This paper concerns shear testing of a quasi-unidirectional non-crimp fabric used for wind turbine blades. In this context “quasi” refers to the fact that the majority of the reinforcement is oriented along the longitudinal direction with a small amount acting as a stabilizing backing layer in the ± 80∘ direction. The bias-extension test is used to investigate the in-plane shear kinematics of the fabric

Advancing in the process of extending the use of composites for structural parts applications, it is inevitable to work on complex shapes. That is the main reason why understanding the complex forming mechanisms and the factors put into play during the process of composite materials is a major interest for both pre-impregnated forming and dry fabric preforming. Thus, the appearance of defects is a

The aim of this study is to investigate the balance between 2D and 3D (or twist) springback of copper-based thin sheets after a deep drawing process. Such materials are widely used in the manufacturing of electric and electronic components, but getting an accurate final geometry is usually difficult due to springback. Three copper-based materials are considered in this study, and in a first step, the

In this study, polypropylene composite reinforced with carbon fibers and calcium carbonate nano-particles is manufactured. Mechanical properties tests showed that composite sample containing nano-particles has 87% more tensile strength, 26% more bending strength and 40% more impact strength than the composite without nano-particles. Then high speed drilling was performed on the composite sample containing

A Correction to this paper has been published: https://doi.org/10.1007/s12289-021-01638-4

The aim of this study is to develop a reduced single-pattern model for a multi-pattern metal forming process called repetitive corrugation and straightening (RCS) which belongs to the category of Severe Plastic Deformation (SPD) processes. The corrugation die in RCS is composed of multiple similarly repeated patterns. First, a full multi-pattern model with a large number of patterns is developed. An

It is impossible to obtain the forming limit curve (FLC) by full zone hydraulic forming test under quasi-static (QS) condition since the liquid will leak from the notches of the specimen once the pressure increases. In this study, a novel method is proposed to investigate the frictionless full zone hydraulic FLC of AA5A06 under high strain rate (HSR) condition based on the impact hydroforming technology

The evolution of grain size and component mechanical behaviour are fundamental aspects to analyse and control when manufacturing processes are considered. In this context, severe plastic deformation (SPD) processes, in which a high shear strain is imposed on the material, are recognized as the main techniques to achieve microstructural changes and material strengthening by the recrystallization, attracting

Electrically vaporizing foil actuators are employed as an innovative high speed sheet metal forming technology, which has the potential to lower tool costs. To reduce experimental try-outs, a predictive physics-based process design procedure is developed for the first time. It consists of a mathematical optimization utilizing numerical forming simulations followed by analytical computations for the

The present paper derives best practices to accurately simulate the installation process of a Blind Rivet Nut (BRN) using FEA. A BRN is a mechanical fastener used to equip plate material with a threaded part. The installation of a BRN inherently induces a high contact force which can have detrimental consequences when applied to non-metals such as polymer composite materials. The effects of the localized

Tailor welded blanks (TWBs) are produced by welding blanks with different characteristics as such thickness and/or coating and/or material, etc. The forming characteristics of a TWB are different from typical sheets, as TWB is a combined blank each section has its own forming behavior. The current investigation aims to analyze the formability characteristics of TWBs made by joining AA6061 aluminum

This study deals with an experimental investigation of the influence of friction stir welding parameters on the subsequent formability during incremental forming of aluminium alloy 6082-T6 blanks. Five welding conditions are considered, based on different combinations of rotational speed and feed rate. Truncated cones are chosen as benchmarks for single point incremental forming and tested up to their

The purpose of this paper is to achieve fast densification prediction of target materials and particularly of difficult-to-sintering materials in small dataset sintering scenarios. A multi-source sintering transfer learning framework based on the domain adversarial network (DANN) was proposed to achieve multi-source sintering transfer learning. Further, a calibration method was presented to enhance

A process chain of compound casting and co-extrusion of AA7075/6060 bilayer billets is introduced to manufacture hybrid components with strength in the core and good corrosion-resistance in the shell. Using optimized compound casting parameter, metallurgical bonding between the shell AA6060 and the core AA7075 can be achieved through remelting and recrystallization of the substrate AA7075. The locally

The parameter solving method for springback control mainly depends on theoretical models and numerical simulation. However, many assumptions are adopted in the theoretical model, which inevitably lead to prediction error in practical application. Therefore, for bending and straightening process, a difference iterative compensation method and secant iterative compensation method based on the implicit

Natural fibers, especially jute fibers, have gained interest in recent decades due to their attractive mechanical properties, high cellulose percentage, low cost, biodegradability, and easy availability. In the present study, flexural and drop weight impact behavior for different weight percentages of glass and jute fiber reinforced epoxy composites are studied experimentally according to ASTM standards

In the present work, a physically-based finite element model simulating the compression moulding process of cork-based agglomerates is presented. The goal is the prediction of the pre-stress state due to the process and its influence on the macroscopic mechanical properties of the agglomerate. An ad-hoc algorithm simulating the mould filling phase (based on a generalised Voronoi’s tesselation algorithm

Additive manufacturing is an appealing solution to produce geometrically complex parts, difficult to manufacture using traditional technologies. The extreme process conditions, in particular the high temperature, complex interactions and couplings, and rich metallurgical transformations that this process entails, are at the origin of numerous process defects. Therefore, the numerical simulation of

In the context of weight reduction for new car design, it is essential to downsize, or rather optimize, the Body In White (BIW) structure. A very effective approach is to take into account the influence of Manufacturing process in the performance analysis such as crash or fatigue. Further, integrating the interaction between Stamping and Crash performance should also improve the predictability of the

In this paper, we aim to investigate the heat generated during friction stir lap welding in polypropylene sheets. In this method, the generated heat significantly depends on the tool’s rotational and linear speed, geometry, and tilt angle. Heat analysis and measurement during welding are performed numerically to validate the experimental results. A 3-D symmetric Finite Element (FE) model was created

This study uses the Marciniak and Kuczynski (M-K) method to present an analytical forming limit diagram (FLD) for sheet metals. The procedure for the analytical FLD prediction is described in detail and step-wise manner, and an algorithm is written using MATLAB. First, an appropriate algorithm is determined to establish the theoretical analyses, and various anisotropic yield functions, such as Hill’s

The superplastic forming/diffusion bonding (SPF/DB) process has been widely applied to manufacture the multi-layer components. In this paper, a four-layer hollow structure with squad grid was fabricated by SPF/DB process. The superplastic behavior of TA15 alloy was investigated by the uni-axial tensile tests at high temperature, and the maximum elongation of 911 % was obtained at 920 °C/0.001 s− 1

Preform shape design for complex forging is an important and intractable aspect in the design of forging process. This paper presents an integrated methodology based on elliptic Fourier analysis (EFA), finite element method (FEM) and genetic algorithms (GA) to determine optimal preform shape. Firstly, an elliptic Fourier analysis, which has the advantages of wide versatility and short design cycle

The optimal design of the tools in bulk metal forming is a crucial task in the early design phase and greatly affects the final accuracy of the parts. The process of tool geometry assessment is resource- and time-consuming, as it consists of experience-based procedures. In this paper, a compensation method is developed with the aim to reduce geometrical deviations in hot forged parts. In order to simplify

Lorentz-force-driven (LFD) stamping process is effective in formability enhancement and shape controlling in deep cup drawing. In this paper, LFD process was proposed for small-sized hole-flanging. A series of LFD flanging experiments under different diameters of pre-fabricated hole were carried out, and conventional flanging was implemented for comparison. Defect-free case with smaller prefabricated

This paper suggests a novel numerical model to accurately simulate the chip formation for a wide range of high cutting speeds. It consists of finite element (FE) modeling of orthogonal machining of titanium alloy (Ti-6Al-4V) in which the Johnson–Cook (JC) material law which can reflect the strain rate hardening and thermal softening influences, and the JC damage law coupled with the displacement-based

During the hot strip tandem rolling (HSTR) process, the strip is compressed and elongated continuously, causing significant elastic deformation of rolls. At the same time, the strip temperature undergoes rapid increase and decrease, and distributes unevenly along the strip width direction. Elastic deformation of rolls and strip temperature variations have a significant effect on strip deformation,

The demands associated with the production of advanced parts made of nickel-base superalloys are continuously increasing to meet the requirements of current environmental laws. The use of lightweight components in load-carrying aero-engine structures has the potential to significantly reduce fuel consumption and greenhouse gas emissions. Furthermore, the competitiveness of the aero-engine industry

The forming limit curve (FLC) of zirconium alloys plays a significant role in the fabrications of spacer grid used for nuclear fuel assembly. The theoretical prediction of FLC has provided a convenient method to calculate the strain limit during the sheet forming process, but the prediction accuracy of zirconium alloy is still unsatisfactory due to its close-packed-hexagonal (HCP) structure. In this

High Strength Steel is more used in automotive industry to combine safety improvements and weight reductions of the vehicles. However, these steels raise new challenges for manufacturer, especially for springback and its prediction. Finite Element Analysis is widely used for the prediction of springback but accuracy is strongly depending on numerical as well as physical parameters. Such parameters

The purpose of the study is to elucidate fiber deformation behavior during the forging of a spur gear by using a carbon fiber reinforced thermoplastic billet. The billet was composed of PA6/UD chips with a fiber length of 30 mm and fiber volume fraction of 50%. A gear forging mold was developed to deform the billet into a gear shape without cutting the fibers. Three types of billets were prepared:

The production of injection moulded components with low shrinkage and warpage is a constant challenge for manufacturers. The thermal design of the injection mould plays an important role for the achievable quality, especially the placement of the cooling channels. This design is usually based on empirical knowledge of the mould designers. The construction is supported iteratively by injection moulding

The mold filling stage of the low-pressure powder injection molding process was simulated numerically and validated by experimental injections. For this, a feedstock formulated from a 17-4PH stainless steel powder (60 vol.%) and a wax-based binder system (40 vol.%) was used. The feedstock was characterized to obtain its thermal properties and rheological profiles at different temperatures. These were

An experimental-numerical methodology was proposed for the parameter identification of constitutive laws, when applied to hot forging. Industrial presses were directly used to generate the reference experiments for identification. The strain and temperature heterogeneity that appears during on-press compression experiments was taken into account by an FE-based inverse method. Specific experiments were

Structural lightweighting is a key initiative in the automotive sector due to regulatory, customer, and powertrain demands. This research focuses on reinforcing aluminum sheet metal in strategic locations using ultrasonic additive manufacturing (UAM), as guided through an iterative optimization and simulation process. Among the three models used, the most successful is the multi-step model (MSM) which

Fluctuations of material properties are one reason for the occurrence of cracks and waviness in series production of car body parts. Especially fluctuating tribological conditions have an effect on the friction behavior and thus on the material flow. So far fluctuating material properties are not considered in the standard FE-simulation and consequently not in the tool design. In order to enhance the

The originality of this work consists in the study of the stamping behaviour of tufted and un-tufted carbon preforms. Several preforms by varying the tufting thread orientations (0°, 90° and 0°/90°) and with different stratifications ([0°/90°,-45°/+45°] and [0°/90°,-45°/+45°]2) were manufactured in order to study their out-of-plane deformability. The stamping test was carried out using a hemispherical

The bimetal sheets products obtained by the incremental forming are gradually widely used because of the excellent properties of the bimetal sheets. But the forming process of the bimetal sheets is more complicated than that of single metal sheet because this process involves a complicated interface of the bimetal sheets. A three-dimensional model including the tool, the bimetal sheet and the cohesive

Most commercial softwares simulating casting process use a scalar field to quantify the shrinkage on final parts. The repartition of this scalar is used to localize shrinkage in the part. In this work, the objective is to use a new approach to predict morphological information about size and shape of shrinkage: the phase field method. This method is based on a parameter order defining the alternating

Single point incremental forming is a promising sheet metal forming technique for small batch production. However, the technique is unable to manufacture vertical walls without significant thickness variation and geometrical errors. Two-point incremental forming has the capability of manufacturing vertical walls but requires actuators and intricate rig designs. This paper presents a design facilitating

Magnetic pulse welding (MPW) has potential applications where fusion welding is problematic, such as in dissimilar joints or where the very part integrity, as in electronic components, is likely to be impaired by hot environments. Mostly suited in lap configuration, its successful implementation hinges on multiple process parameters such as standoff distance between two parts, the discharge energy

A strategy to adjust the product geometry autonomously through an online control of the manufacturing process in incremental sheet forming with active medium is presented. An axial force sensor and a laser distance sensor are integrated into the process setup to measure the forming force and the product height, respectively. Experiments are conducted to estimate the bulging behavior for different pre-determined

The present work aims to assess the joint behaviour of friction stir spot welded sandwich sheets by changing the quality of the epoxy core layer. Lab scale experiments and numerical simulations are conducted for the purpose. The core property is altered by varying hardener to resin (h/r) ratio within a suitable range. Joint mechanical performance and joint characterization are evaluated from experiments

Railway axles, which are an important component of railway vehicles, are generally manufactured using high-speed forging processes. To investigate the microstructure evolution and flow behavior during forging processes, a series of isothermal hot compression and heating tests were conducted in the temperature range of 900–1200 °C and strain rate range of 0.01–20 s−1. A strain-compensated Arrhenius

Axial hydro-forging sequence is an emerging approach in forming the variable-diameter tubes without thinning. However, after the batch production, a barrelling defect occurs at the end of the maximum diameter zone during the process. To investigate the barrelling behavior of the tube in axial hydro-forging sequence, experiments and finite element simulation were carried out in the present work. It

During the conventional disk-forging, the upper die repeatedly compresses materials on the flat stationary base. As the strain distributions of the forged disk are non-uniform owing to friction and uneven temperature distribution, more uniform deformation within the entire volume is desirable to obtain sound disk free from defects. This study proposes an advanced disk-forging process in the production

Al-Mg alloys have the properties of anisotropy, temperature softening and strain rate hardening in warm forming conditions. The former could be modeled by an advanced non-quadratic yield function. The rate-dependent characteristic could be modeled by viscoplastic constitutive models. Up to now, few investigations have combined a viscoplastic model with advanced yield functions for warm forming simulation

It is vital to envisage accurately the fracture limits of high strength superalloys when noticeable localized necking or thinning tendency is not observed during sheet-metal stretch forming process. The present study mainly focuses on fracture limits evaluation of Inconel 718 alloy (IN718) in the effective plastic strain (EPS) vs. average triaxiality space. First, uniaxial tensile test, to analyze

A 3d printing of a thin wall is achieved by a fused filament fabrication process. The influence of the printing velocities on the filament morphology is studied using optical microscopy. The strand morphology is approximated to different geometries and compared to experimental data. The oblong cross-section is a good approximation to estimate the strand’s height and width. A local temperature is recorded

In this work, the mechanical properties and failure characteristics of a Mg-9.0Al-0.8Zn alloy (AZ91) fabricated via the Thixomolding process (TC) were investigated and compared with those of alloys formed via other casting processes, including cold-chamber die-casting (CD) and hot-chamber die-casting (HD). The microstructure of the three cast samples mainly consisted of the α-Mg phase and eutectic

In the present article, the influence of the self-tapping screw’s geometry during the thread forming processes in polymer types used in several industries was studied and analysed using experimental measurement and the finite element method. A number of parameters, such as assembly, type of materials and geometry, were studied. Several commercial screw topologies were also studied, and it was demonstrated

This paper reviews the most recent models for description of the anisotropic plastic behavior and formability of sheet metals. After a brief review of classic isotropic yield functions, recent advanced anisotropic criteria for polycrystalline materials of various crystal structures and their applications to cup drawing are presented. Next, the discussion focuses on novel formulations of anisotropic

Braid-press forming was developed for manufacturing hollow tube parts made of carbon fiber reinforced thermoplastic (CFRTP) tape. The CFRTP tapes were braided to make a tube, which was consolidated under pressure and heat in the press forming process. Internal pressure was applied to the braided CFRTP tube by a silicone rubber rod inserted in the tube using axial compression. The reason for using a

The resulting tensile residual stresses on the surface of cold full-forward extruded parts are unfavorable for the fatigue life of these parts. The final stress state is determined by the combination of two process stages: forming and ejection. This is due to the fact that the workpiece undergoes a second plastic deformation after forming during the ejection from the die. So far, literature is focusing

This extended comment is in response to the letter of Barlat (Int J Mater Form 2020) concerning our recent article (Chandola et al. (Int J Mater Form 12(6):943–954 2019)). The main issue raised is an apparent “mismatch” between some of the F.E. results presented and cup forming data of Tucker (Acta Metall 9:275-286 1961). There is no mismatch because the simulation results presented in our paper correspond

In this paper, an advanced model formulated in the framework of non-associative plasticity is used to accurately predict the springback of advanced high strength steels material. The proposed model strongly couples the isotropic ductile damage to the phenomena a combined nonlinear isotropic and kinematic hardening, initial anisotropic plastic flow and induced anisotropies due to the distortion of the

Various studies show that application of kinematic hardening models significantly improves the accuracy of springback simulation in sheet metal forming. The springback simulation using kinematic hardening models, e.g., the Yoshida-Uemori (YU) model, is highly dependent on the testing strategy and the calibration of model parameters. In this study, the effect of tension-compression (T-C) testing strategy

Predictive computational modeling of the effect of automated fiber placement (AFP) defects on the structural performance of aerospace structural composites is of importance in preliminary design. A finite element method (FEM) based framework is presented for the analysis of the quasi-static tensile response of quasi-isotropic [45/0/ -?45/90]2s laminates containing controlled gaps and overlaps in the