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

Experimental and numerical investigations on the description of cold formability of extra abrasion-resistant steel considering surface roughness effects were performed in this study. A novel multiscale numerical approach to quantitatively evaluate the impacts of surface roughness on the cold formability/bendability of heavy plates was proposed and verified. The macroscopic ductile damage behavior of

We developed a processing technique to apply plastic deformation to solid bamboo impregnated with thermosetting resin. To prevent the forming defects such as incomplete filling during upset forgings, we investigated the factors that affect the deformability of the bamboo. We conducted compression tests of the bamboo impregnated with phenol-formaldehyde resin using flat dies. The die temperature and

The manufacturing research has been focusing on the improvement of product performance and lightweight design. The synergic effects between material properties and manufacturing solutions have been considered, extensively. Specifically, joining techniques have been developing with the aim to propose new suitable solutions considering dissimilarities in the properties of the materials that have to be

The importance of manufacturing of hydrogen fuel tanks due to the application of hydrogen fuels in clean and recyclable energy is one of the most important issues of substituting the petroleum fuels. They consist of two main parts: Plastic liner, as a barrier escape of hydrogen and Carbon Fiber Reinforced Polymer (CFRP) layer to strengthen tanks. The liner plastic could be manufactured by rotational

Friction Stir Welding (FSW) is one of the most used solid-state welding processes in the aeronautical, aerospace, ground transportation and naval fields. Stationary Shoulder Friction Stir Welding (SSFSW) is a recently introduced variant of the process allowing lower heat input into the joints, with beneficial effects in terms of joint mechanical properties, microstructure and top surface finish. In

The present paper deals with preform deformation and resin flow coupled to cure kinetics and chemo-rheology for the VARTM process. By monitoring the coupled resin infusion and curing steps through temperature control, our primary aim is to reduce the cycle time of the process. The analysis is based on the two-phase porous media flow and the preform deformation extended with cure kinetics and heat transfer

Laser-assisted tape winding (LATW) is a highly automated process for manufacturing tubular-like fiber-reinforced thermoplastic composites such as flywheels and pipes. One of the crucial parameters in the LATW process is the temperature of the nip point at which the incoming prepreg tape is bonded with the substrate by a compaction roller. Therefore, the temperature evolution of the nip point plays

A tailored tempering process, whereby the cooling rate for the sheet is controlled to form regions with very high strength and regions of reduced strength but increased ductility. In order to obtain the optimal mechanical properties for CSC-15B22 steel sheets that undergo tailored tempering, experimental and simulation method are used to examine the tempering process. The heated die section is heated

The original publication of this article unfortunately contains error. The word “extrusion” was spelled incorrectly as “extrussion” in the article title.

The predictability of strain distributions and the related prediction of hardening and failure plays a central role in tool and process design for any metal forming process. Studying yielding behaviour, it was discovered that for various well established yield loci no satisfying agreement between DIC (digital image correlation) measurement of strain distribution and simulation result could be obtained

Microwave (MW) technology relies on volumetric heating, where thermal energy is induced from an electromagnetic field. Nowadays, the main drawback of this technology is that the complex physics involved in the conversion of electromagnetic energy into thermal energy is not entirely understood and controlled. The main objective of this work is to model, simulate and validate the interactions of microwaves

Non-intrusive approaches for the construction of computational vademecums face different challenges, especially when a parameter variation affects the physics of the problem considerably. In these situations, classical interpolation becomes inaccurate. Therefore, classical approaches for the construction of an offline computational vademecum, typically by using model reduction techniques, are no longer

During the stretch blow moulding (SBM) process of polyethylene terephthalate (PET) bottle, high viscous dissipation generates self heating phenomena. Since the influence of temperature on polymer’s behavior is important, it is necessary to evaluate the self heating values in order to manage accurately the simulation of the process. An anisotropic visco-hyperelastic model has been developed to manage

The simultaneous hot/cold forging is an innovative production process, taking advantage of the high accuracy for cold forming and low forces for hot forming. However, the choice of a suitable material model for such a large temperature range is a difficult issue and insufficiently regarded. Hence, the aim of this contribution is a critical review and assessment of the prediction capability and accuracy

During the extrusion of thermoplastic particulates, the major problem is to adjust and optimize the experimental conditions of temperature and rotational speed of the screw, to decrease porosity defects, resulting from the coalescence of the polymer grains. In this work, a study of high-density polyethylene (HDPE) coalescence as a function of temperature and shear rate is conducted, with modeling of

Continuous Glass Fiber-Reinforced Thermoplastic Composites (GFRTC) were successfully prepared using two different routes: a reactive laboratory-created approach as well as a compression molding method. Two kinds of high-performance polyphtalamides (PPA) were studied: PPA from a chain extension reaction of its parent prepolymer (named R-PPA) in comparison with a virgin non-reactive PPA (NR-PPA). For

Unsaturated-polyester/glass-fiber composites are worldwide more and more used. Actually, their thermochemical and mechanical recycling paths are quite well-known. But, due to the relatively low value of the end products, these two paths are hardly economically viable. Thus, a third way will be proposed as a thermomechanical path. In order to recycle these composites, a study of their thermo-mechanical

A novel differential lubrication method is proposed to improve the deformation behavior of L-shaped thin-walled with relative bending radius of 1 in push-bending process. The optimized tube blank is divided into four zones: inner deformation zone, inner guide zone, outer deformation zone and outer guide zone, which are lubricated with different lubricants. The differential lubrication and uniform lubrication

The hot deformation behavior of a multi-direction forged (MDFed) T2 copper was investigated by the isothermal compression test at deformation temperatures between 673 and 1173 K and strain rates between 0.001 and 10 s− 1. The results reveal that the deformation characteristics of the flow stress are sensitive to the hot deformation parameters. The deformation activation energy of the MDFed copper under

In this study, the effects of the single and multiple productions of samples by additive manufacturing on residual stress and displacement (distortions) were investigated. The samples were manufactured by Selective Laser Melting (SLM) machine using Ti6Al4V powders. Each time a different number (1, 5 and 13 samples) of cubic shaped samples were produced on the building platform. During the process,

This paper presents an experimental and numerical investigation into the effect of pre-heat temperature on stretch forming of a fibre metal laminate (FML) comprised of alternating layers of steel and woven (0/90) glass-fibre polypropylene in a 2:1 configuration. Hourglass sample geometries were formed in an open die and real-time photogrammetry was used to measure the evolution of strain fields over

The Forming Limit Diagram (FLD) is an essential tool to assess sheet metal formability in sheet metal deep drawing. In FLDs/FLC (Forming Limit Curve) is representation of material formability limits at which material is not able to withstand higher deformation. In this work, different methodologies for FLC determination of mild steel DC01 are investigated. The Nakajima test is a well-known experiment

Nowadays, polyamide 12 (PA-12) is considered as an interesting polymer in the rotomolding process to manufacture different pieces like the liner part in the storage hydrogen tank (type IV). In this study, the pure polyamide-12 and PA12 pieces, incorporated with 0.5%, 1% and 3% wt Nano Carbon Black (NCB), were manufactured by the rotomolding process. Different rotomolding parameters such as heating

Production efficiency in metal forming processes can be improved by implementing robust optimization. In a robust optimization method, the material and process scatter are taken into account to predict and to minimize the product variability around the target mean. For this purpose, the scatter of input parameters are propagated to predict the product variability. Consequently, a design setting is

For conventional material models like Yld2000-2d or BBC05 the equi-biaxial yield strength is required for the parameter identification. In this context, a commonly used test setup is the hydraulic bulge test. However, an inaccuracy in the characterization of the initial yield strength is present in the hydraulic bulge test. Due to the evaluation of the resulting curvature of the specimen, that is nearly

The objective of the research is to determine the effect of friction stir processing (FSP) parameters and vibration on the machining behavior of AZ91 alloy. The article displays the state of the art of AZ91 alloy machinability including chip formation, chip morphology, and cutting forces. In this method, the vibration was applied to the process line through the fixture under the workpiece during the

In this paper, specimens were first pre-stretched to different pre-strain coefficients (0, 0.4 and 0.8) under quasi-static tensile for AA6061-O aluminum alloy. Then, the specimens with different pre-strain coefficients were stretched by a high-speed tensile machine (HTM) at different strain rates (200 s− 1, 400 s− 1 and 600 s− 1). Digital image correlation (DIC) technique was employed to measure the

Aeronautical companies are manufacturing many components of small (less than 200 mm) and medium (between 200 mm and 1000 mm) sizes by flexforming. In order to diversify the production facilities of these components, these companies are interested in evaluating the ability of electromagnetic forming processes to produce small parts. This paper describes the design of a set of experiments of electromagnetic

This paper proposes an innovative electromagnetic forming process for the manufacturing of aluminum alloy tubes, namely electromagnetic impacting medium forming (EIMF) process using flat spiral coil. The proposed EIMF process was implemented and characterized by numerical and experimental methods. Based on medium height and discharge energy, deformation region of tube was analytically determined and

Recent advances in mechanical and civil engineering are noticed in many innovative designs that frequently employ cold-formed High Strength Steels (HSS). Typical mobile cranes benefit from the advanced properties of these steel grades in a bent configuration. Here, the majority of load-carrying members are produced through cold-bending and subsequent welding procedures. These cold-foring processes

The quality of thin strip products is determined by the flow and heat transfer in a molten pool of twin-roll casting, thus it is of great significance to study the structure parameters of the delivery system, including the angle and height of end face nozzle, the angle and height of side nozzle as well as the taper angle of side nozzle. A methodology for simulation of twin-roll thin strips continuous