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Advanced Sheet/Bulk Metal Forming
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Advanced Sheet/Bulk Metal Forming

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

Deadline for manuscript submissions: 20 December 2025 | Viewed by 4435

Special Issue Editors

Dr. Rui L. Amaral

E-Mail Website
Guest Editor
Institute of Science and Innovation in Mechanical and Industrial Engineering, R. Dr. Roberto Frias, 400, 4200-465, Porto, Portugal
Interests: metal forming processes; material characterization; constitutive modelling; numerical simulation; experimental validation; inverse optimization techniques
Special Issues, Collections and Topics in MDPI journals
Dr. Abel Dias dos Santos

E-Mail Website
Guest Editor
Department of Mechanical Engineering, Faculty of Engineering, University of Porto, 4200-465 Porto, Portugal
Interests: manufacturing processes; metal forming technology and processing; sheet metal forming; numerical simulation; experimental validation; material testing and constitutive modelling
Special Issues, Collections and Topics in MDPI journals
Dr. Tiago E. F. Silva

E-Mail Website
Guest Editor
Institute of Science and Innovation in Mechanical and Industrial Engineering, R. Dr. Roberto Frias, 400, 4200-465 Porto, Portugal
Interests: advanced manufacturing, metal cutting, mechanical characterization; numerical simulation

Special Issue Information

Dear Colleagues,

The manufacturing of sheet and bulk metal components has undergone significant computerization and industrialization. Researchers and industry continually explore state-of-the-art methods to develop cost-effective and efficient advanced forming solutions. This pursuit targets the enhancement of existing processes, ensuring ongoing advancements in productivity.

This Special Issue aims to focus on the most recent developments and trends in advanced sheet and bulk metal forming processes. Our goal is to highlight the latest state-of-the-art approaches that can be applied to advanced forming technology, as well as new solutions for the experimental characterization and numerical modelling of sheet and bulk formability, using different metallic alloys under general processing conditions.

The Special Issue will cover, but will not be limited to, the following topics:

  • Designing and modelling of metal forming processes (e.g., stamping, deep drawing, roll forming, bending, forging , extrusion, rolling, etc);
  • Formability, fracture, and fatigue: experiments, modelling, and numerical prediction;
  • Identification of constitutive material models through inverse analysis and artificial intelligence (AI);
  • Intelligent and emerging metal processing technologies;
  • Forming process contact conditions;
  • Mechanical performance of products.

Dr. Rui L. Amaral
Dr. Abel Dias dos Santos
Dr. Tiago E. F. Silva
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

  • sheet metal forming
  • bulk metal forming
  • manufacturing process conditions
  • constitutive modelling
  • finite element analysis
  • material characterization
  • experimental validation

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Published Papers (4 papers)

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Research

16 pages, 3908 KB  
Article
Numerical Study on the Solidification Microstructure Evolution in Industrial Twin-Roll Casting of Low-Carbon Steel
by Yulong Shi, Kongfang Feng, Liang Liu, Gaorui He and Bo Wang
Materials 2025, 18(19), 4484; https://doi.org/10.3390/ma18194484 - 26 Sep 2025
Abstract
Twin-roll strip casting (TRSC) is a key development in near-net-shape casting technology, offering the potential for high-efficiency and low-cost production. During the TRSC process, the solidification characteristics of the strip are largely governed by the configuration of the melt delivery system as well [...] Read more.
Twin-roll strip casting (TRSC) is a key development in near-net-shape casting technology, offering the potential for high-efficiency and low-cost production. During the TRSC process, the solidification characteristics of the strip are largely governed by the configuration of the melt delivery system as well as by various process parameters. In this study, a three-dimensional model of low-carbon steel strip casting was developed using ProCAST software to investigate microstructure evolution under industrial-scale conditions. Simulation results revealed that the solidified strip exhibits a typical three-layer structure: a surface equiaxed grain zone in contact with the cooling rolls, a subsurface columnar grain zone, and a central equiaxed grain zone. Introducing side holes into the delivery system promoted the formation of a distinct columnar grain region near the side dams, resulting in a reduction in the average grain size in this region from 43.7 μm to 38.2 μm compared to the delivery system without side holes. Increasing the heat transfer coefficient at the interface between the molten pool and the cooling rolls significantly enlarged the columnar grain zone. This change had little effect on the average grain size and grain density, with the average grain size remaining close to 37 μm and the grain density variation being less than 0.7%. In contrast, when the casting speed was raised from 50 m min−1 to 70 m min−1, a reduction in the area of the columnar grain zone was observed, while the average grain size decreased slightly (by less than 0.5 μm), and the grain density increased accordingly. This study provides valuable insights for optimizing process parameters and designing more effective melt delivery systems in industrial twin-roll strip casting. Full article
(This article belongs to the Special Issue Advanced Sheet/Bulk Metal Forming)
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17 pages, 3157 KB  
Article
Research on Online Traceability Methods for the Causes of Longitudinal Surface Crack in Continuous Casting Slab
by Junqiang Cong, Qiancheng Lv, Zihao Fan, Haitao Ling and Fei He
Materials 2025, 18(15), 3695; https://doi.org/10.3390/ma18153695 - 6 Aug 2025
Viewed by 455
Abstract
In the casting and rolling production process, surface longitudinal cracks are a typical casting defect. Tracing the causes of longitudinal cracks online and controlling the key parameters leading to their formation in a timely manner can enhance the stability of casting and rolling [...] Read more.
In the casting and rolling production process, surface longitudinal cracks are a typical casting defect. Tracing the causes of longitudinal cracks online and controlling the key parameters leading to their formation in a timely manner can enhance the stability of casting and rolling production. To this end, the influencing factors of longitudinal cracks were analyzed, a data integration storage platform was constructed, and a tracing model was established using empirical rule analysis, statistical analysis, and intelligent analysis methods. During the initial production phase of a casting machine, longitudinal cracks occurred frequently. The tracing results using the LightGBM-SHAP method showed that the relative influence of the narrow left wide inner heat flow ratio of the mold was significant, followed by the heat flow difference on the wide symmetrical face of the mold and the superheat of the molten steel, with weights of 0.135, 0.066, and 0.048, respectively. Based on the tracing results, we implemented online emergency measures. By controlling the cooling intensity of the mold, we effectively reduced the recurrence rate of longitudinal cracks. Root cause analysis revealed that the total hardness of the mold-cooling water exceeded the standard, reaching 24 mg/L, which caused scaling on the mold copper plates and uneven cooling, leading to the frequent occurrence of longitudinal cracks. After strictly controlling the water quality, the issue of longitudinal cracks was brought under control. The online application of the tracing method for the causes of longitudinal cracks has effectively improved efficiency in resolving longitudinal crack problems. Full article
(This article belongs to the Special Issue Advanced Sheet/Bulk Metal Forming)
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15 pages, 6446 KB  
Article
Study on Stamping–Bulging Process of Thin-Walled Superalloy Diaphragm for S-Shaped Bellows
by Zhubin He, Qingsong Zhao, Kun Zhang, Jian Ning, Yi Xu and Xianggang Ruan
Materials 2024, 17(12), 2829; https://doi.org/10.3390/ma17122829 - 10 Jun 2024
Viewed by 1400
Abstract
A combined stamping–bulging forming process was proposed to achieve high-precision forming of large-diameter, ultra-thin-walled, superalloy welded S-type corrugated diaphragms. The underlying principle is to enhance the diaphragm’s forming accuracy by increasing the plastic deformation region and reducing springback. Using the ABAQUS version 6.14 [...] Read more.
A combined stamping–bulging forming process was proposed to achieve high-precision forming of large-diameter, ultra-thin-walled, superalloy welded S-type corrugated diaphragms. The underlying principle is to enhance the diaphragm’s forming accuracy by increasing the plastic deformation region and reducing springback. Using the ABAQUS version 6.14 finite element analysis software, finite element models were constructed for the stamping, hydraulic bulging, and combined stamping–bulging forming processes of the welded S-type metal corrugated diaphragms. A comparative analysis was conducted on the forming processes of the welded S-type metal corrugated diaphragms under the three forming methods, focusing on equivalent stress, distribution of wall thickness, and forming accuracy. This analysis determined the optimal forming process and the corresponding process parameters for superalloy welded S-type metal corrugated diaphragms. The results show that under a constant drawing force, as the bulging pressure increases, the plastic deformation of the straight sections of the diaphragm becomes more pronounced, resulting in improved shape accuracy. The combined stamping–bulging forming process guarantees the highest degree of shape accuracy for the diaphragm. The optimal process parameters were identified as a 30 t force and a 5 MPa pressure, with a maximum shape error of 0.02 mm. Concerning a plate thickness of 0.3 mm, the maximum deviation rate was found to be 6.7%, which represents a 30% improvement over traditional stamping processes. The maximum wall thinning rate was found to be 3.3%, a 1% reduction compared to traditional stamping processes, confirming the process’s feasibility. Full article
(This article belongs to the Special Issue Advanced Sheet/Bulk Metal Forming)
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14 pages, 9655 KB  
Article
New Method for Detecting Flange Fracture Initiation in Incremental Radial Extrusion
by Grzegorz Winiarski
Materials 2024, 17(5), 1054; https://doi.org/10.3390/ma17051054 - 25 Feb 2024
Cited by 2 | Viewed by 1298
Abstract
This study investigates flange fracture formation in unconventional incremental radial extrusion. This manufacturing technique involves using rings with a gradually increasing inside diameter for constraining the free flow of material in the radial direction. As a result, the shaped flange has a constant [...] Read more.
This study investigates flange fracture formation in unconventional incremental radial extrusion. This manufacturing technique involves using rings with a gradually increasing inside diameter for constraining the free flow of material in the radial direction. As a result, the shaped flange has a constant thickness and a significantly larger diameter than that formed using the standard extrusion process conducted without the use of rings. EN AW 6060 aluminum alloy tube sections were used as the billet material, and the extrusion process was conducted under cold forming conditions at ambient temperature. For the determination of material fracture initiation, a new method was proposed involving the analysis of strain, strain rate and values of the normalized Cockcroft–Latham fracture criterion integral. The main advantage of the new method is that it allows for the prediction of fracture initiation via only FEM results analysis, i.e., it is not necessary to carry out additional experiments aimed at calibrating or determining limit parameters of a given material. It was shown that the occurrence of differences in the distribution of the above-mentioned parameters coincided with flange fracture initiation. Full article
(This article belongs to the Special Issue Advanced Sheet/Bulk Metal Forming)
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