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Metals
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Advanced Plastic Forming Processes: Theory, Experiments and Numerical Simulations
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Advanced Plastic Forming Processes: Theory, Experiments and Numerical Simulations

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Computation and Simulation on Metals".

Deadline for manuscript submissions: 31 August 2025 | Viewed by 5429

Special Issue Editor

Dr. Gaochao Yu

E-Mail Website
Guest Editor
1. Key Laboratory of Advanced Forging & Stamping Technology and Science, Ministry of Education of China, Yanshan University, Qinhuangdao 066004, China
2. Department of Mechanical Engineering, Imperial College London, London SW7 2AZ, UK
Interests: materials processing; metal forming; material modeling; mechanical properties; pipe; finite element method; numerical simulation; bending springback
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Plastic forming technology is an important part of the advanced manufacturing field. Using this technology, not only can complex shape components be obtained but excellent comprehensive service performance can also be given. These tools are widely used in, for example, aerospace, the automobile industry, high-speed rail and nuclear power. This Special Issue aims to present the latest research on plastic forming technology, including advanced forming processes, theories, experiments and numerical simulations. Original research articles and reviews are welcome. Research areas may include (but are not limited to) the following: sheet forming processes, tube forming processes, forging forming process, plastic forming theory, forming machines and finite-element methods.

Dr. Gaochao Yu
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. Metals 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 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

  • plastic forming technology
  • sheet forming process
  • tube forming process
  • forging forming process
  • plastic forming theory
  • forming machines
  • finite-element methods

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Published Papers (6 papers)

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Research

20 pages, 3841 KiB  
Article
The Effects of Pass Number and Die Channel Angle of Equal Channel Angular Pressing on Innovative Magnesium Composite Material
by Xin Zhang, Jian Han, Jing Tian, Lisong Zhu, Peng Zhang, Yue Wang and Zhengyi Jiang
Metals 2025, 15(4), 349; https://doi.org/10.3390/met15040349 - 23 Mar 2025
Viewed by 210
Abstract
The effects of the designed equal channel angular pressing (ECAP) procedures on microstructures, mechanical properties and corrosion resistances of newly developed nano-MgO/Mg–Zn–Ca composite materials have been investigated in this study. The die channel angles selected by the ECAP processes are 90°and 120°, and [...] Read more.
The effects of the designed equal channel angular pressing (ECAP) procedures on microstructures, mechanical properties and corrosion resistances of newly developed nano-MgO/Mg–Zn–Ca composite materials have been investigated in this study. The die channel angles selected by the ECAP processes are 90°and 120°, and the corresponding composite materials are kept for 15 min in the ECAP mold at 300 °C before 1, 4, and 8 passes through route BC. It can be understood that the sizes of grains and second phases were significantly reduced because of continuous dynamic recrystallization (C-DRX) and mechanical shearing, and the ECAP process with the die angle of 90° shows more evidence of grain refinement owing to the higher shear stress. The obtained mechanical properties stipulated that both the yield and ultimate strength were improved after ECAP, which is related to the interaction of grain and texture evolution, while the elongation increases drastically from 14% (as-extruded state) to 34% (ECAP-ed state). Meanwhile, the improvement of corrosion resistance by microstructural evolution is more significant than adverse effects originating from the internal defects of the material itself as well as the defects originating from the number of passes. Ultimately, the conclusions were made based on the results regarding performance improvement by the optimized parameters designed and utilized in ECAP for this novel Mg composite material. Full article
(This article belongs to the Special Issue Advanced Plastic Forming Processes: Theory, Experiments and Numerical Simulations)
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26 pages, 13368 KiB  
Article
Mechanical Properties of 7075-T6 Aluminum Alloy in Electrically Assisted Forming
by Shasha Dou, Zhuang Liu, Zhijun Li, Haojie Shi, Kang Zhou and Jiansheng Xia
Metals 2025, 15(2), 117; https://doi.org/10.3390/met15020117 - 25 Jan 2025
Viewed by 1181
Abstract
The coupling effects of electrical pulse, temperature, strain rate, and strain on the flow behavior and plasticity of 7075-T6 aluminum alloy were investigated and characterized. The isothermal tensile test and electrically assisted isothermal tensile test were performed at the same temperature, and the [...] Read more.
The coupling effects of electrical pulse, temperature, strain rate, and strain on the flow behavior and plasticity of 7075-T6 aluminum alloy were investigated and characterized. The isothermal tensile test and electrically assisted isothermal tensile test were performed at the same temperature, and the typical models were further embedded in ABAQUS for numerical simulation to illustrate the electroplastic effect. The results showed that electrical pulses reduced deformation resistance but greatly increased elongation. Compared with the traditional Johnson–Cook model, the proposed modified electroplasticity constitutive equations have a certain improvement in calibration accuracy for a highly nonlinear and thermoelectric coupling dynamic behavior. Moreover, combined with the electrically assisted three-point bending experiment, it was found that the springback angle decreases with the increase in current density. This is very close to the experimental result, further verifying the effectiveness of the thermoelectric coupling constitutive equation. Full article
(This article belongs to the Special Issue Advanced Plastic Forming Processes: Theory, Experiments and Numerical Simulations)
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16 pages, 10297 KiB  
Article
Effect of Electric Pulse Treatment on the Interfacial Properties of Copper/304 Stainless Steel Composite Thin Strips Fabricated by Roll Bonding
by Zefeng Wang, Xiaomiao Niu, Ming Wang, Yu Yang, Dongping He and Wangzhe Du
Metals 2025, 15(2), 112; https://doi.org/10.3390/met15020112 - 24 Jan 2025
Viewed by 718
Abstract
Annealing is a commonly used post-processing method for composite thin strips but suffers from drawbacks such as long processing time, high energy consumption, and susceptibility to oxidation. Replacing annealing with electric pulse treatment (EPT) can address these issues. In this study, a specially [...] Read more.
Annealing is a commonly used post-processing method for composite thin strips but suffers from drawbacks such as long processing time, high energy consumption, and susceptibility to oxidation. Replacing annealing with electric pulse treatment (EPT) can address these issues. In this study, a specially designed fixture was used to investigate the effects of pulsed current on the bonding strength of T2 copper (Cu)/304 stainless steel (SS) composite thin strips. The initial strip, with a 50% reduction rate, was prepared using a two-high mill, resulting in a Cu/SS composite strip with a thickness of 0.245 mm. Pulsed current treatment was applied with peak temperatures ranging from 350 °C to 600 °C. The results showed that EPT significantly improved the bonding strength. A pulsed current of 55 A resulted in the highest average peel strength of 10.66 ± 0.93 N/mm, with a maximum Fe content on the Cu side of 7.39 ± 0.84%, while a pulsed current of 65 A resulted in the highest Cu content on the SS side, reaching 57.54 ± 2.06%. This study demonstrates that EPT effectively controls the deformation behavior and interface state of composite strips, producing Cu/SS composite thin strips with high bonding strength. Full article
(This article belongs to the Special Issue Advanced Plastic Forming Processes: Theory, Experiments and Numerical Simulations)
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18 pages, 8361 KiB  
Article
Multi-Physical Field Coupling Analysis of Electro-Controlled Permanent Magnet Blank Holder Processes Considering Thermal Magnetic Losses
by Zhanshan Wang, Linyuan Meng, Gaochao Yu and Xiaoyu Ji
Metals 2025, 15(1), 39; https://doi.org/10.3390/met15010039 - 3 Jan 2025
Viewed by 585
Abstract
Electro-permanent magnet (EPM) technology is characterized by high integration, strong modularity, and stable magnetic force, making it a current research focus when combined with sheet metal deep drawing processes to develop EPM blank holder deep drawing technology. In this study, we investigated the [...] Read more.
Electro-permanent magnet (EPM) technology is characterized by high integration, strong modularity, and stable magnetic force, making it a current research focus when combined with sheet metal deep drawing processes to develop EPM blank holder deep drawing technology. In this study, we investigated the issue of thermal magnetic quantitative magnetic loss after the prolonged use of the EPMBH process, analyzing the variation in magnetic force with the temperature increase to provide necessary data support for the application of the EPMBH. First, a thermal network model for the four-magnetic pole unit EPM magnetic device was established, and through calculations on this model, the thermal equilibrium temperatures for the permanent magnet (PM)-NdFeB and reversible magnet (RM)-AlNiCo were found to be 72.13 °C and 72.41 °C, respectively. Second, the magnetic performance of PM and RM at different temperature points was measured to analyze the variation in their magnetic characteristics with the temperature increase. Third, a magnetic force model of the EPM magnetic device was established, and finite element analysis was conducted using the measured magnetic characteristics data of RM and PM. The results indicated that an increase in temperature leads to a reduction in magnetic force, with a maximum reduction of 18.57% observed after thermal equilibrium. An experimental testing platform was designed and built to validate the calculation and simulation results. Finally, a sheet metal deep drawing experiment using the EPMBH process was conducted, taking into account thermal magnetic loss factors. The results showed that magnetic force loss due to temperature rise affects the forming quality of the sheet metal. Therefore, in practical applications, it is necessary to establish a real-time temperature monitoring system and develop a temperature-based magnetic force compensation module. Full article
(This article belongs to the Special Issue Advanced Plastic Forming Processes: Theory, Experiments and Numerical Simulations)
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19 pages, 8007 KiB  
Article
Study on Near-Net Shape Forging of Large Marine Crank Throws
by Longjiang Niu, Qingliang Zhang, Yongwan Zhang, Jingyu Wang, Weiping Luo, Donghang Liu, Tengfei Ma and Xavier Velay
Metals 2025, 15(1), 14; https://doi.org/10.3390/met15010014 - 28 Dec 2024
Viewed by 940
Abstract
The crankshaft is a critical component in large marine ships, often regarded as the “heart” of the vessel due to its role in transmitting power and motion. This article addresses the technological challenges in the forging of marine crank throws, a key segment [...] Read more.
The crankshaft is a critical component in large marine ships, often regarded as the “heart” of the vessel due to its role in transmitting power and motion. This article addresses the technological challenges in the forging of marine crank throws, a key segment of the crankshaft. The study employed finite element simulations to evaluate three Near-Net-Shape (NNS) forming methods: One-Step Extrusion (OSE), Upsetting/Backward Extrusion (U/BE), and Grooving–upsetting/Backward Extrusion (G–U/BE). The results show that the G–U/BE method requires the lowest load. The grooving–upsetting step in the G–U/BE process forms a rigid journal end web shape that influences the subsequent backward extrusion, with the relative groove depth (the ratio of groove depth to width) playing a crucial role in the final forging quality. Optimal crank throw formation occurs when the ratio is 1.5; deeper grooves increase the load required, diminishing the effectiveness of the grooving–upsetting step. Scaled-down experiments validate G–U/BE as a practical and feasible method for producing large marine crank throw forgings, ensuring both the desired shape and microstructural properties. Full article
(This article belongs to the Special Issue Advanced Plastic Forming Processes: Theory, Experiments and Numerical Simulations)
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19 pages, 8427 KiB  
Article
Theoretical Study of Asymmetric Bending Force on Metal Deformation in Cold Rolling
by Zhuwen Yan, Shuaizhen Pan, Yingxin Tang and Wenjun Cao
Metals 2024, 14(10), 1168; https://doi.org/10.3390/met14101168 - 13 Oct 2024
Viewed by 1165
Abstract
A three-dimensional elastic–plastic finite element model of a six-roll cold rolling mill has been developed using the finite element software ABAQUS. The actual parameters of the rolling mill have been incorporated into the finite element model, with the working conditions applied as boundary [...] Read more.
A three-dimensional elastic–plastic finite element model of a six-roll cold rolling mill has been developed using the finite element software ABAQUS. The actual parameters of the rolling mill have been incorporated into the finite element model, with the working conditions applied as boundary constraints and load conditions. Subsequently, a non-symmetrical bending force is introduced to the finite element model. Through simulation calculations, this study analyzes the patterns of change in the transverse pressure of the rolling mill and roller pressure during non-symmetrical bending, as well as the variations in strip thickness, crown, edge drop, and flatness. Additionally, the regulating function of the bending force is examined. Each adjustment of 5 t in the asymmetric bending force results in an increase of approximately 0.01 mm in the thickness of the positive bending side of the strip while causing a decrease of about 0.01 mm in the thickness of the negative bending side. Therefore, the application of asymmetric bending forces proves to be effective in controlling the shape of lateral wave defects on the edges of steel strips. Full article
(This article belongs to the Special Issue Advanced Plastic Forming Processes: Theory, Experiments and Numerical Simulations)
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