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A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Mechanical Engineering".

Deadline for manuscript submissions: closed (20 March 2022) | Viewed by 26938

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Special Issue Editor

Dr. Kotov Anton

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Guest Editor

Department of Physical Metallurgy of Non-Ferrous Metals, National University of Science and Technology “MISiS”, Moscow, Russia
Interests: metal science; non-ferrous alloys; metal forming; superplastic deformation; microstructure; heat treatment; mechanical properties; mechanical behavior of materials; mechanical testing
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Special Issue Information

Dear Colleagues,

It is a great honor to serve as the Guest Editor of a Special Issue of Applied Sciences focusing on metals forming. I am pleased to inform you of the opportunity to submit a research paper or review paper to this Special Issue.

Metal forming processes are used to produce structural parts and semi-finished products, which are widely used in many industries, including automotive, aerospace, marine, and many others. In the analysis of metal forming, a large number of process parameters must be optimized to ensure the good quality of the final product. In addition to the desired geometry, material properties are very important parameters. The chemical composition and mechanical properties of the materials affect the processing modes that form the desired microstructures. On the other hand, the structure evolution during the deformation process affects the forming process. Thus, a thorough understanding of the relationship between these parameters is necessary to optimize metal forming processes.

This Special Issue will present the latest works in research related to several aspects of the metal forming processes, from microstructure formation to simulation and industrial applications. We are inviting papers that include but are not limited to any of the following thematic areas:

Metal Forming problems;
Structure and properties evolution during plastic deformation;
Mathematical Modeling and Simulation of metals forming;
Structure formation during metals forming processes;
Superplasticity and superplastic forming;
Shape memory effect.

Dr. Kotov Anton
Guest Editor

Manuscript Submission Information

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Keywords

metal forming
plastic deformation
metallic alloys
microstructure
mechanical properties
stress-strain data
deformation behavior
modeling
simulation
superplasticity
shape memory effect

Published Papers (11 papers)

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Research

12 pages, 2349 KiB

Open AccessArticle

Regression Approach to a Novel Lateral Flatness Leveling System for Smart Manufacturing

by Sung-Yu Tsai and Jen-Yuan Chang

Appl. Sci. 2021, 11(14), 6645; https://0-doi-org.brum.beds.ac.uk/10.3390/app11146645 - 20 Jul 2021

Cited by 4 | Viewed by 4808

Abstract

Sheet metal coils are widely used in the steel, automotive, and electronics industries. Many of these coils are processed through metal stamping or laser cutting to form different types of shapes. Sheet metal coil leveling is an essential procedure before any metal forming process. In practice, this leveling procedure is now executed by operators and primarily relies on their experience, resulting in many trials and errors before settling on the correct machine parameters. In smart manufacturing, it is required to digitize the machine’s parameters to achieve such a leveling process. Although smart manufacturing has been adopted in the manufacturing industry in recent years, it has not been implemented in steel leveling. In this paper, a novel leveling method for flatness leveling is proposed and validated with data collected by flatness sensors for measuring each roll adjustment position, which is later processed through the multi-regression method. The regression results and experienced machine operator results are compared. From this research, not only can the experience of the machine operators be digitized, but the results also indicate the feasibility of the proposed method to offer more efficient and accurate machine settings for metal leveling operations. Full article

(This article belongs to the Special Issue Metal Forming)

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23 pages, 1598 KiB

Open AccessArticle

Advanced Crystal Plasticity Modeling of Multi-Phase Steels: Work-Hardening, Strain Rate Sensitivity and Formability

by Jesús Galán-López, Behnam Shakerifard, Jhon Ochoa-Avendaño and Leo A. I. Kestens

Appl. Sci. 2021, 11(13), 6122; https://0-doi-org.brum.beds.ac.uk/10.3390/app11136122 - 30 Jun 2021

Cited by 1 | Viewed by 2312

Abstract

This work presents an advanced crystal plasticity model for the simulation of the mechanical behavior of multiphase advanced high-strength steels. The model is based on the Visco-Plastic Self-Consistent (VPSC) model and uses information about the material’s crystallographic texture and grain morphology together with a grain constitutive law. The law used here, based on the work of Pantleon, considers how dislocations are created and annihilated, as well as how they interact with obstacles such as grain boundaries and inclusions (carbides). Additionally, strain rate sensitivity is implemented using a phenomenological expression derived from literature data that does not require any fitting parameter. The model is applied to the study of two bainitic steels obtained by applying different heat treatments. After fitting the required parameters using tensile experiments in different directions at quasi-static and high strain rates, formability properties are determined using the model for the performance of virtual experiments: uniaxial tests are used to determine r-values and stress levels and biaxial tests are used for the calculation of yield surfaces and forming limit curves. Full article

(This article belongs to the Special Issue Metal Forming)

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17 pages, 9170 KiB

Open AccessArticle

Vision-Based Path Guidance to Achieve Dies-Free Roller Hemming Process

by Yi-Ping Huang, Bor-Tung Jiang, Chia-Hung Wu and Jen-Yuan Chang

Appl. Sci. 2021, 11(12), 5741; https://0-doi-org.brum.beds.ac.uk/10.3390/app11125741 - 21 Jun 2021

Cited by 1 | Viewed by 2856

Abstract

Due to its high production flexibility, roller hemming has become the mainstream process for forming and joining metal sheets in the automotive industry. The traditional roller hemming process requires specific dies to support sheet metal parts and repeated offline manual adjustment of hemming routes, resulting in high die costs, high time consumption, and excessive labor inputs. The universal platform presented in this paper could replace specific dies to effectively reduce costs and expand production flexibility. To reach this objective, a vision-based automatic compensation path to achieve a dies-free roller hemming process is proposed and investigated in this paper. Hand–eye sensor modules assisted by multi-coordinate synchronization calibration for the roller hemming were designed to reconstruct three-dimensional (3-D) shape data of the incoming materials. Results from the proposed system were validated with experimental measurements for the sheet offset and the compensation of the arm hemming position, showing that the single-axis error can be reduced to ≤0.1 mm. Full article

(This article belongs to the Special Issue Metal Forming)

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9 pages, 2793 KiB

Open AccessArticle

Flow Stress Modelling and 3D Processing Maps of Al4.5Zn4.5Mg1Cu0.12Zr Alloy with Different Scandium Contents

by Maxim G. Khomutov, Andrey V. Pozdniakov, Alexander Yu. Churyumov, Ruslan Yu. Barkov, Alexey N. Solonin and Maria V. Glavatskikh

Appl. Sci. 2021, 11(10), 4587; https://0-doi-org.brum.beds.ac.uk/10.3390/app11104587 - 18 May 2021

Cited by 11 | Viewed by 1534

Abstract

The hot deformation behaviour of an Al4.5Zn4.5Mg1Cu0.12Zr based alloy with 0.05, 0.1 and 0.15% Sc was investigated at temperatures between 300–450 °C and a strain rate of 0.1–15 s⁻¹. The materials constants of a flow stress model based on the Zener-Hollomon parameter were determined (AARE was 5.8%). Three-dimensional processing maps were established by combining power dissipation efficiency and flow stability diagrams. Based on processing maps analysis and microstructures investigations, the optimal deformation parameters were determined as a temperature range of 350–400 °C and strain rates of 0.1–1 s⁻¹ for the alloys with 0.05% and 0.1% Sc, and 0.1 s⁻¹ for the alloy with 0.15% Sc. Full article

(This article belongs to the Special Issue Metal Forming)

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16 pages, 9999 KiB

Open AccessArticle

Investigation of Magnetic Anisotropy and Barkhausen Noise Asymmetry Resulting from Uniaxial Plastic Deformation of Steel S235

by Martin Pitoňák, Miroslav Neslušan, Peter Minárik, Jiří Čapek, Katarína Zgútová, Martin Jurkovič and Tomáš Kalina

Appl. Sci. 2021, 11(8), 3600; https://0-doi-org.brum.beds.ac.uk/10.3390/app11083600 - 16 Apr 2021

Cited by 4 | Viewed by 1449

Abstract

This study investigates alterations in magnetic anisotropy and the marked asymmetry in Barkhausen noise (MBN) signals after the uniaxial plastic straining of steel S235 obtained from a shipyard and used as standard structural steel in shipbuilding. It was found that the initial easy axis of magnetisation in the direction of previous rolling, and also in the direction of loading, becomes the hard axis of magnetisation as soon as the plastic strain attains the critical threshold. This behaviour is due to the preferential matrix orientation and the corresponding realignment of the magneto-crystalline anisotropy. Apart from the angular dependence of MBN, the asymmetry in the consecutive MBN bursts at the lower plastic strains is also analysed and explained as a result of magnetic coupling between the grains plastically strained and those unaffected by the tensile test. It was found that, by increasing the degree of plastic strain, the marked asymmetry in MBN tends to vanish. Moreover, the asymmetry in MBN bursts occurs in the direction of uniaxial tension and disappears in the perpendicular direction. Besides the MBN technique, XRD and EBSD techniques were also employed in order to provide a deeper insight into the investigated aspects. Full article

(This article belongs to the Special Issue Metal Forming)

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15 pages, 58221 KiB

Open AccessArticle

United Approach to Modelling of the Hot Deformation Behavior, Fracture, and Microstructure Evolution of Austenitic Stainless AISI 316Ti Steel

by Alexander Yu. Churyumov, Svetlana V. Medvedeva, Olga I. Mamzurina, Alena A. Kazakova and Tatiana A. Churyumova

Appl. Sci. 2021, 11(7), 3204; https://0-doi-org.brum.beds.ac.uk/10.3390/app11073204 - 02 Apr 2021

Cited by 10 | Viewed by 2327

Abstract

Hot deformation is one of the main technological stages of products made from metallic materials. It is strictly required to decrease the costs of developing optimized technologies at this stage without a significant decrease in the products’ quality. The present investigation offers an algorithm to unite three different models to predict the hot deformation behavior, fracture, and microstructure evolution. The hot compression and tension tests of the AISI 316Ti steel were conducted using the thermomechanical simulator Gleeble 3800 for the models’ construction. The strain-compensated constitutive model and the Johnson–Mehl–Avrami–Kolmogorov (JMAK)-type model of the grain structure evolution show a satisfactory accuracy of 4.38% and 6.9%, respectively. The critical values of the modified Rice and Tracy fracture criteria were determined using the experimental values of the relative cross-section reduction and finite element calculation of the stress triaxiality. The developed models were approved for the stainless AISI 316Ti steel by the hot torsion with tension test. Full article

(This article belongs to the Special Issue Metal Forming)

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20 pages, 9026 KiB

Open AccessArticle

Characterization of Superplastic Deformation Behavior for a Novel Al-Mg-Fe-Ni-Zr-Sc Alloy: Arrhenius-Based Modeling and Artificial Neural Network Approach

by Ahmed O. Mosleh, Anton D. Kotov, Anna A. Kishchik, Oleg V. Rofman and Anastasia V. Mikhaylovskaya

Appl. Sci. 2021, 11(5), 2208; https://0-doi-org.brum.beds.ac.uk/10.3390/app11052208 - 03 Mar 2021

Cited by 11 | Viewed by 2018

Abstract

The application of superplastic forming for complex components manufacturing is attractive for automotive and aircraft industries and has been of great interest in recent years. The current analytical modeling theories are far from perfect in this area, and the results deduced from it characterize the forming conditions insufficiently well; therefore, successful numerical modeling is essential. In this study, the superplastic behavior of the novel Al-Mg-Fe-Ni-Zr-Sc alloy with high-strain-rate superplasticity was modeled. An Arrhenius-type constitutive hyperbolic-sine equation model (ACE) and an artificial neural network (ANN) were developed. A comparative study between the constructed models was performed based on statistical errors. A cross validation approach was utilized to evaluate the predictability of the developed models. The results revealed that the ACE and ANN models demonstrated strong workability in predicting the investigated alloy’s flow stress, whereas the ACE approach exhibited better predictability than the ANN. Full article

(This article belongs to the Special Issue Metal Forming)

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12 pages, 11768 KiB

Open AccessArticle

Anti-Galling Cold, Dry Forging of Pure Titanium by Plasma-Carburized AISI420J2 Dies

by Tatsuhiko Aizawa, Tomoaki Yoshino, Yohei Suzuki and Tomomi Shiratori

Appl. Sci. 2021, 11(2), 595; https://0-doi-org.brum.beds.ac.uk/10.3390/app11020595 - 09 Jan 2021

Cited by 9 | Viewed by 1432

Abstract

A bare AISI420J2 punch often suffers from severe adhesion of metallic titanium as well as titanium oxide debris particles in dry, cold forging of biomedical titanium alloys. This punch was plasma-carburized at 673 K for 14.4 ks to harden it up to 1200 HV on average and to achieve carbon supersaturation in the carburized layer. This plasma-carburized punch was employed in the cold, dry forging of a pure titanium wire into a flat plate while reducing the thickness by 70%. The contact interface width approached the forged workpiece width with increasing the reduction ratio. This smaller bulging deformation reveals that the workpiece is upset by homogeneous plastic flow with a lower friction coefficient. This low-friction and anti-galling forging process was sustained by an in situ solid lubrication mechanism. Unbound free carbon was isolated from the carbon-supersaturated AISI420J2 matrix and deposited as a thin tribofilm to protect the contact interface from mass transfer of metallic titanium. Full article

(This article belongs to the Special Issue Metal Forming)

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16 pages, 5020 KiB

Open AccessArticle

Numerical Investigations on the Shape Optimization of Stainless-Steel Ring Joint with Machine Learning

by Minsoo Kim, Sarang Yi and Seokmoo Hong

Appl. Sci. 2021, 11(1), 223; https://0-doi-org.brum.beds.ac.uk/10.3390/app11010223 - 28 Dec 2020

Cited by 1 | Viewed by 2176

Abstract

Since pipes used for water pipes are thin and difficult to fasten using welding or screws, they are fastened by a crimping joint method using a metal ring and a rubber ring. In the conventional crimping joint method, the metal ring and the rubber ring are arranged side by side. However, if water leaks from the rubber ring, there is a problem that the adjacent metal ring is rapidly corroded. In this study, to delay and minimize the corrosion of connected water pipes, we propose a spaced crimping joint method in which metal rings and rubber rings are separated at appropriate intervals. This not only improves the contact performance between the connected water pipes but also minimizes the load applied to the crimping jig during crimping to prevent damage to the jig. For this, finite element analyses were performed for the crimp tool and process analysis, and the design parameters were set as the curling length at the top of the joint, the distance between the metal rings and rubber rings, and the crimp jig radius. Through FEA of 100 cases, data to be trained in machine learning were acquired. After that, training data were trained on a machine learning model and compared with a regression model to verify the model’s performance. If the number of training data is small, the two methods are similar. However, the greater the number of training data, the higher the accuracy predicted by the machine learning model. Finally, the spaced crimping joint to which the derived optimal shape was applied was manufactured, and the maximum pressure and pressure distribution applied during compression were obtained using a pressure film. This is almost similar to the value obtained by finite element analysis under the same conditions, and through this, the validity of the approach proposed in this study was verified. Full article

(This article belongs to the Special Issue Metal Forming)

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12 pages, 6512 KiB

Open AccessArticle

Multi-Pass Stamping Forming a Concave Ring

by Song Zhang, Xuedao Shu, Jianan Shi and Zixuan Li

Appl. Sci. 2020, 10(18), 6434; https://0-doi-org.brum.beds.ac.uk/10.3390/app10186434 - 16 Sep 2020

Cited by 2 | Viewed by 2209

Abstract

To improve the production quality and efficiency of the concave ring, a multi-pass stamping technology is used to replace the spinning technology to form the concave ring. First, the multi-pass stamping dies are designed according to the structural characteristics of the concave ring. Then, the process parameters are determined based on the bending conditions and the dimensional requirements of the concave ring. Next, the rationality of the designed stamping dies is verified by analyzing the stress and strain field of the multi-pass stamping concave ring. Finally, the stamping experiments are carried out. Experimental results show that the dimensional error of the concave ring formed by multi-pass stamping is less than 0.5%. The multi-pass stamping technology is feasible to form the concave ring. The reasonable design of the mold is the key factor to prevent defects in the workpiece. The concave ring formed by multi-pass stamping meets the industrial requirements. Full article

(This article belongs to the Special Issue Metal Forming)

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8 pages, 1672 KiB

Open AccessArticle

The Phase Composition and Mechanical Properties of the Novel Precipitation-Strengthening Al-Cu-Er-Mn-Zr Alloy

by Sayed Amer, Olga Yakovtseva, Irina Loginova, Svetlana Medvedeva, Alexey Prosviryakov, Andrey Bazlov, Ruslan Barkov and Andrey Pozdniakov

Appl. Sci. 2020, 10(15), 5345; https://0-doi-org.brum.beds.ac.uk/10.3390/app10155345 - 03 Aug 2020

Cited by 28 | Viewed by 2486

Abstract

The microstructure, phase composition, and mechanical properties during heat treatment and rolling of the novel Al-5.0Cu-3.2Er-0.9Mn-0.3Zr alloy were evaluated. A new quaternary (Al,Cu,Mn,Er) phase with possible composition Al₂₅Cu₄Mn₂Er was found in the as-cast alloy. Al₂₀Cu₂Mn₃ and Al₃(Zr,Er) phases were nucleated during homogenization, and θ″(Al₂Cu) precipitates were nucleated during aging. The metastable disc shaped θ″(Al₂Cu) precipitates with a thickness of 5 nm and diameter of 100–200 nm were nucleated mostly on the Al₃(Zr,Er) phase precipitates with a diameter of 35 nm. The hardness Vickers (HV) peak was found after the annealing of a rolled alloy at 150 °C due to strengthening by θ″(A₂Cu) precipitates, which have a larger effect in materials hardness than do the softening processes. The novel Al-Cu-Er-Mn-Zr alloy has a yield strength (YS) of 320–332 MPa, an ultimate tensile strength (UTS) of 360–370 MPa, and an El. of 3.2–4.0% in the annealed alloy after rolling condition. Full article

(This article belongs to the Special Issue Metal Forming)

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