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Recent Advances and Trends in Metal Forming

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (30 September 2021) | Viewed by 25577

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Dr. Janusz Tomczak

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Faculty of Mechanical Engineering, Lublin University of Technology, 36 Nadbystrzycka Str, 20-618 Lublin, Poland
Interests: rolling processes; forging processes; new metalworking techniques; physical and numerical modelling; innovative designs of metal forming machines
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Special Issue Information

Dear Colleagues,

The dominant trend in the global industry is the search for new technological solutions that, on the one hand, ensure reduced consumption of materials, energy, and harmful emissions and, on the other, provide highly efficient technologies, allowing the production of high-quality machine parts. This trend is particularly evident in the area of forming processes for metals and metal alloys, where great progress has recently been made. The development of new metalworking techniques can practically be observed in all fields of forming, and it is focused on manufacturing finished and semifinished products with high strength and accuracy and with reduced machining allowance at the same time. Today, metal working is not only about forming materials to the required shape but also about shaping the structure and properties of materials through appropriately designed processes. All this is aimed at reducing manufacturing costs, improving product quality and strength, and obtaining the desired functional characteristics of products.

This Special Issue is an attempt at reporting recent findings in the field of metal working, from forming processes and materials engineering to the optimization of manufacturing processes. The primary objective of the Materials Special Issue is to present the latest achievements in forming metals and metal alloys and to indicate trends in the development of metalworking processes.

The upcoming Special Issue of Materials aims to present new developments in forming metals and metal alloys. We are pleased to invite you to submit research papers and reviews related to the latest achievements and developments in the forming of metals and metal alloys. All comments and suggestions for the Special Issue are welcome.

Prof. Dr. Janusz Tomczak
Guest Editor

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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. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

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Keywords

Rolling
Forging
Extrusion
Press forming
Bending
Special forming methods
Micro- and macrostructure of wrought materials

Published Papers (12 papers)

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Research

10 pages, 20284 KiB

Open AccessArticle

The Influence of the Soaking Temperature Rotary Forging and Solution Heat Treatment on the Structural and Mechanical Behavior in Ni-Rich NiTi Alloy

by Patrícia Freitas Rodrigues, Rodolfo S. Teixeira, Naiara V. Le Sénéchal, Francisco Manuel Braz Fernandes and Andersan S. Paula

Materials 2022, 15(1), 63; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15010063 - 22 Dec 2021

Cited by 2 | Viewed by 2111

Abstract

The structural and thermophysical characteristics of an Ni-rich NiTi alloy rod produced on a laboratory scale was studied. The soak temperature of the solution heat-treatment steps above 850 °C taking advantage of the precipitate dissolution to provide a matrix homogenization, but it takes many hours (24 to 48) when used without thermomechanical steps. Therefore, the suitable reheating to apply between the forging process steps is very important, because the product’s structural characteristics are dependent on the thermomechanical processing history, and the time required to expose the material to high temperatures during the processing is reduced. The structural characteristics were investigated after solution heat treatment at 900 °C and 950 °C for 120 min, and these heat treatments were compared with as-forged sample structural characteristics (one hot deformation step after 800 °C for a 30 min reheat stage). The phase-transformation temperatures were analyzed through differential scanning calorimetry (DSC), and the structural characterization was performed through synchrotron radiation-based X-ray diffraction (SR-XRD) at room temperature. It was observed that the solution heat treatment at 950 °C/120 min presents a lower martensitic reversion finish temperature (A_f); the matrix was fully austenitic; and it had a hardness of about 226 HV. Thus, this condition is the most suitable for the reheating stages between the hot forging-process steps to be applied to this alloy to produce materials that can display a superelasticity effect, for applications such as crack sensors or orthodontic archwires. Full article

(This article belongs to the Special Issue Recent Advances and Trends in Metal Forming)

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20 pages, 5817 KiB

Open AccessEditor’s ChoiceArticle

A Comparative Analysis of the Physical Modelling of Two Methods of Balls Separation

by Łukasz Wójcik, Zbigniew Pater, Tomasz Bulzak, Janusz Tomczak and Konrad Lis

Materials 2021, 14(23), 7126; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14237126 - 23 Nov 2021

Cited by 2 | Viewed by 1330

Abstract

The article presents the results of model tests with which a comparative analysis of two methods of ball separation during the skew rolling process was carried out. A verification of the results obtained in the physical modelling process with the results obtained in the real process of skew ball rolling was also carried out. During the physical modelling, the effect of changing the ball separation method on the quality of the products obtained, variations in maximum torque values and maximum radial forces were analyzed. In the case of real tests, the results were verified with the results of physical modelling, in which the surface quality and torque values for one of the tool sets were compared. Physical modelling was used to verify the differences between the two methods of ball separation. Commercial plasticine based on synthetic wax from the manufacturer PRIMO was used as a model material for physical analysis. The plasticine used for testing was cooled to 0 °C and the cooling process took 24 h. The tools used for the physical modelling were 3D printed and the material used was ABS. The method of physical modelling using plasticine as a model material allows for a correct analysis of hot metal forming processes. Full article

(This article belongs to the Special Issue Recent Advances and Trends in Metal Forming)

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12 pages, 4237 KiB

Open AccessArticle

Ductile Fracture Prediction in Cross-Wedge Rolling of Rail Axles

by Tomasz Bulzak

Materials 2021, 14(21), 6638; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14216638 - 04 Nov 2021

Cited by 9 | Viewed by 1400

Abstract

In the process of cross-wedge rolling, axial-symmetric forgings are formed using wedge tools. These tools may be flat- or roll-shaped. This article presents two methods of cross-wedge rolling of rail axles, traditional and multi-wedge, as well as their advantages and disadvantages. Two cross-wedge rolling processes are modelled numerically using Simufact Forming. Numerical results are then verified by experiments performed on a flat wedge rolling mill. Results obtained with the two rolling methods are compared in terms of material fracture, force parameters, effective strain and thermal conditions during rolling. Results show that material fracture poses a serious problem in these rolling processes. It is found that the Cockcroft–Latham ductile fracture criterion does not predict material fracture correctly. Results demonstrate that the fracture of railway axles in cross-wedge rolling can be best predicted by the fracture criteria developed by Ayada, Brozzo, Ko, Rice and Tracey. Full article

(This article belongs to the Special Issue Recent Advances and Trends in Metal Forming)

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14 pages, 5455 KiB

Open AccessArticle

Ultrasonic Assessment of the Influence of Cold Rolling and Recrystallization Annealing on the Elastic Constants in a TWIP Steel

by Linton Carvajal, María Sosa, Alfredo Artigas, Nelson Luco and Alberto Monsalve

Materials 2021, 14(21), 6559; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14216559 - 01 Nov 2021

Cited by 2 | Viewed by 1194

Abstract

The evolution of the elastic constants,

C_{33}

C_{44}

and

C_{55},

The evolution of the elastic constants,

C_{33}

C_{44}

and

C_{55},

Poisson’s ratio and acoustic birefringence of a Fe-0.5 wt% C-21.5 wt% Mn twinning-induced plasticity (TWIP) steel with reduction by cold rolling and recrystallization annealing was assessed from measurements of the times of flight of ultrasonic waves propagating along the thickness of the rolled plates. As the reduction increased, changes in the elastic constants resulted in a steadily increasing orthotropy, which was clearly shown by Poisson’s ratio and acoustic birefringence. Although optical metallography and hardness measurements showed that partial or full recrystallization is attained after annealing at 600 °C and 700 °C, the ultrasonic measurements revealed that a high level of orthotropy remains. Full article

(This article belongs to the Special Issue Recent Advances and Trends in Metal Forming)

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17 pages, 5401 KiB

Open AccessArticle

Numerical Simulation and Experimental Analysis of the Semi-Solid Thixotropic Extrusion Forming Process for Producing the Thin-Wall Wrought Aluminum Alloy Mobile Phone Shells

by Yi Guo, Yongfei Wang and Shengdun Zhao

Materials 2021, 14(13), 3505; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14133505 - 23 Jun 2021

Cited by 2 | Viewed by 1522

Abstract

Aluminum alloys have been widely used in various engineering applications due to their excellent physical properties such as low density, high strength and good cutting capacity. In this paper, the semi-solid thixotropic extrusion forming process is proposed to produce aluminum alloy 6063 shells for mobile phones. The effects of the operating parameters on the equivalent stress distribution, velocity field, temperature field, and the load of the top mould were investigated through numerical simulations. Optimal parameters were identified from the simulation results. The experiment was then conducted at these optimal parameters. The macromorphology and microstructure results of the mobile phone shells produced from the experiment are presented and discussed. It was found that the optimal process parameters for preparing aluminum alloy 6063 shell by the semi-solid thixotropic extrusion process were a billet temperature of 630 °C, mould temperature of 400 °C, and top mould speed of 10 mm/s. It was found that the mobile phone shells fabricated under the optimal operating conditions were fully filled with a clear outline and a smooth surface. The solid grains in the microstructure were small, uniform and nearly spherical. The average grain size of the microstructure for the product was obtained as 76.92 μm and the average shape factor was found as 0.76. Full article

(This article belongs to the Special Issue Recent Advances and Trends in Metal Forming)

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11 pages, 10859 KiB

Open AccessArticle

The Chosen Aspects of Skew Rolling of Hollow Stepped Shafts

by Jarosław Bartnicki, Yingxiang Xia and Xuedao Shu

Materials 2021, 14(4), 764; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14040764 - 06 Feb 2021

Cited by 6 | Viewed by 2814

Abstract

The paper presents chosen aspects of the skew rolling process of hollow stepped products with the use of a skew rolling mill designed and manufactured at the Lublin University of Technology. This machine is characterized by the numerical control of spacing between the working rolls and the sequence of the gripper axial movement, which allows for the individual programming of the obtained shapes of parts such as stepped axles and shafts. The length of these zones and the values of possibly realizable cross-section reduction and obtained outlines are the subject of this research paper. The chosen results regarding the influence of the technological parameters used on the course of the process are shown in the present study. Numerical modelling using the finite element method in Simufact Forming, as well as the results of experimental tests performed in a skew rolling mill, were applied in the conducted research. The work takes into account the influence of cross-section reduction of the hollow parts and the feed rate per rotation on the metal flow mechanisms in the skew rolling process. The presented results concern the obtained dimensional deviations and changes in the wall thickness determining the proper choice of technological parameters for hollow parts formed by the skew rolling method. Knowledge about the cause of the occurrence of these limitations is very important for the development of this technology and the choice of the process parameters. Full article

(This article belongs to the Special Issue Recent Advances and Trends in Metal Forming)

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15 pages, 9690 KiB

Open AccessEditor’s ChoiceArticle

Skew Rolling of Bimetallic Rods

by Janusz Tomczak, Tomasz Bulzak, Zbigniew Pater, Łukasz Wójcik and Tomasz Kusiak

Materials 2021, 14(1), 18; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14010018 - 22 Dec 2020

Cited by 11 | Viewed by 2611

Abstract

The present article reports selected results of a preliminary study of the process of skew rolling of bimetallic rods. The experiments were conducted using a numerically controlled three-roller skew rolling mill. During the tests, bimetallic rods were rolled from billets whose cores and outer sleeves (bushings) were made of different types of steel. The results demonstrate that the proposed method can be successfully used in the production of bimetallic rods. However, proper fastening of the two materials depends on the geometrical parameters of the billets, and the quality of bimetallic rods depends on the heating method used. When the rods are heated without protective atmospheres, the surface layer of the core gets decarburized and the surfaces of the materials being joined together are oxidized, which hinders the welding process and adversely affects the physical and chemical properties of such products. The results of numerical modeling indicate that the material near the surface tends to flow, which may have a negative impact on the welding process. In addition, the distribution of stress in the tool–workpiece contact zone may make welding of the materials difficult. The results reported in this paper are preliminary and constitute a prelude to a more detailed analysis of bimetallic rod rolling. Full article

(This article belongs to the Special Issue Recent Advances and Trends in Metal Forming)

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14 pages, 5931 KiB

Open AccessEditor’s ChoiceArticle

A Rotary Compression Process for Producing Hollow Gear Shafts

by Arkadiusz Tofil, Janusz Tomczak, Tomasz Bulzak, Zbigniew Pater, Marcin Buczaj and Andrzej Sumorek

Materials 2020, 13(24), 5718; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13245718 - 15 Dec 2020

Cited by 3 | Viewed by 2639

Abstract

This paper presents selected numerical and experimental results of a study investigating the process of forming hollow stepped gear shafts from tubes by rotary compression. The objective of the study was to determine whether the rotary compression process is an effective method of producing hollow stepped gear shafts and to identify limitations of this manufacturing method. A theoretical analysis involved the numerical modeling of the proposed process by the finite element method (FEM). 3D simulations were performed using the commercial simulation software package Simufact Forming. The analysis involved examining the material flow pattern along with thermal and force parameters of the process. The FEM results were verified with experimental tests conducted under laboratory conditions. The experiments were performed on a machine specially designed for the rotary compression of hollow parts. Results demonstrate that it is difficult to form a stepped gear shaft in one operation. For this reason, such parts should be formed in two operations. The first operation involves the forming of a hollow stepped shaft by rotary compression, while in the second operation, a gear is formed on one of the steps of the shaft. Full article

(This article belongs to the Special Issue Recent Advances and Trends in Metal Forming)

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15 pages, 30193 KiB

Open AccessArticle

Experimental Investigation and Optimization of the Semisolid Multicavity Squeeze Casting Process for Wrought Aluminum Alloy Scroll

by Yi Guo, Yongfei Wang and Shengdun Zhao

Materials 2020, 13(22), 5278; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13225278 - 21 Nov 2020

Cited by 5 | Viewed by 2184

Abstract

Scroll compressors are popularly applied in air-conditioning systems. The conventional fabrication process causes gas and shrinkage porosity in the scroll. In this paper, the electromagnetic stirring (EMS)-based semisolid multicavity squeeze casting (SMSC) process is proposed for effectively manufacturing wrought aluminum alloy scrolls. Insulation temperature, squeeze pressure, and the treatment of the micromorphology and mechanical properties of the scroll were investigated experimentally. It was found that reducing the insulation temperature can decrease the grain size, increase the shape factor, and improve mechanical properties. The minimum grain size was found as 111 ± 3 μm at the insulation temperature of 595 °C. The maximum tensile strength, yield strength, and hardness were observed as 386 ± 8 MPa, 228 ± 5 MPa, and 117 ± 5 HV, respectively, at the squeeze pressure of 100 MPa. The tensile strength and hardness of the scroll could be improved, and the elongation was reduced by the T6 heat treatment. The optimal process parameters are recommended at an insulation temperature in the range of 595–600 °C and a squeeze pressure of 100 MPa. Under the optimal process parameters, scroll casting was completely filled, and there was no obvious shrinkage defect observed inside. Its microstructure is composed of fine and spherical grains. Full article

(This article belongs to the Special Issue Recent Advances and Trends in Metal Forming)

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14 pages, 7557 KiB

Open AccessArticle

Influence of Plastic Deformation on Microstructural Evolution of 100Cr6 Bearing Ring in Hot Ring Rolling

by Guanghua Zhou, Wenting Wei and Qinglong Liu

Materials 2020, 13(19), 4355; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13194355 - 30 Sep 2020

Cited by 2 | Viewed by 1749

Abstract

The hot ring rolling technology as the crucial procedure for the manufacture of bearing rings plays an important role in determining the final microstructure of bearing rings. In this work, the influence of the hot ring rolling process on the microstructural evolution of 100Cr6 bearing rings was investigated using a three-dimensional (3D) numerical model and microstructural characterization. It was found that the significant microstructural refinement occurs at the different regions of the rings. However, owing to the non-uniform plastic deformation of hot rolling, the refinement rate of grain size and decrease of pearlite lamellar spacing (PLS) also showed uniformity at different regions of the rings. Furthermore, the degree of grain refinement had been limited with the increase of rolling reduction. Due to the refined grain size and decreased PLS, the Vickers hardness increased with the increase of rolling reduction. Moreover, the Vickers hardness from the outer surface to the inner surface of the ring is asymmetrical u-shaped, which had the law of lower hardness in the center area and higher hardness on the surface. Full article

(This article belongs to the Special Issue Recent Advances and Trends in Metal Forming)

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15 pages, 5040 KiB

Open AccessArticle

Using of Radial-Shear Rolling to Improve the Structure and Radiation Resistance of Zirconium-Based Alloys

by Alexandr Arbuz, Anna Kawalek, Kirill Ozhmegov, Henryk Dyja, Evgeniy Panin, Anuar Lepsibayev, Sanzhar Sultanbekov and Rakhima Shamenova

Materials 2020, 13(19), 4306; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13194306 - 27 Sep 2020

Cited by 20 | Viewed by 2382

Abstract

An overview of the prospects for the development of nuclear technologies and the conclusion of the relevant requirements for advanced structural materials, their classification and features were performed. In order to obtain a bar with a modified radiation-resistant outer layer, an experiment of radial-shear rolling under the most stringent conditions was carried out. For the same conditions, a FEM-simulation of sequential rolling in eight passes with a total compression of 70.7% (from a diameter of 37 mm to 20 mm) was conducted. For adequate simulation results a new material database for Zr-1%Nb alloy using plastometry investigations was generated. An experimental obtaining of a gradient-modified structure with an ultrafine-grained (UFG) periphery and an elongated rolling texture in the center of the bar was performed. Full article

(This article belongs to the Special Issue Recent Advances and Trends in Metal Forming)

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21 pages, 8742 KiB

Open AccessArticle

A Comparative Analysis of Forming Railway Axles in 3- and 4-Roll Rolling Mills

by Zbigniew Pater

Materials 2020, 13(14), 3084; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13143084 - 10 Jul 2020

Cited by 9 | Viewed by 2126

Abstract

The paper presents a comparative analysis of skew rolling in 3- and 4-roll CNC rolling mills. The analysis is performed using the FEM-based commercial simulation software Simufact.Forming. The formation of both solid and hollow railway axles is analyzed. Distributions of effective strain, temperature and damage criterion in rolled axles are determined, and loads and torques acting on the tools during rolling are estimated. An innovative concept of calibrating hollow axles by the rotary compression technique developed at the Lublin University of Technology is presented. Experimental tests of rolling solid axles in a 3-roll rolling mill (in a scale of 1:5) are performed, and basic force parameters of the rolling process are measured. Numerical and experimental loads and torques show a high agreement in terms of both quality and quantity. Full article

(This article belongs to the Special Issue Recent Advances and Trends in Metal Forming)

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