Article
Chemistry, Physical
Tomasz Trzepiecinski, Andrzej Kubit, Romuald Fejkiel, Lukasz Chodola, Daniel Ficek, Ireneusz Szczesny
Summary: This study analyzed the impact of different parameters on the coefficient of friction of steel sheets through friction tests, constructed a friction model using artificial neural networks, and found that increasing the drawbead height will increase the coefficient of friction. In addition, the chlorine-based Heavy Draw 1150 compound provides more effective friction reduction compared to LAN-46 machine oil.
Review
Chemistry, Physical
Yong Hou, Dongjoon Myung, Jong Kyu Park, Junying Min, Hyung-Rim Lee, Ali Abd El-Aty, Myoung-Gyu Lee
Summary: Lightweight sheet metals are attractive for aerospace and automotive applications due to their exceptional properties. Sheet metal forming (SMF) plays a key role in manufacturing lightweight thin-walled complex-shaped components. This article provides a comprehensive review of historical development in SMF and discusses advanced characterization and modelling approaches for lightweight metallic materials.
Article
Chemistry, Physical
Wojciech Wieckowski, Janina Adamus, Marcin Dyner, Maciej Motyka
Summary: Friction, wear, and lubrication are common challenges in metal-forming processes, especially when forming titanium materials. Using environmentally friendly lubricants with boric acid can effectively reduce tool wear and eliminate galling. This paper explores the tribological aspects of forming titanium sheets with these lubricants through technological tests and numerical simulations. The results demonstrate the positive impact of lubricants with boric acid on sheet titanium forming.
Article
Engineering, Mechanical
Meghshyam Shisode, Javad Hazrati, Tanmaya Mishra, Matthijn de Rooij, Carel ten Horn, Jeroen van Beeck, Ton van den Boogaard
Summary: A multi-scale friction model applicable for coated sheets is developed in this study, taking into account the physical behavior of coatings and the surface topographies of sheet and tools. The model is validated through experiments on zinc coated steel sheets, demonstrating its effectiveness in predicting friction in forming processes.
TRIBOLOGY INTERNATIONAL
(2021)
Article
Multidisciplinary Sciences
Trunal Bhujangrao, Fernando Veiga, Mariluz Penalva, Adriana Costas, Cristina Ruiz
Summary: This paper presents a process analysis of manufacturing parts by metal forming using a finite element model. It provides guidelines for manufacturing based on the correct set of parameters.
Article
Engineering, Mechanical
Wencheng Liu, Jia Huang, Yong Pang, Ke Zhu, Shugen Li, Jun Ma
Summary: Accurate modelling of local evolving texture and yield surface evolution in complex strain path is crucial for accurate sheet metal forming simulations. This study proposes a novel multi-scale computational scheme that utilizes full-field crystal plasticity modelling mapped onto each integration point in the finite element model, allowing for real-time updates along the local strain path. The developed method is thoroughly validated through comprehensive tests, demonstrating the significant influence of evolving texture induced plastic anisotropy on the prediction accuracy of deep drawing simulations. Furthermore, this method is cost-effective and enables simulation of complex forming processes.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2023)
Article
Automation & Control Systems
Liangchi Zhang, Chuhan Wu, Hossein Sedaghat
Summary: This paper presents a thorough investigation on incremental sheet metal forming assisted by ultrasonic vibration. Utilizing a new acoustoplasticity constitutive model, the study conducted extensive numerical analyses and experimental investigations to examine the effects of critical parameters on forming force, sheet thickness reduction, and springback. The models were found to accurately predict the sheet metal forming process under ultrasonic vibration, with potential to advance ultrasonic vibration-assisted forming techniques.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Mechanical
Kijung Lee, Jinheung Park, Jinwoo Lee, Soon Woo Kwon, Insuk Choi, Myoung-Gyu Lee
Summary: A micromechanics-based friction model is proposed to improve an existing surface asperity-based friction model. The model considers the equilibrium between the plastically deformable workpiece and contact tool, and implements the plowing effect through a newly proposed geometrical modeling of the tool surface. The model is validated by comparing the calculated friction coefficients with experimental results and is then implemented in finite element software to simulate forming processes.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2023)
Review
Chemistry, Physical
Valentin Oleksik, Tomasz Trzepiecinski, Marcin Szpunar, Lukasz Chodola, Daniel Ficek, Ireneusz Szczesny
Summary: Incremental sheet forming of titanium and its alloys plays a significant role in modern manufacturing industry by producing high-quality, complex-shaped products at low cost. The development of single-point incremental forming technique in titanium alloys, especially for difficult-to-form types, is highlighted, with potential applications in various industries, particularly in the medical field. The need for appropriate lubrication in the forming process of titanium alloys is emphasized due to their unfavorable tribological properties. Insufficient research on the synergistic effect of rotational speed and tool rotation direction on surface roughness of workpieces was also noted in the literature review.
Article
Chemistry, Physical
Yuhuai Wang, Lidong Wang, Huixi Zhang, Yong Gu, Yaokun Ye
Summary: Incremental sheet metal forming, characterized by increased flexibility and local plastic deformation, is suitable for low-production-run manufacturing and the trial production of complex shapes. However, thickness thinning remains an obstacle to its application. This study proposes a novel mathematical algorithm based on NURBS surface, which effectively predicts and calculates the final thickness of arbitrary parts in incremental forming. The proposed model is validated through finite element simulation and forming experiments, showing good agreement with the theoretical predictions.
Article
Mechanics
Yang Wang, Kangmin Niu, Ying Wu
Summary: The development of a coarse-grained graphene model and corresponding potential was systematically conducted, with the study demonstrating its robustness through comparison analysis and compatibility with a copper/graphene nanocomposite from tensile tests. The model successfully reproduced the architectural parameters, elastic, fracture, and interlayer adhesion properties of graphene sheets, serving as an effective strategy for researching hybrid composite systems.
COMPOSITE STRUCTURES
(2021)
Article
Engineering, Industrial
Zhidong Chang, Jun Chen
Summary: This article introduces a novel dieless incremental sheet forming method that can produce lightweight thin wall panels at room temperature, improving deformation consistency and formability. Experimental studies demonstrate the potential of this method for flexible manufacturing of low-ductility panels in the medical and aerospace fields.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2022)
Article
Materials Science, Multidisciplinary
Armando E. Marques, Mario A. Dib, Ali Khalfallah, Martinho S. Soares, Marta C. Oliveira, Jose V. Fernandes, Bernardete M. Ribeiro, Pedro A. Prates
Summary: The aim of the study is to predict the strain values for edge cracking in hole expansion tests using machine learning models. Experimental datasets of rolled ferritic carbon steel sheets were used to construct the models, with the results showing that machine learning-based predictive models outperform traditional polynomial regression methods. Gaussian Processes and Support Vector Regression were identified as the best machine learning algorithms for robust predictive models.
Article
Chemistry, Physical
Zhou Yan, Hany Hassanin, Mahmoud Ahmed El-Sayed, Hossam Mohamed Eldessouky, J. R. P. Djuansjah, Naser A. Alsaleh, Khamis Essa, Mahmoud Ahmadein
Summary: Single-point incremental forming (SPIF) is a flexible technology suitable for small and medium customised production. Despite some drawbacks such as geometrical inaccuracy and thickness uniformity issues, these can be reduced through optimization.
Article
Engineering, Mechanical
Tomasz Trzepiecinski, Marek Szewczyk, Krzysztof Szwajka
Summary: Lubrication is a basic and effective method to reduce friction in sheet metal forming operations. This article compares the lubrication performance of non-edible oils (karanja and moringa) with edible oils (sunflower and rape-seed), and finds that karanja oil exhibits better lubrication under specific conditions.
Article
Mathematics, Interdisciplinary Applications
Shuheng Liao, Tianju Xue, Jihoon Jeong, Samantha Webster, Kornel Ehmann, Jian Cao
Summary: Understanding the thermal behavior of additive manufacturing processes is crucial for quality control and process design. This study develops a hybrid physics-based data-driven thermal modeling approach using physics-informed neural networks. The results demonstrate the effectiveness of the model in identifying unknown parameters and accurately capturing the full-field temperature, making it suitable for iterative process design and real-time process control of additive manufacturing.
COMPUTATIONAL MECHANICS
(2023)
Article
Engineering, Manufacturing
Robin Gitschel, Oliver Hering, Andre Schulze, A. Erman Tekkaya
Summary: The evolution of ductile damage in cold forging can be controlled without changing the geometry of the produced part by adjusting process parameters and introducing counterpressure. The load path-dependent damage can be controlled by varying extrusion strain and shoulder opening angle. Introducing counterpressure helps decrease triaxiality in the forming zone without affecting the products' geometries.
JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME
(2023)
Article
Engineering, Manufacturing
Mojtaba Mozaffar, Shuheng Liao, Jihoon Jeong, Tianju Xue, Jian Cao
Summary: This paper presents a differentiable simulation method for optimizing the thermal behavior of materials in additive manufacturing processes. By using automatic differentiation to compute gradients, high-dimensional design spaces can be handled. The methodology is validated through experimental testing.
ADDITIVE MANUFACTURING
(2023)
Article
Engineering, Industrial
Shuheng Liao, Jihoon Jeong, Rujing Zha, Tianju Xue, Jian Cao
Summary: A simulation-guided feedforward-feedback control framework is developed for effective control of the melt pool temperature in additive manufacturing processes. The experimental results demonstrate that the feedforward-feedback control method significantly improves control performance compared to conventional feedback control.
CIRP ANNALS-MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Industrial
Fred M. Carter III, Dominik Kozjek, Conor Porter, Samuel J. Clark, Kamel Fezzaa, Makoto Fujishima, Naruhiro Irino, Jian Cao
Summary: A co-axial photodiode monitoring system with high temporal resolution has been integrated into a proven test bench, allowing for synchronized side-view high-speed X-ray imaging for observing melt pool dynamics and top-view spectral emission characterization of the melt pool. The correlation between these two monitoring systems can be directly scaled to commercial systems. The study shows a 92% detection rate of keyhole collapse phenomena related to defect generation in selective laser melting (SLM), as well as investigates the impact of gas flow on monitoring signals to understand its fundamental importance in commercial systems.
CIRP ANNALS-MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Industrial
Guido Tosello, Giuliano Bissacco, Jian Cao, Dragos Axinte
Summary: This paper presents the state-of-the-art in modeling and simulation of surface texture and topography generation at micro and nano scales. It reviews three main manufacturing processes for surface generation and discusses various modeling techniques. The application of these techniques in predicting surface characteristics and geometry are presented, along with a roadmap for a complete surface generation digital twin in manufacturing.
CIRP ANNALS-MANUFACTURING TECHNOLOGY
(2023)
Article
Mathematics, Interdisciplinary Applications
Shuheng Liao, Ashkan Golgoon, Mojtaba Mozaffar, Jian Cao
Summary: This paper presents a method for rapid thermomechanical simulation of metal additive manufacturing using a fully vectorized implementation on graphical processing units. The method utilizes implicit time discretization and the finite element method, solving the incremental elastoplastic problem using the conjugate gradient method. Sparse representation of algorithmic (tangent) stiffness matrix and the strain-displacement operator are used. The GPU implementation is 10-25x faster than the CPU version, enabling fast prediction of residual stress in additive manufacturing to improve process design effectiveness and avoid process defects.
COMPUTATIONAL MECHANICS
(2023)
Article
Engineering, Industrial
Clayton Cooper, Jianjing Zhang, Joshua Huang, Jennifer Bennett, Jian Cao, Robert X. Gao
Summary: This research explores a data-driven predictive model with Shapley additive explanation (SHAP) to improve the accuracy and interpretability of predicting mechanical properties in directed energy deposition (DED) processes. The results demonstrate that by interpreting input features and reducing model complexity, both the accuracy and effectiveness of predictive models for Inconel 718 (IN718) tensile strength can be improved.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2023)
Article
Engineering, Manufacturing
Stephan Rosenthal, Marlon Hahn, A. Erman Tekkya
Summary: The deep drawability of additively manufactured stainless steel sheets with a core structure is investigated and it is shown that the sheets have good formability. Numerical analysis and experimental validation of the deep drawing process are conducted, revealing that the main failure mode is fracture of the face sheets. The core structure remains intact, ensuring structural integrity of the parts after the deep drawing process. A modified Siebel's method can reasonably predict the process forces and a process window diagram is derived.
INTERNATIONAL JOURNAL OF MATERIAL FORMING
(2023)
Correction
Engineering, Manufacturing
Stephan Rosenthal, Marlon Hahn, A. Erman Tekkaya
INTERNATIONAL JOURNAL OF MATERIAL FORMING
(2023)
Article
Computer Science, Interdisciplinary Applications
Tianju Xue, Shuheng Liao, Zhengtao Gan, Chanwook Park, Xiaoyu Xie, Wing Kam Liu, Jian Cao
Summary: This paper introduces JAX-FEM, an open-source differentiable finite element method (FEM) library that is implemented with pure Python and scalable for solving moderate to large problems. It achieves significant acceleration compared to commercial FEM codes and enables automatic solving of inverse problems. JAX-FEM also serves as an integrated platform for machine learning-aided computational mechanics.
COMPUTER PHYSICS COMMUNICATIONS
(2023)
Article
Engineering, Manufacturing
Mike Kamaliev, Jan Flesch, Joshua Grodotzki, A. Erman Tekkaya
Summary: The isothermal high temperature pneumoforming process for forming tubes at constant elevated temperatures by means of internal pressure was investigated using a ferritic and a martensitic stainless steel. Material characterization was performed at the temperature and strain rate of the process, and a new method for quantifying thermal softening was presented. Numerical models were validated and used to study the influence of process parameters on the final part geometry. Process windows were derived based on internal pressure and die edge length, and good agreement with experiments was observed.
INTERNATIONAL JOURNAL OF MATERIAL FORMING
(2023)
Article
Materials Science, Multidisciplinary
Mathilde Laurent-Brocq, Lola Lilensten, Clemence Pinot, Andre Schulze, Amandine Duchaussoy, Julie Bourgon, Eric Leroy, A. Erman Tekkaya
Summary: Solid-state recycling of metallic alloys is a promising alternative method for reducing CO2-emission compared to remelting. This study quantifies and localizes oxygen contamination at each step of the process, revealing an increase in oxygen content and the formation of oxide layers. Alloying elements are involved in oxidation, resulting in a complex network of oxides with thin thickness and low density. Tuning processing parameters is a promising approach to limit oxidation and improve chip welding.
Article
Multidisciplinary Sciences
Samantha Webster, Newell Moser, Kamel Fezzaa, Tao Sun, Kornel Ehmann, Edward Garboczi, Jian Cao
Summary: The use of metal additive manufacturing (AM) components is currently limited in industries due to process defects resulting in shorter fatigue life, potential catastrophic failure, and lower strength. Scientists have started analyzing the conditions and mechanisms of these defects to improve reliability and structural integrity of these highly customized parts.
Review
Engineering, Mechanical
Stefani Bruschi, Andrea Ghiotti, Enrico Simonetto
Summary: This paper reviews the recent research on forming processes on steel sheets and tubes carried out at elevated temperatures. The development of forming processes involving heating the sheet at high temperatures has been driven by the increasing demand for high strength-to-weight ratio components in sectors like automotive and aerospace. The paper focuses on variants of the hot stamping process on high strength-to-weight steel sheets and tubes to achieve desired part characteristics.
MECHANICS & INDUSTRY
(2023)
