Dual-pressure tube hydroforming (THF) is a tube-forming process that involves applying fluid pressure to a tube’s inner and outer surfaces to achieve deformation. This study investigates the effect of dual-pressure loading paths on material for...
Accurate preform design in forging processes is critical for improving part quality, conserving material, reducing manufacturing costs, and eliminating secondary operations. This paper presents a finite element (FE) simulation-based methodology for p...
Hydroforging is a hybrid forming operation whereby a thick tube is formed to a desired geometry by combining forging and hydroforming principles. Through this process hollow structures with high strength-to-weight ratio can be produced for applicatio...
The progressive stamping process includes blanking, piercing, bending, and drawing operations on press machines with a single die set for high production runs. The processing conditions at individual progressive stamping stations are intricately coup...
The paper presents the results of research on the influence of the settings of lubrication and cooling system parameters (solenoid valve opening time and lubricant feed pressure in terms of its quantity) in order to select the optimal lubricating con...
The forging industry has increasingly emphasised quality and reproducibility, making computer simulations essential for predicting and improving the process. A major challenge in cold upset forging is billet buckling, which leads to defective product...
Power metallurgy hot isostatic pressing (PM-HIP) is a manufacturing technique capable of producing net shape or near-net shape components with complicated geometries from materials that are difficult to melt and cast, mechanically deform or weld. How...
Achieving a uniform thickness and defect-free production in the flat die extrusion of polymer sheets and films is a major challenge. Dies are designed for one extrusion scenario, for a polymer grade with specified rheological behavior, and for a give...
This study presents the design and performance evaluation of a custom extrusion die for producing grass-cutting lines from high-density polyethylene (HDPE) with twist angles of 0°, 15°, 30°, and 45°. The mechanical properties, cutting...
Quenching and partitioning (Q&P) heat treatments of low-alloy steels with exceptional property combinations are particularly promising. In this study, we characterize for the first time a new low-alloy steel to be processed using Q&P heat tre...
In this article, an efficient die-bonding technology based on silver sintering due to induction heating is presented. By using this technology, the heat for the sintering reaction is locally limited to the bonding area and heating of the entire power...
Thin stamped bipolar plates (BPPs) are viewed as promising alternatives to traditional graphite BPPs in proton exchange membrane fuel cells. Metallic BPPs provide good thermal/electrical conductivity and exhibit high mechanical strength, to support t...
Optimizing end mill geometry is critical for improving performance and reducing costs in the high-volume manufacturing of tools, dies and molds. This study demonstrates a successful optimization framework for solid end mills machining 1.2379 cold-wor...
This article presents a modular open chamber stand which simulates the densification process that occurs in a single channel of a pelletising die. The results of the verification tests confirmed the suitability of this stand for determining the optim...
Forming complex geometries using the casting process is a big challenge for bulk metallic glasses (BMGs), because of a lack of time of the window for shaping under the required high cooling rate. In this work, we open an approach named the “ent...
In conventional wear simulation, the geometry must be updated for succeeding iterations to predict the accumulated wear. However, repeating this procedure up to the desired iteration is rather time consuming. Thus, a wear simulation process capable o...
During the service life of automotive panel stamping dies, the surface is often subjected to high loads and repeated friction, resulting in excessive wear. This leads to die failure, reduced machining accuracy, and decreased production efficiency. To...
In this study, the rheological characteristics of a titanium alloy have been obtained by multi-dome bulging test. Free bulging process is an experimental technique that can be used to characterize material in conditions of biaxial tension during supe...
Bistable metal shells with a fully closed unfolded geometry are of great interest as lightweight construction parts which could be transported without housing and unfolded at the construction place. In order to achieve the effect of bistability in me...
During the porthole die extrusion, the separated metal streams are welded together in the welding chamber. The conditions under which this occurs and the integrity of weld seam in the extrudate are impacted by the design of the bridge, including feat...
The paper presents the numerical and experimental results of research aimed at determining the influence of hardness in the range of 50–90 Shore A of layered tools composed of elastomeric materials on the possibility of forming Inconel 625 nick...
Metallic components can gain defects such as dents, cracks, wear, heat checks, deformation, etc., that need to be repaired before reinserting into service for extending the lifespan of these parts. In this study, a hybrid process was developed to int...
After conventional forming processes, the residual stress distribution in wires is frequently unfavorable for subsequent processes, such as bending operations. High tensile residual stresses typically occur near the wire surface and normally limit fu...
An environmentally friendly alternative to phosphate-based lubrication was studied through the lateral cold extrusion forging of internal gears using pulsating motion. A die set with a removable punch enabled a detailed observation of relubrication,...
This article presents the analysis of the deformability, structure and properties of the AZ61 cast magnesium alloy on the example of a new forging process of aircraft mount forgings. It was assumed that their production process would be based on drop...
Severe plastic deformation (SPD) can produce ultrafine grained (UFG) and nanocrystalline (NC) materials by imposing intense plastic strain. One of the many options for inducing large plastic strains is to pass the material through a torsional/twist e...
This study evaluates the application of metal additive manufacturing—specifically the laser powder bed fusion (LPBF) process—for producing aluminium die-casting mould components, comparing 300-grade maraging steel inserts with conventiona...
The zygomatic bone area experiences frequent mechanical damage in the middle craniofacial region, including the orbital floor. The orbital floor bone is very thin, ranging from 0.74 mm to 1.5 mm. Enhancing digitization, reconstruction, and CAD modeli...
This work presents the design and characterization of a resonant CMOS-MEMS pressure sensor manufactured in a standard 180 nm CMOS industry-compatible technology. The device consists of aluminum square plates attached together by means of tungsten via...
Fabry disease is an X-linked lysosomal storage disorder caused by alpha-galactosidase A deficiency. The genetic defect leads to progressive intracellular accumulation of Gl3 in various tissues, including heart, kidney, vascular endothelium and the ne...
Sheet metal forming processes are widely used in applications such as those in the automotive or aerospace industries. Among them, punching is of great interest due to its high productivity and low operating cost. However, it is necessary to optimize...
Incremental sheet metal forming can manufacture various sheet metal products without a dedicated punch and die set. In this study, we developed a two-stage incremental forming process to decrease shape errors in the conventional incremental forming p...
The precision and accuracy of the final geometry in micro-parts is crucial, particularly for high-value-added metallic products. Micro-extrusion is one of the most promising processes for delivering high-precision micro-parts. The curving tendency ob...
This article presents the outcome of research on modelling the process of the extrusion of crystalline dry ice. The purpose of this process is to densify the material and obtain pellets of several millimeters in diameter. This reduces the sublimation...
Distortion (1), residual stresses and hot cracks can facilitate significant decreases in quality characteristics of casting products. Their reduction by a suitable component design (2) and process control is therefore desirable. In the casting proces...
Plastic injection molding is a versatile process, and a major part of the present plastic manufacturing industry. The traditional die design is limited to straight (drilled) cooling channels, which don’t impart optimal thermal (or thermomechani...
Phenomenological plasticity models that relate relative density to plastic strain are frequently used to simulate ceramic powder compaction. With respect to the form implemented in finite element codes, they need to be modified in order to define gov...
Die-sinking Electrical Discharge Machining (EDM) is a manufacturing process for fabricating complex geometries in challenging applications. However, its energy-intensive nature and complex parameter interactions pose challenges in balancing productiv...
In the extrusion of plastics, the thermal and material homogeneity of the plastic melt at the die entry are of high importance for the extrudate quality. While static mixers are widely used to improve the melt homogeneity, previous attempts at optimi...
Since the popularization of press hardening in the early noughties, die and tooling systems have experienced considerable advances, with tool refrigeration as an important focus. However, it is still complicated to obtain homogeneous cooling and avoi...
The material combination of aluminum and copper is increasingly coming into focus, especially for electrical contact applications. Investigations of different casting processes show that a significant influence for the formation of a material bond is...
This article proposes an indirect measurement method based on a dimensional and shape analysis of forgings for the evaluation of the manufacture and the proper operation of the key elements of the crank press, in which after modernization, a quick to...
Excessive surface friction encountered during metal-forming processes typically leads to die wear and seizure in part surfaces, which consequently shortens the die’s service lifespan and lowers the surface quality of the formed parts. To minimi...
The article is devoted to the optimization of the degassing parameters of the AlSi9Cu3(Fe) alloy. The alloy was degassed with a solid degasser (Ecosal) and nitrogen or argon. The variable parameters were time and type of degasser. The test castings w...
The warm-forging technology of the spiral bevel gear (873 K–1073 K) was studied. Based on the rigid–plastic finite element method, a numerical simulation was carried out by using DEFORM V11.0 software to explore the influence of different...
A comprehensive mathematical model of the hot extrusion process for aluminum alloys has been developed and validated. The plasticity module was developed using a commercial finite element package, DEFORM-2D, a transient Lagrangian model which couples...
The present research investigates the optimization of the punching process in cold forming manufacturing, focusing on enhancing tool life, reducing damage, and improving product quality. Punching, a shearing process widely used in sheet metal forming...
This study develops an analytical model for the plastic bending of anisotropic sheet materials, incorporating strain-hardening effects. The model, experimentally validated with aluminum alloy samples and digital image correlation, accurately predicts...
Three-dimensionally printed metals and polymers have been widely used and studied in medical applications, yet ceramics also require attention. Ceramics are versatile materials thanks to their excellent properties including high mechanical properties...
This study investigates the sensitivity of the square cup forming process. It analyses how the uncertainties in the material properties, friction and process conditions affect the results of the square cup, such as equivalent plastic strain, geometry...
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