Advances in Sheet Metal Forming and Structures

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

Deadline for manuscript submissions: closed (31 May 2021) | Viewed by 7415

Special Issue Editor


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Guest Editor
Department of Mechanical, Industrial & Manufacturing Engineering, University of Toledo, 2801 W. Bancroft, Toledo, OH 43606, USA
Interests: design for manufacturing; metals processing; origami sheet metal forming; sustainable manufacturing

Special Issue Information

Dear Colleagues,

Recent developments in the field of sheet metal focus on emerging forming techniques to produce parts with non-traditional operations, both in terms of the forming process and the produced structure’s design and material. The global efforts in manufacturing energy reduction have directed research efforts towards sheet metal forming processes without major dies and encouraged the exploration of non-traditional forming operations. In addition, the continuously evolving computational capabilities have enabled better analysis and understanding of the sheet metal material, structure, forming forces and limits, as well as the manufacturing process parameters.

The need to establish metamorphic manufacturing schemes to meet customized demand led to the development of sheet metal structures that can shift shape in different stages of the production. As a result, the manufacturing processes need to be as flexible and as accommodating as possible.

This Special Issue is dedicated to shedding light on recent developments in the field of sheet metal forming and structures, with a focus on emerging manufacturing processes along with the computational and modeling tools utilized to facilitate such advancements.  

We are particularly interested in (but not limited to) contributions that focus on topics such as:

  • Die-less sheet metal manufacturing processes;
  • Metamorphic manufacturing in sheet metal operations;
  • New sheet metal structures design, including adaptive sheet metal;
  • New approaches to modeling and analyzing forming limits;
  • Functional-based design and fabrication of sheet metal;
  • Strategies to increase geometrical forming accuracy;
  • Hybrid sheet metal forming operations that employ additive manufacturing.

Dr. Ala Qattawi
Guest Editor

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Keywords

  • finite element analysis
  • die-less fabrication
  • feature-based metal fabrication
  • adaptive sheet metal structures
  • formability limit
  • hybrid sheet metal operations
  • metamorphic manufacturing

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Published Papers (2 papers)

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Research

12 pages, 5723 KiB  
Article
Hole-Expansion: Sensitivity of Failure Prediction on Plastic Anisotropy Modeling
by Jinjin Ha and Yannis P. Korkolis
J. Manuf. Mater. Process. 2021, 5(2), 28; https://doi.org/10.3390/jmmp5020028 - 25 Mar 2021
Cited by 21 | Viewed by 2898
Abstract
The influence of yield function parameters on hole-expansion (HE) predictions are investigated for an anisotropic AA6022-T4 aluminum sheet. The HE experiment is performed in a fully-instrumented double-action hydraulic press with a flat-headed punch. Full strain fields are measured by a stereo-type digital image [...] Read more.
The influence of yield function parameters on hole-expansion (HE) predictions are investigated for an anisotropic AA6022-T4 aluminum sheet. The HE experiment is performed in a fully-instrumented double-action hydraulic press with a flat-headed punch. Full strain fields are measured by a stereo-type digital image correlation (DIC) system. The stress state gradually changes from uniaxial to plane-strain tension to biaxial tension in the radial direction. Besides HE, the plastic anisotropy of AA6022-T4 is characterized by uniaxial tension and plane-strain tension experiments. Uniaxial tension is considered as the most important, since it is the stress state along the hoop direction in the hole. For the finite element (FE) simulation, the Yld2000-2d non-quadratic anisotropic yield function is used with two different parameter sets, calibrated by: (1) uniaxial tension only (termed Calib1) and, (2) both uniaxial and plane-strain tension (Calib2). The strain field predictions show a good agreement with the experiments only for Calib2, which takes into account plane-strain as well uniaxial tension. This indicates the importance of biaxial modes, and in particular plane-strain tension, for the adopted yield function to produce accurate HE simulations. Full article
(This article belongs to the Special Issue Advances in Sheet Metal Forming and Structures)
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16 pages, 8374 KiB  
Article
Experimental Investigation of Dimensional Precision of Deep Drawn Cups Using Direct Polymer Additive Tooling
by Georg Bergweiler, Falko Fiedler, Ahsan Shaukat and Bernd Löffler
J. Manuf. Mater. Process. 2021, 5(1), 3; https://doi.org/10.3390/jmmp5010003 - 30 Dec 2020
Cited by 12 | Viewed by 3797
Abstract
While deep drawing of sheet metals is economical at high volumes, it can be very costly for manufacturing prototypes, mainly due to high tooling costs. Additively manufactured polymer tools have the potential to be more cost-efficient for small series, but they are softer [...] Read more.
While deep drawing of sheet metals is economical at high volumes, it can be very costly for manufacturing prototypes, mainly due to high tooling costs. Additively manufactured polymer tools have the potential to be more cost-efficient for small series, but they are softer and thus less resilient than conventional steel tools. This work aimed to study the dimensional precision of such tools using a standard cup geometry. Tools were printed with FFF using two different materials, PLA and CF-PA. A test series of 20 parts was drawn from each tool. Afterwards, the dimensional precisions of the drawn parts were analyzed using an optical measuring system. The achieved dimensional accuracy of the first drawn cup using the PLA toolset was 1.98 mm, which was further improved to 1.04 mm by altering shrinkage and springback allowances. The repeatability of the deep drawing process for the CF-reinforced PA tool was 0.17 mm during 20 drawing operations and better than that of the PLA tool (1.17 mm). To conclude, deep drawing of standard cups is doable using direct polymer additive tooling with a dimensional accuracy of 1.04 mm, which can be further improved by refining allowances incorporated to the CAD model being printed. Full article
(This article belongs to the Special Issue Advances in Sheet Metal Forming and Structures)
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