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Metals
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Numerical Modelling of Metal-Forming Processes
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Numerical Modelling of Metal-Forming Processes

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

Deadline for manuscript submissions: closed (30 April 2025) | Viewed by 1852

Special Issue Editors

Dr. João Pedro da Fonseca Matos Pragana

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Guest Editor
IDMEC, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1049-001 Lisboa, Portugal
Interests: metal forming; joining processes; additive manufacturing
Special Issues, Collections and Topics in MDPI journals
Dr. Carlos Alves da Silva

E-Mail Website1 Website2
Guest Editor
IDMEC, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1049-001 Lisboa, Portugal
Interests: metal forming; hybrid manufacturing; experimentation
Special Issues, Collections and Topics in MDPI journals
Dr. Ivo Manuel Ferreira de Bragança

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Guest Editor
CIMOSM, Instituto Superior de Engenharia de Lisboa, Instituto Politécnico de Lisboa, R. Conselheiro Emídio Navarro 1, 1959-007 Lisboa, Portugal
Interests: metal forming; formability; non-conventional machining
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Metal forming is a widespread manufacturing technology used to shape metal workpieces into components with added value through plastic deformation. Historically, processes such as forging, rolling, extrusion, or stamping have been crucial in various industries with technological development primarily driven by trial-and-error experimentation. However, the current need to reduce production costs, conserve materials, minimize waste, and adhere to stringent environmental regulations makes trial-and-error development unsustainable.

This is where numerical modelling has emerged as a powerful alternative. By simulating metal-forming processes using computational techniques, numerical modelling provides a more efficient, cost-effective, and environmentally friendly approach for process optimization, while also driving innovation in material design, tooling, and process mechanisms, contributing to significant advancements in the field of metalworking and manufacturing.

This Special Issue aims to provide novel contributions to the field of metal forming with emphasis on numerical modelling. This Special Issue will include original research articles; however, state-of-the-art reviews are also welcome.

Research areas may include (but are not limited to) the following:

  • Finite element analysis of metal-forming processes;
  • New material constitutive models;
  • Thermo-mechanical coupling involving heat generation and/or phase transformation;
  • Friction and contact modelling;
  • Multiscale modelling;
  • Formability analysis for predicting defects;
  • Simulation of hybrid processes involving additive manufacturing or joining processes;
  • Mesh-free or adaptive meshing methods;
  • Use of artificial intelligence and machine learning in metal forming.

We look forward to receiving your contributions.

Dr. João Pedro da Fonseca Matos Pragana
Dr. Carlos Alves da Silva
Dr. Ivo Manuel Ferreira de Bragança
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. 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
  • numerical modelling
  • material constitutive models
  • thermo-mechanical coupling
  • friction
  • multiscale modeling
  • forming limit diagrams
  • hybrid manufacturing
  • artificial intelligence

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Published Papers (4 papers)

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Research

20 pages, 3408 KiB  
Article
Friction Stress Analysis of Slag Film in Mold of Medium-Carbon Special Steel Square Billet
by Xingjuan Wang, Xulin Si, Liguang Zhu, Tianshuo Wei and Xuelong Zheng
Metals 2025, 15(7), 702; https://doi.org/10.3390/met15070702 - 24 Jun 2025
Viewed by 162
Abstract
Non-uniform friction and lubrication are the key factors affecting the surface quality of the casting billet. Based on the three-layer structure of the casting powder in the mold, the frictional stress in the mold was calculated and analyzed by using the relationship between [...] Read more.
Non-uniform friction and lubrication are the key factors affecting the surface quality of the casting billet. Based on the three-layer structure of the casting powder in the mold, the frictional stress in the mold was calculated and analyzed by using the relationship between the frictional stress and the thickness and viscosity of the liquid slag film, and the lubrication state between the cast billet and the mold was evaluated. Based on the actual production data of 40Mn2 steel and combined with the numerical simulation results of the solidification and shrinkage process of the molten steel in the mold by ANSYS 2022 R1 software, the frictional stress on the cast billet in the mold was calculated. It was found that within the range of 44~300 mm from the meniscus, the friction between the cast billet and the mold was mainly liquid friction, and the friction stress value increased from 0 to 145 KPa. Within 300–720 mm from the meniscus, the billet shell is in direct contact with the mold. The friction between the cast billet and the mold is mainly solid-state friction, and the friction stress value increases from 10.6 KPa to 26.6 KPa. It indicates that the excessive frictional stress inside the mold causes poor lubrication of the cast billet. By reducing the taper of the mold and optimizing the physical and chemical properties of the protective powder, within the range of 44~550 mm from the meniscus, the friction between the cast billet and the mold is mainly liquid friction, and the friction stress value varies within the range of 0–200 Pa. It reduces the frictional stress inside the mold, improves the lubrication between the billet shell and the mold, and completely solves the problem of mesh cracks on the surface of 40Mn2 steel cast billets. Full article
(This article belongs to the Special Issue Numerical Modelling of Metal-Forming Processes)
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20 pages, 4609 KiB  
Article
A Microstructure-Integrated Ductile Fracture Criterion and FE-Based Framework for Predicting Warm Formability of AA7075 Sheets
by Wan-Ling Chen and Rong-Shean Lee
Metals 2025, 15(6), 655; https://doi.org/10.3390/met15060655 - 12 Jun 2025
Viewed by 653
Abstract
Variations in the warm formability of AA7075 sheets are primarily attributed to differences in precipitate morphology resulting from distinct thermal histories. To better understand this relationship, this study systematically investigates the influence of precipitate characteristics—quantified by the product of precipitate volume fraction and [...] Read more.
Variations in the warm formability of AA7075 sheets are primarily attributed to differences in precipitate morphology resulting from distinct thermal histories. To better understand this relationship, this study systematically investigates the influence of precipitate characteristics—quantified by the product of precipitate volume fraction and average radius—on forming limits across various thermal routes in warm forming processes. A modified Cockcroft–Latham ductile fracture model incorporating this microstructural parameter was developed, calibrated against experimental data from warm isothermal Nakajima tests, and implemented within a finite element framework. The proposed model enables the accurate prediction of forming limit curves with minimal experimental effort, thereby significantly reducing the reliance on extensive mechanical testing. Building upon the validated FE model, a practical methodology for rapid R-value estimation under warm forming conditions was established, involving the design of specimen geometries optimised for isothermal Nakajima testing. This approach achieved R-value predictions within 5% deviation from conventional uniaxial tensile test results. Furthermore, experimental results indicated that AA7075 sheets exhibited nearly isotropic deformation behaviour under retrogression warm forming conditions. Overall, the methodology proposed in this study bridges the gap between formability prediction and process simulation, offering a robust and scalable framework for the industrial optimisation of warm forming processes for high-strength aluminium alloys. Full article
(This article belongs to the Special Issue Numerical Modelling of Metal-Forming Processes)
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15 pages, 4813 KiB  
Article
Double-Flush Riveting for Hybrid Busbar Assembly
by Rui F. V. Sampaio, João P. M. Pragana, Miguel P. Figueiredo, Ivo M. F. Bragança, Carlos M. A. Silva and Paulo A. F. Martins
Metals 2025, 15(5), 521; https://doi.org/10.3390/met15050521 - 5 May 2025
Viewed by 336
Abstract
This paper explores a novel double-flush riveting process for assembling hybrid busbars made from aluminum and copper sheets. The process involves drilling and forging countersunk holes with controlled geometry in both materials followed by compression of cylindrical rivets into the holes to create [...] Read more.
This paper explores a novel double-flush riveting process for assembling hybrid busbars made from aluminum and copper sheets. The process involves drilling and forging countersunk holes with controlled geometry in both materials followed by compression of cylindrical rivets into the holes to create strong, form- and force-closed mechanical joints. Experimental and numerical analyses are combined to examine material flow, quantify the required forces, and assess the structural integrity of the joints through destructive testing. Additionally, the electrical resistance of these novel joints is evaluated and compared with that of ideal and conventional fastened hybrid busbar joints in order to assess their performance and reliability in real-world electrical service conditions. The results indicate that the novel double-flush riveting process is a viable alternative to other conventional joining processes, such as fastening, delivering good structural integrity and enhanced electrical conductivity for hybrid busbar applications. Full article
(This article belongs to the Special Issue Numerical Modelling of Metal-Forming Processes)
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12 pages, 1387 KiB  
Article
Numerical Analysis of the Laser Forming Process of Cylindrical Surfaces
by Daniel Cabezas, Diego J. Celentano, Marcela A. Cruchaga, Claudio García-Herrera and Alberto Monsalve
Metals 2025, 15(4), 402; https://doi.org/10.3390/met15040402 - 3 Apr 2025
Viewed by 296
Abstract
This research reports on numerical simulations of the multi-pass laser forming process aimed at obtaining cylindrical surfaces from planar AISI 304 stainless-steel sheets. The effect of laser power, scanning speed, and distance between irradiation lines on the thermomechanical material response is assessed, with [...] Read more.
This research reports on numerical simulations of the multi-pass laser forming process aimed at obtaining cylindrical surfaces from planar AISI 304 stainless-steel sheets. The effect of laser power, scanning speed, and distance between irradiation lines on the thermomechanical material response is assessed, with particular emphasis on the final curvature radius, maximum temperature, and final plastic deformation. To this end, a coupled thermomechanical finite element formulation is applied to the analysis of different experimental tests reported in the literature. The predictive capabilities of this model are demonstrated in the analysis of bent parts exhibiting a wide range of curvature radii, whose values were found in this work to inversely correlate with the total line energy input to the workpiece. In such situations, it was found that both the thermal response and the effective plastic strain values obtained in each test correlate directly with the line energy value. Furthermore, the distance between irradiation lines was identified as a key parameter in the formation of cylindrical surfaces, as it significantly influences the displacement and induced deformation. However, no significant impact of this parameter on the effective plastic strain was observed. Full article
(This article belongs to the Special Issue Numerical Modelling of Metal-Forming Processes)
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