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Metals
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Application of FEM-Simulation in Metal Forming
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Application of FEM-Simulation in Metal Forming

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: closed (31 July 2021) | Viewed by 19054

Special Issue Editor

Dr. Aleksander Czekanski

E-Mail Website
Guest Editor
Department of Mechanical Engineering, York University, Toronto, ON M3J 1P3, Canada
Interests: finite element method; selective laser melting; powder compaction; effective thermal conductivity; additive manufacturing modeling
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

This Special Issue of Metals is dedicated to recent research results in metal forming.

Contributions focused on this manufacturing process on any of the following topics are of particular interest:

- Development and characterization of materials;

- Numerical modeling/simulation;

- Development of continuum damage mechanics;

- Modeling of contact frictional problems;

- Innovative metal-forming applications.

Prof. Aleksander Czekanski
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

  • Metal forming
  • Finite element analysis
  • Finite volume method
  • Simulations
  • Multiscale material modeling
  • Anisotropy
  • Strain rate
  • Continuum damage mechanics
  • 3D adaptive remeshing
  • Springback
  • Contact/friction

Published Papers (5 papers)

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Research

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18 pages, 9139 KiB  
Article
Analysis of Wall Thickness Eccentricity in the Rotary Tube Piercing Process Using a Strain Correlated FE Model
by Alberto Murillo-Marrodán, Eduardo García, Jon Barco and Fernando Cortés
Metals 2020, 10(8), 1045; https://doi.org/10.3390/met10081045 - 03 Aug 2020
Cited by 16 | Viewed by 3898
Abstract
The wall thickness eccentricity is one of the most important weaknesses that appears in seamless tubes production, since this imperfection is subsequently transferred downstream through the manufacturing stages until the final product. For this reason, in this article a finite element model of [...] Read more.
The wall thickness eccentricity is one of the most important weaknesses that appears in seamless tubes production, since this imperfection is subsequently transferred downstream through the manufacturing stages until the final product. For this reason, in this article a finite element model of the rotary tube piercing (RTP) process is developed aimed at analysing the wall thickness eccentricity imperfection. Experimental data extracted from the industrial process is used for the validation of the model, including operational process variables like power consumption and process velocity, and deformation variables as elongation and longitudinal torsion, originated by axial and shear strain respectively. The cause of longitudinal torsion is also analysed. The two most important conclusions derived from this study are: (I) the longitudinal torsion of the tube is a crucial parameter for the correct model validation, and (II) the combined effect between the uneven temperature distribution of the billet and the plug bending deformation is identified as the major cause of the wall thickness eccentricity flaw. Full article
(This article belongs to the Special Issue Application of FEM-Simulation in Metal Forming)
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12 pages, 6641 KiB  
Article
Application of the Progressive Forming Method in Simulation and Experimental Study of Rectangular Fins in a Heat Exchanger
by Chul Kyu Jin
Metals 2020, 10(3), 395; https://doi.org/10.3390/met10030395 - 19 Mar 2020
Cited by 2 | Viewed by 3048
Abstract
A progressive forming method is applied where stamping is continuously executed to produce the rectangular fins of the plate fin heat exchanger. This process produced the fins one-by-one instead of by bundles. In order to produce a fin having a depth of more [...] Read more.
A progressive forming method is applied where stamping is continuously executed to produce the rectangular fins of the plate fin heat exchanger. This process produced the fins one-by-one instead of by bundles. In order to produce a fin having a depth of more than 6.0 mm, the forming load and effective stress according to the size of the edge radii of punch and die are predicted by forming simulation. Furthermore, the process of forming the second, as well as the third, fins is predicted. As the edge radii of the die and those of the punch became smaller, the effective stresses generated during deformation became smaller. The forming load during deformation also became smaller. The sizes of the edge radii of die and punch were set to 0.5 mm and 0.2 mm, respectively. When the second fin was formed, overforming occurred at the ribs. The punch was therefore modified so that the rib could be compressed at the same time the fin was formed. With the designed process, the inner fins close to the target size could be manufactured. The resulting fins had right-angled ribs, although the fin width was a slightly opened isosceles trapezoid due to the spring-back. Full article
(This article belongs to the Special Issue Application of FEM-Simulation in Metal Forming)
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22 pages, 16061 KiB  
Article
Springback Reduction of L-Shaped Part Using Magnetic Pulse Forming
by Xiaohui Cui, Ang Xiao, Zhihao Du, Ziqin Yan and Hailiang Yu
Metals 2020, 10(3), 390; https://doi.org/10.3390/met10030390 - 18 Mar 2020
Cited by 11 | Viewed by 2952
Abstract
This study proposes an electromagnetic-assisted stamping (EMAS) method with magnetic-force loading at the sheet end in order to control the springback phenomenon. The new method does not change the structure of the mold and does not generate a magnetic force at the sheet [...] Read more.
This study proposes an electromagnetic-assisted stamping (EMAS) method with magnetic-force loading at the sheet end in order to control the springback phenomenon. The new method does not change the structure of the mold and does not generate a magnetic force at the sheet corner compared to traditional EMAS. Thus, the new approach could greatly extend the mold lifespan and could be readily adopted in commercial production environments. The effects of technological parameters, such as the distance between the blank holder and die, discharge voltage, and sheet thickness on the springback phenomenon were analyzed. Our results suggest that tangential stress and elastic strain energy both decrease with the increase of discharge voltage. The simulation method accurately predicted the deformation of the sheet during the quasi-static stamping and dynamic magnetic forming processes. The simulation and experimental results both show that as the discharge voltage increases, the bent angle after springback decreases. Full article
(This article belongs to the Special Issue Application of FEM-Simulation in Metal Forming)
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29 pages, 43207 KiB  
Article
Simulation of Adiabatic Shear Bands in Orthogonal Machining of Ti6Al4V Using a Rigid-Viscoplastic Finite Element Analysis
by Orestis Friderikos, Dimitrios Sagris, Constantine N. David and Apostolos Korlos
Metals 2020, 10(3), 338; https://doi.org/10.3390/met10030338 - 03 Mar 2020
Cited by 11 | Viewed by 4443
Abstract
Catastrophic shear instability is the dominant mechanism during orthogonal cutting of Ti6Al4V. Chip segmentation even at low speeds testifies to the emergence of some kind of instability during plastic deformation of the material. Among the theoretical models, catastrophic thermoplastic slip is proposed as [...] Read more.
Catastrophic shear instability is the dominant mechanism during orthogonal cutting of Ti6Al4V. Chip segmentation even at low speeds testifies to the emergence of some kind of instability during plastic deformation of the material. Among the theoretical models, catastrophic thermoplastic slip is proposed as a mechanism to explain the destabilization of homogeneous plastic deformation, which results in localized, band-like adiabatic shear deformation. On the other hand, fracture models which consider machining as a mechanism of ductile or brittle fracture are used to explain the segmented chip formation as a periodic crack generation mechanism. This work aims at elucidating the fundamental mechanisms of the above theoretical models using a coupled thermomechanical rigid-viscoplastic FEM analysis. Introducing an energy criterion for ductile damage, numerical results showed that failure within the adiabatic shear band (ASB) is a post-localization mechanism occurring after intense shear localization. Simulations revealed a void initiation and coalescence mechanism which resembles an array of discontinuous degraded elements of nearly ellipsoidal shapes that grows and progressively coalesces forming a macro crack inside the ASB. Several aspects of ASB formation are addressed, among others, the micro-scale spatial temperature profile, parametric studies of critical damage energies, chip segmentation frequency, etc. Experimental results of ASB formation pertaining to chip morphology and cutting forces are compiled and analyzed to evaluate the FEM model at the low speed regime. Full article
(This article belongs to the Special Issue Application of FEM-Simulation in Metal Forming)
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Review

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22 pages, 12120 KiB  
Review
A Short Review on the Finite Element Method for Asymmetric Rolling Processes
by Ana Graça and Gabriela Vincze
Metals 2021, 11(5), 762; https://doi.org/10.3390/met11050762 - 06 May 2021
Cited by 8 | Viewed by 3533
Abstract
Several studies on asymmetric rolling processes use the Finite Element Method (FEM) to predict material deformation and optimize process parameters, such as rolls’ forces and torques. Early studies focused on the observation and measure of curvature effects due to the asymmetric conditions. However, [...] Read more.
Several studies on asymmetric rolling processes use the Finite Element Method (FEM) to predict material deformation and optimize process parameters, such as rolls’ forces and torques. Early studies focused on the observation and measure of curvature effects due to the asymmetric conditions. However, these models could not predict mechanical behavior associated with the texture evolution during the rolling processes. More recent studies introduced crystal plasticity (CP) models into the FEM to analyze and quantify the texture evolution during plastic forming. However, these coupled techniques need more investigation, especially concerning the mechanical behavior of the material during and after multi-stage ASR procedures. The purpose of this work is to present an up-to-date literature review on the implementation of asymmetric rolling processes in finite element analysis. It shows a summarized overview of the asymmetric rolling model parameters from different authors and gives a brief description of the crystallographic models used in their studies. In the end, some suggestions for future work dedicated to the analysis of ASR through FEM are given. Full article
(This article belongs to the Special Issue Application of FEM-Simulation in Metal Forming)
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