components in the aerospace industry. Aluminum–lithium alloys may be used in aerospace components because of their high modulus, specific strength and specific stiffness. Therefore, the creep deformation, mechanical properties and [...] Read more.
Creep age forming (CAF) is a new technology developed for manufacturing large aluminum components in the aerospace industry. Aluminum–lithium alloys may be used in aerospace components because of their high modulus, specific strength and specific stiffness. Therefore, the creep deformation, mechanical properties and aging precipitation of Al-Li-S4 alloy under CAF conditions were studied. It was found that the creep behavior presents double steady state creep stages during the creep aging process. With the increase of stress level, the first steady creep rate increased, but the second steady creep rate was slightly reduced. Coincidentally, in the first steady state creep stage, the yield strength of the studied alloy also showed a slow increase stage. TEM observation showed that Al-Li-S4 alloy mainly contains two precipitation phases, T1 phase and θ’ phase. A few precipitates form during the first steady creep stage. Then, a lot of nucleation and growth of T1 phase resulted in rapid increase of yield strength. At the same time, the increase of stress level effectively inhibited the growth of T1 phase, which resulted in these strengthening phases being more uniform, and thus improved the mechanical properties of materials. On this basis, the relationship between the multi-step behaviors of creep, mechanical properties and aging precipitates are discussed. It is considered that the main reasons for the multi-step phenomenon of creep and mechanical properties are strongly related to the nucleation, growth and distribution of T1 phase. Full article
(This article belongs to the Special Issue Analysis and Design of Metal-Forming Processes)
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