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Advances in Material Forming: 2nd Edition
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Advances in Material Forming: 2nd Edition

A special issue of Journal of Manufacturing and Materials Processing (ISSN 2504-4494).

Deadline for manuscript submissions: 31 March 2026 | Viewed by 4431

Special Issue Editor

Prof. Dr. Chetan P. Nikhare

E-Mail Website
Guest Editor
Advanced Manufacturing and Innovation Center, Mechanical Engineering Department, The Pennsylvania State University, Erie, PA 16510, USA
Interests: sustainable and efficient manufacturing processes; electrically assisted forming; sheet metal forming and hydroforming; micro-forming; multi-scale modeling; thermo-mechanical modeling; analytical modeling; DRX modeling; fatigue and fracture
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

We cordially invite you to submit your research to this Special Issue of the Journal of Manufacturing and Materials Processing published by MDPI on “Advances in Material Forming: 2nd Edition”. Recent advances made in the field of materials such as advanced high-strength steel, higher grades of aluminum, and Inconel alloys are directing current research trends toward more efficient, cost-effective, and novel forms of manufacturing. In addition, the automotive and aerospace industries are driving the need for new lightweight parts. This is has led to the creation of new manufacturing processes, i.e., non-traditional approaches to manufacturing and forming such parts. There are challenges to deforming high-strength materials using these non-traditional approaches which result in different stress states compared to conventional processes and can change the characterizations of these materials. Therefore, there is a significant need for experimentation, analysis, and simulation to formulate and evaluate theories which can address these new processes and materials.

For this Special Issue, we invite researchers to submit their new and precious work related to the use of novelty in manufacturing processes, uncovering the mechanics, and carrying out computational analyses, process development, and characterization of the processing materials used within the formation of metals and materials. The work should include theoretical, numerical, or experimental approaches, either separately or in combination, to provide solutions to the challenges outlined above.

We encourage you to submit work related to the following research areas:

  • Materials testing and characterization;
  • Sub-specimen characterization;
  • Testing of additively manufactured materials;
  • Defects in high-strength material forming;
  • Limits in material forming;
  • Constitutive modeling;
  • Multiscale forming/simulations;
  • Damage modeling;
  • Rolling and preforming processes;
  • Sheet metal forming and challenges;
  • Tube forming;
  • Bulk metal forming, including forging, wire drawing, and extrusion;
  • Novel processes including hybrid forming processes;
  • Non-traditional approaches such as die-less, electric-assisted, high-speed forming, and additive manufacturing;
  • Warm and hot forming;
  • Dynamic testing and crash analysis;
  • Process monitoring, optimization, and control;
  • Data-driven forming 4.0.

Prof. Dr. Chetan P. Nikhare
Guest Editor

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. Journal of Manufacturing and Materials Processing is an international peer-reviewed open access monthly 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 1800 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

  • forming
  • rolling
  • forging
  • wire drawing
  • extrusion

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Further information on MDPI's Special Issue policies can be found here.

Related Special Issue

Published Papers (5 papers)

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21 pages, 9556 KiB  
Article
DP600 Steel Stampability Analysis Through Microstructural Characterization by Electron Backscatter Diffraction and Nanoindentation
by Rafael Guetter Bohatch, Alex Raimundo de Oliveira, Chetan P. Nikhare, Ravilson Antonio Chemin Filho and Paulo Victor Prestes Marcondes
J. Manuf. Mater. Process. 2025, 9(7), 234; https://doi.org/10.3390/jmmp9070234 - 8 Jul 2025
Viewed by 29
Abstract
In recent decades, the automotive industry has faced challenges around improving energy efficiency, reducing pollutant emissions, increasing occupant safety, and reducing production costs. To solve these challenges, it is necessary to reduce the weight of vehicle bodies. In this way, the steel industry [...] Read more.
In recent decades, the automotive industry has faced challenges around improving energy efficiency, reducing pollutant emissions, increasing occupant safety, and reducing production costs. To solve these challenges, it is necessary to reduce the weight of vehicle bodies. In this way, the steel industry has developed more efficient metal alloys. To combine vehicle mass reduction with improved performance in deformations in cases of impact, a new family of advanced steels is present, AHSS (Advanced High-Strength Steels). However, this family of steels has lower formability and greater springback compared to conventional steels; if it is not properly controlled, it will directly affect the accuracy of the product and its quality. Different regions of a stamped component, such as the flange, the body wall, and the punch pole, are subjected to different states of stress and deformation, determined by numerous process variables, such as friction/lubrication and tool geometry, in addition to blank holder force and drawbead geometry, which induce the material to different deformation modes. Thus, it is understood that the degree of work hardening in each of these regions can be evaluated by grain morphology and material hardening, defining critical regions of embrittlement that, consequently, will affect the material’s stampability. This work aims to study the formability of the cold-formed DP600 steel sheets in the die radius region using a Modified Nakazima test, varying drawbead geometry, followed by a nanohardness evaluation and material characterization through the electron backscatter diffraction (EBSD). The main objective is to analyze the work hardening in the critical blank regions by applying these techniques. The nanoindentation evaluations were consistent in die radius and demonstrated the hardening influence, proving that the circular drawbead presented the most uniform hardness variation along the profile of the stamped blank and presented lower hardness values in relation to the other geometries, concluding that the drawbead attenuates this variation, contributing to better sheet formability, which corroborates the Forming Limit Curve results. Full article
(This article belongs to the Special Issue Advances in Material Forming: 2nd Edition)
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28 pages, 5550 KiB  
Article
Physics-Informed Preform Design for Flashless 3D Forging via Material Point Backtracking and Finite Element Simulations
by Gracious Ngaile and Karthikeyan Kumaran
J. Manuf. Mater. Process. 2025, 9(6), 202; https://doi.org/10.3390/jmmp9060202 - 18 Jun 2025
Viewed by 264
Abstract
Accurate preform design in forging processes is critical for improving part quality, conserving material, reducing manufacturing costs, and eliminating secondary operations. This paper presents a finite element (FE) simulation-based methodology for preform design aimed at achieving flashless and near-flashless forging. The approach leverages [...] Read more.
Accurate preform design in forging processes is critical for improving part quality, conserving material, reducing manufacturing costs, and eliminating secondary operations. This paper presents a finite element (FE) simulation-based methodology for preform design aimed at achieving flashless and near-flashless forging. The approach leverages material point backtracking within FE models to generate physics-informed preform geometries that capture complex material flow, die geometry interactions, and thermal gradients. An iterative scheme combining backtracking, surface reconstruction, and point-cloud solid modeling was developed and applied to several three-dimensional forging case studies, including a cross-joint and a three-lobe drive hub. The methodology demonstrated significant reductions in flash formation, particularly in parts that traditionally exhibit severe flash under conventional forging. Beyond supporting the development of new flashless forging sequences, the method also offers a framework for modifying preforms during production to minimize waste and for diagnosing preform defects linked to variability in frictional conditions, die temperatures, or material properties. Future integration of the proposed method with design of experiments (DOE) and surrogate modeling techniques could further enhance its applicability by optimizing preform designs within a localized design space. The findings suggest that this approach provides a practical and powerful tool for advancing both new and existing forging production lines toward higher efficiency and sustainability. Full article
(This article belongs to the Special Issue Advances in Material Forming: 2nd Edition)
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19 pages, 9051 KiB  
Article
Development of Deep Drawing Processes Under Indirect Hot Stamping Method for an Automotive Internal Combustion Engine Oil Pan Made from Ultra-High-Strength Steel (UHSS) Sheets Using Finite Element Simulation with Experimental Validation
by Yongyudth Thanaunyaporn, Phiraphong Larpprasoetkun, Aeksuwat Nakwattanaset, Thawin Hart-Rawung and Surasak Suranuntchai
J. Manuf. Mater. Process. 2025, 9(6), 199; https://doi.org/10.3390/jmmp9060199 - 14 Jun 2025
Viewed by 393
Abstract
This study presents the development of a deep drawing process under an indirect hot stamping method for manufacturing an automotive internal combustion engine oil pan from ultra-high-strength steel (UHSS) sheets, specifically 22MnB5. The forming process involves two stages—cold stamping followed by hot stamping—and [...] Read more.
This study presents the development of a deep drawing process under an indirect hot stamping method for manufacturing an automotive internal combustion engine oil pan from ultra-high-strength steel (UHSS) sheets, specifically 22MnB5. The forming process involves two stages—cold stamping followed by hot stamping—and is finalized with rapid quenching to achieve a martensitic microstructure. Finite element simulation using AutoForm R8 was conducted to determine optimal forming conditions. The simulation results guided the design of the forming tools and were validated through experimental trials. The final oil pan component exhibited no cracks or wrinkles, with maximum thinning below 18%, a hardness of 550.63 HV, and a fully martensitic phase. This research demonstrates a novel and effective solution for producing deep-drawn, high-strength components using indirect hot stamping, contributing to the advancement of automotive forming processes in Thailand. Full article
(This article belongs to the Special Issue Advances in Material Forming: 2nd Edition)
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19 pages, 6579 KiB  
Article
Flange Buckling Mechanism in Incremental Shape Rolling of an Automotive-Type Variable Width Component
by Abdelrahman Essa, Buddhika Abeyrathna, Bernard Rolfe and Matthias Weiss
J. Manuf. Mater. Process. 2024, 8(6), 290; https://doi.org/10.3390/jmmp8060290 - 15 Dec 2024
Viewed by 1024
Abstract
Automotive structural components from Advanced High-Strength Steels (AHSS) can be manufactured with Flexible Roll Forming (FRF). The application of FRF in the automotive industry is limited due to flange wrinkling defects that increase with material strength. The new Incremental Shape Rolling process (ISR) [...] Read more.
Automotive structural components from Advanced High-Strength Steels (AHSS) can be manufactured with Flexible Roll Forming (FRF). The application of FRF in the automotive industry is limited due to flange wrinkling defects that increase with material strength. The new Incremental Shape Rolling process (ISR) has been shown to reduce wrinkling severity compared to FRF and therefore presents a promising alternative for the manufacture of high-strength automotive components. The current work analyzes for the first time the mechanisms that lead to wrinkling reduction in ISR based on the critical stress conditions that develop in the flange. For this, finite element process models are validated with experimental forming trials and used to investigate the material deformation and the forming stresses that occur in FRF and ISR when forming a variable-width automotive component. The results show that in ISR, the undeformed flange height decreases with increasing forming; this increases the critical buckling and wrinkling stresses with each forming pass and prevents the development of wrinkles towards the end of the forming process. In contrast, in FRF, the critical buckling or wrinkling stress is constant, while the longitudinal compressive stress in the flange increases with the number of forming passes and exceeds the critical stress. This leads to the development of severe wrinkles in the flange. Full article
(This article belongs to the Special Issue Advances in Material Forming: 2nd Edition)
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14 pages, 8100 KiB  
Article
Additive Manufacturing of Ti3AlC2/TiC and Ti3AlC2/SiC Ceramics Using the Fused Granules Fabrication Technique
by Maksim Krinitcyn, Georgy Kopytov and Egor Ryumin
J. Manuf. Mater. Process. 2024, 8(3), 123; https://doi.org/10.3390/jmmp8030123 - 13 Jun 2024
Cited by 4 | Viewed by 1863
Abstract
In this work, SiC–Ti3AlC2 and TiC–Ti3AlC2 composites produced by additive manufacturing are investigated. The issue of obtaining ceramic materials using additive manufacturing technologies is currently relevant, since not many modern additive technologies are suitable for working with [...] Read more.
In this work, SiC–Ti3AlC2 and TiC–Ti3AlC2 composites produced by additive manufacturing are investigated. The issue of obtaining ceramic materials using additive manufacturing technologies is currently relevant, since not many modern additive technologies are suitable for working with ceramic materials. The study is devoted to the optimization of additive manufacturing parameters, as well as the study of the structure and properties of the resulting objects. The fused granules fabrication (FGF) method as one kind of the material extrusion additive manufacturing (MEAM) technology is used to obtain composite samples. The main advantage of the FGF technology is the ability to obtain high-quality samples from ceramic materials by additive manufacturing. Composites with different ratios between components and different powder/polymer ratios are investigated. The technological features of the additive formation of composites are investigated, as well as their structure and properties. The optimal sintering temperature to form the best mechanical properties for both composites is 1300 °C. The composites have a regulatable porosity. Ti3AlC2 content, sintering temperature, and polymer content in the feedstock are the main parameters that regulate the porosity of FGF samples. Full article
(This article belongs to the Special Issue Advances in Material Forming: 2nd Edition)
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