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Advanced Computational Methods in Manufacturing Processes

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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: 10 November 2024 | Viewed by 4515

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Special Issue Editors

Dr. Spyros Papaefthymiou

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Guest Editor

School of Mining & Metallurgical Engineering, National Technical University of Athens, Athens, Greece
Interests: advanced materials; forming; welding; manufacturing; computational materials engineering; industrial processes
Special Issues, Collections and Topics in MDPI journals

Prof. Dr. Dimitrios Manolakos

E-Mail Website
Guest Editor

School of Mechanical Engineering, National Technical University of Athens, 157-73 Athens, Greece
Interests: manufacturing processes (rolling, forging, extrusion, sheet metal forming, metal removal processing, welding, casting, explosive cladding); precision and ultra-precision manufacturing; nanotechnology
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Manufacturing processes of advanced materials become more complex as materials tend to depend on tailored process routes. Computational methods together with phenomenological, empirical modeling and simulation approaches support the optimization, further enhancement and development of materials and processes. This Special Issue aims to bring together contributions from experts in the field of advanced computational modeling and simulation that focus their efforts on the manufacturing processes of modern advanced materials.

Multi-scale modeling from nano to micro, meso and macro scale using thermodynamic, phase field and crystal plasticity approaches are expected to shed light on the microstructure evolution modeling of advanced materials. Works on microstructure-property relationships, prediction of mechanical properties using Finite Element Modeling and numerical simulations that focus on the effect of deformation and the forming operation are expected to underline the importance of advanced manufacturing processes including traditional forming methods such as rolling, extrusion, forging, drawing, but also embrace new ones such as Additive Manufacturing processes, e.g., 3D printing, Selective Laser Melting, etc. Additionally, works that focus on process modeling using Computational Fluid Dynamics are also welcome as they may include thermal treatment steps, etc.

Therefore, contributions are welcome to focus on all computational aspects of manufacturing processes embracing process and microstructural relevant aspects and approaches, which are critical for the production of advanced materials and alloys. Simulation approaches alone works validated by industrial practices and/or enhanced by experimental aspects are welcome.

Dr. Spyros Papaefthymiou
Prof. Dr. Dimitrios Manolakos
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

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.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

metals
multi scale modeling (from nano to micro, to meso and macro scale)
rolling, extrusion, forging, drawing
additive manufacturing, 3D printing, SLM
microstructure-property relationships modeling
microstructure modeling
mechanical properties modeling
thermodynamic modeling
crystal plasticity modeling
phase field modeling
FEM & numerical modeling
CFD & process modeling
machine learning and AI

Published Papers (5 papers)

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Research

28 pages, 5727 KiB

Open AccessArticle

On the Fundamentals of Reverse Ring Rolling: A Numerical Proof of Concept

by Ioannis S. Pressas, Spyros Papaefthymiou and Dimitrios E. Manolakos

Materials 2024, 17(9), 2055; https://doi.org/10.3390/ma17092055 - 27 Apr 2024

Viewed by 349

Abstract

Ring Rolling is a near-net manufacturing process with some measurable dimensional inaccuracies in its products. This fact is exaggerated even more under the scope of high-precision manufacturing, where these imprecisions render such products unfitting for the strict dimensional requirements of high-precision applications (e.g., bearings, casings for turbojets, etc.). In order to remedy some of the dimensional inaccuracies of Ring Rolling, the novel approach of Reverse Ring Rolling is proposed and investigated in the current analysis. The conducted research was based on a numerical simulation of a flat Ring Rolling process, previously presented by the authors. Since the final dimensions of the ring from the authors’ previous work diverged from those initially expected, the simulation of a subsequent Reverse Ring Rolling process was performed to reach the target dimensions. The calculated deformational results revealed a great agreement in at least two of the three crucial dimensions. Additionally, the evaluation of the calculated stress, strain, temperature and load results revealed key aspects of the mechanisms that occur during the proposed process. Overall, it was concluded that Reverse Ring Rolling can effectively function as a corrective process, which can increase the dimensional accuracy of a seamless ring product with little additional post-processing and cost. Full article

(This article belongs to the Special Issue Advanced Computational Methods in Manufacturing Processes)

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22 pages, 9467 KiB

Open AccessArticle

Multi-Mode Damage and Fracture Mechanisms of Thin-Walled Tubular Parts with Cross Inner Ribs Manufactured via Flow Forming

by Xiang Zeng, Leheng Huang, Xiaoguang Fan, Hongwei Li, Mei Zhan, Zhongbao Mi, Xuefeng Xu and Yubin Fan

Materials 2024, 17(7), 1576; https://doi.org/10.3390/ma17071576 - 29 Mar 2024

Viewed by 400

Abstract

In order to study the multi-mode damage and fracture mechanisms of thin-walled tubular parts with cross inner ribs (longitudinal and transverse inner ribs, LTIRs), the Gurson–Tvergaard–Needleman (GTN) model was modified with a newly proposed stress state function. Thus, tension damage and shear damage were unified by the new stress state function, which was asymmetric with respect to stress triaxiality. Tension damage dominated the modification, which coupled with the shear damage variable, ensured the optimal prediction of fractures of thin-walled tubular parts with LTIRs by the modified GTN model. This included fractures occurring at the non-rib zone (NRZ), the longitudinal rib (LIR) and the interface between the transverse rib (TIR) and the NRZ. Among them, the stripping of material from the outer surface of the tubular part was mainly caused by the shearing of built-up material in front of the rollers under a large wall thickness reduction (ΔT). Shear and tension deformation were the causes of fractures occurring at the NRZ, while axial tension under a large TIR interval (l) mainly resulted in fractures on LIRs. Fractures at the interface between the TIR and NRZ were due to the shearing applied by rib grooves and radial tension during the formation of ribs. This study can provide guidance for the manufacturing of high-performance aluminum alloy thin-walled tubular components with complex inner ribs. Full article

(This article belongs to the Special Issue Advanced Computational Methods in Manufacturing Processes)

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30 pages, 9533 KiB

Open AccessArticle

Numerical Investigation of the Damage Effect on the Evolution of Adiabatic Shear Banding and Its Transition to Fracture during High-Speed Blanking of 304 Stainless Steel Sheets

by Konstantina D. Karantza, Spyros A. Papaefthymiou, Nikolaos M. Vaxevanidis and Dimitrios E. Manolakos

Materials 2024, 17(7), 1471; https://doi.org/10.3390/ma17071471 - 23 Mar 2024

Viewed by 478

Abstract

This paper investigates numerically the effect of damage evolution on adiabatic shear banding (ASB) formation and its transition to fracture during high-speed blanking of 304 stainless steel sheets. A structural-thermal-damage-coupled finite element (FE) analysis is developed in LS-DYNA considering the modified Johnson–Cook thermo-viscoplastic model for both plasticity flow rule and damage law, while further, a temperature-dependent fracture criterion is implemented by introducing a critical temperature. The modeling approach is initially validated against experimental data regarding the fracture profile and ASB width. Next, FE simulations are conducted to examine the effect of strain rate and temperature dependence on damage law, while the effect of damage coupling is also evaluated, aiming to highlight the connection between thermal and damage softening and attribute them a specific role regarding ASB formation and transition to fracture. Also, the influence of dynamic recrystallization (DRX) softening is studied macroscopically, while further, a parametric analysis of the Taylor–Quinney coefficient is conducted to highlight the effect of plastic work-to-internal heat conversion efficiency on ASB formation. The results revealed that the implementation of damage coupling reacts to reduced ASB width and provides an S-shaped fracture profile, while it also decreases the peak force and results in an earlier fracture. Both findings are enhanced when accounting further for DRX softening and a higher value of the Taylor–Quinney coefficient. Finally, the simulations indicated that thermal softening precedes damage softening, showing that the temperature rise is responsible for ASB initiation, while instead, damage evolution drives ASB propagation and fracture. Full article

(This article belongs to the Special Issue Advanced Computational Methods in Manufacturing Processes)

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16 pages, 52203 KiB

Open AccessArticle

The Influence of Materials on Footwear Behaviour: A Finite Element Simulation Study

by Arina Seul, Aura Mihai, Mariana Costea, Alexandra Bodoga and Antonela Curteza

Materials 2023, 16(22), 7203; https://doi.org/10.3390/ma16227203 - 17 Nov 2023

Viewed by 1263

Abstract

The objective of this study was to analyse the influence of materials and their position within the upper assembly on the behaviour of casual footwear using finite element simulation tools. The study was carried out on three models of casual footwear, which are identical in terms of design lines, varying only in the materials of the upper assembly, namely calfskin leather (M1), knitted fabric (M2), and combination of knitted fabric and calfskin leather (M3). The footwear models were designed according to the design constraints specific to casual footwear. The foot was reconstructed based on the shoe last obtained based on anthropometric data. Material definition, 3D models editing, setting up analysis conditions, and constraints were performed using the Ansys 17.2 software. Gait biomechanics were taken into account to define the loading model, force distribution, force values, and constraints. The study evaluates footwear behaviour in terms of directional deformation (Z axis), equivalent von Mises stress, and equivalent elastic strain distribution. This paper explores a methodology that has the potential to enhance the footwear design and manufacturing process, providing designers with information about the deformations and stress distribution on upper parts of the footwear product. Full article

(This article belongs to the Special Issue Advanced Computational Methods in Manufacturing Processes)

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29 pages, 22282 KiB

Open AccessArticle

Deformation-Induced Surface Roughening of an Aluminum–Magnesium Alloy: Experimental Characterization and Crystal Plasticity Modeling

by Yannis P. Korkolis, Paul Knysh, Kanta Sasaki, Tsuyoshi Furushima and Marko Knezevic

Materials 2023, 16(16), 5601; https://doi.org/10.3390/ma16165601 - 12 Aug 2023

Viewed by 1183

Abstract

The deformation-induced surface roughening of an Al-Mg alloy is analyzed using a combination of experiments and modeling. A mesoscale oligocrystal of AA5052-O, obtained by recrystallization annealing and subsequent thickness reduction by machining, that contains approx. 40 grains is subjected to uniaxial tension. The specimen contains one layer of grains through the thickness. A laser confocal microscope is used to measure the surface topography of the deformed specimen. A finite element model with realistic (non-columnar) shapes of the grains based on a pair of Electron Back-Scatter Diffraction (EBSD) scans of a given specimen is constructed using a custom-developed shape interpolation procedure. A Crystal Plasticity Finite Element (CPFE) framework is then applied to the voxel model of the tension test of the oligocrystal. The unknown material parameters are determined inversely using an efficient, custom-built optimizer. Predictions of the deformed shape of the specimen, surface topography, evolution of the average roughness with straining and texture evolution are compared to experiments. The model reproduces the averaged features of the problem, while missing some local details. As an additional verification of the CPFE model, the statistics of surface roughening are analyzed by simulating uniaxial tension of an AA5052-O polycrystal and comparing it to experiments. The averaged predictions are found to be in good agreement with the experimentally observed trends. Finally, using the same polycrystalline specimen, texture–morphology relations are discovered, using a symbolic Monte Carlo approach. Simple relations between the Schmid factor and roughness can be inferred purely from the experiments. Novelties of this work include: realistic 3D shapes of the grains; efficient and accurate identification of material parameters instead of manual tuning; a fully analytical Jacobian for the crystal plasticity model with quadratic convergence; novel texture–morphology relations for polycrystal. Full article

(This article belongs to the Special Issue Advanced Computational Methods in Manufacturing Processes)

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Planned Papers

The below list represents only planned manuscripts. Some of these manuscripts have not been received by the Editorial Office yet. Papers submitted to MDPI journals are subject to peer-review.

Title: Development of predictive tool of the Young’s Modulus of structures fabricated using Multiphoton Lithography
Author: Mavrikos
Highlights: Multiple factors study of the Young's Modulus of structures fabricated via Two-Photon Polymerization Prediction of Young's Modulus using Artificial Neural Networks and Genetic Algorithms Prediction of Young's Modulus using Artificial Neural Networks and closed-loop control system

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