Journal articles: 'Hot metal forming'

1

Liu, Cai-yi, Yan Peng, Ling Kong, Lu-han Hao, and Ren Zhai. "Hot forming with a nonuniform temperature field using die partition cooling." Metallurgical Research & Technology 116, no. 6 (2019): 613. http://dx.doi.org/10.1051/metal/2019044.

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High strength steel hot forming technology plays an important role in achieving lightweight vehicles, improving the safety of vehicles. The tensile strength of the blank formed by traditional hot forming process is as high as 1500–2000 MPa, the strength of the formed blank is high, but the elongation is usually low and comprehensive mechanical property is not high. In this article, the process control of material gradient properties hot forming technology is summarized through the analysis of strengthening mechanism of gradient distribution hot forming technology. Based on the traditional hot forming technology, a new hot forming technology based on partition cooling to achieve material property gradient distribution is proposed. By changing the cooling rate of blank in different zones is different, and the gradient distribution of material properties is finally obtained. The DEFORM is used to analyze the hot forming process of the blank under the nonuniform temperature field of the partition cooling. A set of partition cooling hot forming die was designed independently to verify the experimental results. The evolution mechanism of microstructure and its effect on material properties during hot forming under nonuniform temperature field with partition cooling were revealed.

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Beynon, J. H. "Tribology of hot metal forming." Tribology International 31, no. 1-3 (January 1998): 73–77. http://dx.doi.org/10.1016/s0301-679x(98)00009-7.

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Ma, Ning, Ping Hu, and Zong Hua Zhang. "Research on a New Type of Metal Composite Material in Hot Forming and its Application." Advanced Materials Research 156-157 (October 2010): 582–91. http://dx.doi.org/10.4028/www.scientific.net/amr.156-157.582.

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A new type of metal composite material can be manufactured by controlling heating temperature and designing the layout of cooling pipes in hot forming process of ultra high strength steel. The yield strength of this type of metal material varies from 380 MPa to 1000 MPa continuously, and its strength limitation varies from 480 MPa to 1600 MPa continuously. In this new hot forming technology, boron steel named as 22MnB5 is stamped by one-step process of hot forming to obtain the metal composite material and manufacture the part consisting of the metal composite at the same time. The hot forming technology of U-shaped part consisting of the metal composite material is provided. Then the microstructure of the U-shaped metal composite material is analyzed and the tensile test is also implemented. The experimental results show the material properties have the characteristics of continuous distribution along the main direction of energy absorption during crash process, which indicates the feasibility of hot forming technology of the metal composite material. The top-hat thin-wall structure consisting of U-shaped metal composite material is employed to analyze the crashworthiness of the new type of metal composite material. By distributing the single phase material of U-shaped composite part properly, the energy absorption ability is increased by 58.7% and the crash force is decreased by 23.4%, which indicate the new type of metal composite material has the comprehensive performance of every single phase material. So the metal composite is a good alternative material in application of crash resistance.

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Bambach, Markus, Irina Sizova, and Aliakbar Emdadi. "Towards Damage Controlled Hot Forming." Applied Mechanics and Materials 885 (November 2018): 56–63. http://dx.doi.org/10.4028/www.scientific.net/amm.885.56.

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Metal forming processes may induce internal damage in the form of voids in the workpiece under unfavorable deformation conditions. Controlling the amount of damage induced by metal forming operations may increase service performance of the produced parts. Damage is crucial in high-performance components of limited workability such as jet engine turbine blades. Recent developments have introduced forged titanium aluminides into commercial jet engines. Titanium aluminides are lightweight intermetallic compounds with excellent creep properties but very limited ductility. Their low workability requires isothermal forging at slow strain rates, which is typically kept constant in the process. This work explores the possibility of increasing the ram speed during the process so that the process time is reduced while the amount of damage introduced into the workpiece is controlled. The results show that a 25% reduction in process time seems viable without increase in damage by solving an optimal control problem, in which the ram speed profile is determined off-line by minimization.

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Geindreau, Christian, Didier Bouvard, and Pierre Doremus. "Constitutive behaviour of metal powder during hot forming." European Journal of Mechanics - A/Solids 18, no. 4 (July 1999): 597–615. http://dx.doi.org/10.1016/s0997-7538(99)00101-1.

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Yu, Hai Yan, Li Bao, You Zhi Deng, and Wei Cao. "Forming Response of Ultra High Strength Steel Sheet to Stamping Speed during Hot Forming." Advanced Materials Research 160-162 (November 2010): 123–29. http://dx.doi.org/10.4028/www.scientific.net/amr.160-162.123.

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Stamping speed is an important parameter in sheet metal forming especially in hot forming. In this study, hot forming of a U-shaped part made of ultra high strength boron steel (22MnB5) sheet is simulated with solid elements. The mechanical properties of 22MnB5 steel sheet and the key process parameters are introduced in detail. Emphasis is laid on the forming response of the boron steel sheet to stamping speeds of 3.25m/s, 0.325m/s and 0.0325m/s. The mechanism of stamping speed acting on hot formability and temperature field of the stamped part is analyzed. It is demonstrated that stamping speed affects both formability and the heat transferred from blank to tools and to environment during hot forming. And the coupling effect of material properties, the heat produced during plastic deformation and heat boundary condition decides the formability and temperature field. An appropriate stamping speed is more important for hot forming than that for common cold forming.

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Xu, Yong, Xiu-Wen Lv, Yun Wang, Shi-Hong Zhang, Wen-Long Xie, Liang-Liang Xia, and Shuai-Feng Chen. "Effect of Hot Metal Gas Forming Process on Formability and Microstructure of 6063 Aluminum Alloy Double Wave Tube." Materials 16, no. 3 (January 29, 2023): 1152. http://dx.doi.org/10.3390/ma16031152.

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The hot metal gas forming process can significantly improve the formability of a tube and is suitable for the manufacturing of parts with complex shapes. In this paper, a double wave tube component is studied. The effects of different temperatures (400 °C, 425 °C, 450 °C and 475 °C) and different pressures (1 MPa, 1.5 MPa, 2 MPa, 2.5 MPa and 3 MPa) on the formability of 6063 aluminum alloy tubes were studied. The influence of hot metal gas forming process parameters on the microstructure was analyzed. The optimal hot metal gas forming process parameters of 6063 aluminum alloy tubes were explored. The results show that the expansion rate increases with the increase in pressure. The pressure affects the deformation of the tube, which in turn has an effect on the dynamic softening of the material. The expansion rate of parts also increases with the increase in forming temperature. The increased deformation temperature is beneficial to the dynamic recrystallization of 6063, resulting in softening of the material and enhanced deformation uniformity between grains, so that the formability of the material is improved. The optimum hot metal gas forming process parameters of 6063 aluminum alloy tubes are the temperature of 475 °C and the pressure of 2.5 MPa; the maximum expansion ratio is 41.6%.

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Rana, Radhakanta, Theo Kop, Peter Beentjes, and Ellen van der Aa. "Low Temperature Hot Press Forming of a Zinc Coated Third Generation Advanced High Strength Steel." Materials Science Forum 1105 (November 29, 2023): 225–30. http://dx.doi.org/10.4028/p-udks6s.

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A 7 wt.% Mn steel was designed and was cast and processed to 1.5 mm sheets. The sheets were continuous annealed and coated with a Zn alloy by hot dip galvanizing before subjecting them to hot press forming cycles. The final microstructure was characterized by ultrafine ferrite grains and a high fraction of retained austenite. Excellent combinations of in-service strength-ductility-bendability were achieved for hot forming in the temperature range of 530-675 °C. The use of the low temperature hot forming minimized the liquid metal embrittlement induced cracking with Zn coating during hot forming and spot welding. Various application properties such as oxidation resistance, corrosion resistance, and springback were found at optimum levels for hot forming at 675 °C.

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Sana, Guillaume, Alain Petiot, and Arnaud Giraudet. "Hot Forming and Superplastic Forming: Presses Evolution and New Applications in the Aerospace Industry." Materials Science Forum 838-839 (January 2016): 563–67. http://dx.doi.org/10.4028/www.scientific.net/msf.838-839.563.

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ACB (France) and its sister company Cyril Bath (USA) have a long experience in the fields of hydraulic presses and metal forming for the aerospace industry. This experience is particularly focused on the manufacturing of structural and engines parts. The purpose of this presentation is to show how the combination of both activities in the fields of Hot Forming/Sizing and Superplastic Forming results in continual progress and how recent evolution open new fields of applications. First, both processes will be shortly introduced. The advantages of Hot Forming, Superplastic forming and Diffusion Bonding technologies will be demonstrated regarding current customer’s requirements. To conclude an overview of on-going research programs will be made to present strong advantages of dual presses combining Hot Forming and Superplastic processes.

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Müller, Roland, and André Mosel. "Characterisation of Tool Coatings for Press Hardening." Advanced Materials Research 966-967 (June 2014): 259–69. http://dx.doi.org/10.4028/www.scientific.net/amr.966-967.259.

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Hot sheet metal forming is gaining in importance in many fields, because of its capability to produce more complex components than possible with cold forming. Hot forming is also used to influence the final material properties with the hot forming of manganese-boron steels being a good example. One of the major challenges in hot forming is the tribological conditions between the tool and sheet material at the required high temperatures. This article will discuss the influence of different tool material coatings, ranging from PVD to mechanically bonded ceramic coatings, on the tribological conditions during forming. It will also shed light on how these coatings influence the heat transfer between the component ́s material and the tool material.

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Weroński, Wiesław, Zbigniew Pater, and Andrzej Gontarz. "Research on 19MnCr5G Steel under Hot Metal Forming Conditions." Key Engineering Materials 233-236 (January 2003): 401–6. http://dx.doi.org/10.4028/www.scientific.net/kem.233-236.401.

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DOHDA, Kuniaki, and Numpon MAHAYOTSANUN. "Evaluation Method of Tribo-characteristics for Hot Metal Forming." Journal of the Japan Society for Technology of Plasticity 54, no. 630 (2013): 575–80. http://dx.doi.org/10.9773/sosei.54.575.

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13

Alberti, N., L. Cannizzaro, and F. Micari. "Coupled Thermal-Mechanical Analysis of Hot Metal Forming Processes." CIRP Annals 39, no. 1 (1990): 231–34. http://dx.doi.org/10.1016/s0007-8506(07)61042-7.

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14

Bylya, O. I., M. K. Sarangi, N. Rohit, A. Nayak, R. A. Vasin, and P. L. Blackwell. "Simulation Of The Material Softening During Hot Metal Forming." Archives of Metallurgy and Materials 60, no. 3 (September 1, 2015): 1887–94. http://dx.doi.org/10.1515/amm-2015-0322.

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Abstract Deformation softening is quite often observed during hot working of different alloys. Steels, aluminium, titanium or nickel alloys can demonstrate a decrease in flow stress under active deformation at constant temperatures and strain rates. Though the background microstructural mechanisms as well as the softening rates can be quite different, the treatment of such processes requires special attention. Deformation softening can cause significant non-uniformity of the metal flow resulting in flow localization, formation of shear bands and variation of the microstructure across the workpiece. This paper is devoted to the investigation of the specific issues which arise in this respect in FEM simulation of processes involving softening. The possible role of softening in shear band formation is studied using numerical simulation and physical modelling. The effect of the softening rate on the probability of flow localization is discussed. The interplay of deformation softening with the stain rate and temperature sensitivity is demonstrated using as an example the simulation of Equal Channel Angular Pressing (ECAP). An approach to account for the deformation softening in FEM simulations via process modelling of the microstructure refinement is proposed.

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Li, Chao, Shaosong Jiang, and Kaifeng Zhang. "Pulse current-assisted hot-forming of light metal alloy." International Journal of Advanced Manufacturing Technology 63, no. 9-12 (February 5, 2012): 931–38. http://dx.doi.org/10.1007/s00170-012-3934-5.

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Saby, M., P. O. Bouchard, and M. Bernacki. "Void closure criteria for hot metal forming: A review." Journal of Manufacturing Processes 19 (August 2015): 239–50. http://dx.doi.org/10.1016/j.jmapro.2014.05.006.

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17

Yanagimoto, J., K. Karhausen, A. J. Brand, and R. Kopp. "Incremental Formulation for the Prediction of Flow Stress and Microstructural Change in Hot Forming." Journal of Manufacturing Science and Engineering 120, no. 2 (May 1, 1998): 316–22. http://dx.doi.org/10.1115/1.2830129.

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In metal forming, the workpieces are formed to the desired shapes or profiles. Especially in hot forming, the microstructure of workpiece changes during plastic deformation. Modern forming technologies allow to control the shape and the microstructure of formed product in a wide range and will gain increasing importance in future in the field of metal forming. In order to develop this forming technology which may be called “macroscopic microscopic materials processing”, theoretical predictions of plastic deformation as well as microstructural changes are indispensable. A new mathematical formulation to predict flow stress and microstructural change in hot forming will be presented in this paper. This model is based on an incremental formulation taking the dislocation density as a representative variable.

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18

Filzek, Jan, Lukas Schell, and Peter Groche. "Reibwertermittlung für die Alu-Warmblechumformung/Measuring friction for aluminum hot forming." wt Werkstattstechnik online 112, no. 10 (2022): 649–54. http://dx.doi.org/10.37544/1436-4980-2022-10-19.

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Tribometer für die Reibwertermittlung konventioneller Blechumformprozesse wurden bereits im 20. Jahrhundert zu hohem Reifegrad entwickelt. Insbesondere der Streifenziehversuch hat sich in der Branche als Standardprüfmethode etabliert. Neue Herausforderungen ergeben sich durch moderne Aluminium-Warmumformprozesse: Was ist bei der Reibwertermittlung für diese Prozesse zu beachten und wo stößt physikalische Modellbildung an Grenzen? Sophisticated tribometers for determining the friction coefficient of conventional sheet metal forming processes had already been developed in the 20th century. The strip drawing test, in particular, was established as a standard test method for sheet metal forming. New challenges arise from modern aluminum hot forming processes: What needs to be considered when determining the friction coefficient for these processes and where are the limits of physical based modelling?

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Zhang, Tao, Huapu Sha, Lei Li, Shihong Lu, and Hai Gong. "Dynamic recrystallization kinetics and microstructure evolution of 7055 aluminum alloy during hot compression." Metallurgical Research & Technology 116, no. 6 (2019): 605. http://dx.doi.org/10.1051/metal/2019034.

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7055 aluminum alloy is widely used in manufacture of key components in fields of aerospace. Hot forming is the vital process for manufacture of components. Dynamic recrystallization (DRX) plays a significant role in grain refinement. Hot compressions and metallographic tests are conducted. Equations of DRX kinetics are fitted by least square method and finite element models (FEM) coupled with DRX kinetics equations are established to study the effects of forming parameters on microstructure evolution. The results show that true stress increases with ascending strain rate and decreases with ascending temperature. Large strain, small strain rate and high temperature are beneficial to sufficient DRX fraction and grain refinement. Deformation energy and thermally activated motion of atoms and molecules resulting from large strain and high temperature contribute to dynamic nucleation; meanwhile, small strain rate provides sufficient time for growth of recrystallized grains. The FEM results agree with experiments.

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Pujante, Jaume, Borja González, and Eduard Garcia-Llamas. "Pilot Demonstration of Hot Sheet Metal Forming Using 3D Printed Dies." Materials 14, no. 19 (September 30, 2021): 5695. http://dx.doi.org/10.3390/ma14195695.

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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 avoid hot spot issues in complex geometries. Additive Manufacturing allows designing cavities inside the material volume with little limitation in terms of channel intersection or bore entering and exit points. In this sense, this technology is a natural fit for obtaining surface-conforming cooling channels: an attractive prospect for refrigerated tools. This work describes a pilot experience in 3D-printed press hardening tools, comparing the performance of additive manufactured Maraging steel 1.2709 to conventional wrought hot work tool steel H13 on two different metrics: durability and thermal performance. For the first, wear studies were performed in a controlled pilot plant environment after 800 hot stamping strokes in an omega tool configuration. On the second, a demonstrator tool based on a commercial tool with hot spot issues, was produced by 3D printing including surface-conformal cooling channels. This tool was then used in a pilot press hardening line, in which tool temperature was analyzed and compared to an equivalent tool produced by conventional means. Results show that the Additive Manufacturing technologies can be successfully applied to the production of press hardening dies, particularly in intricate geometries where new cooling channel design strategies offer a solution for hot spots and inhomogeneous thermal loads.

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Chung, S. H., H. Park, K. D. Jeon, K. T. Kim, and S. M. Hwang. "An Optimal Container Design for Metal Powder Under Hot Isostatic Pressing." Journal of Engineering Materials and Technology 123, no. 2 (January 15, 2001): 234–39. http://dx.doi.org/10.1115/1.1354992.

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Near-net-shape forming of 316L stainless-steel powder was investigated under hot isostatic pressing. To simulate densification and deformation of a powder compact in a container during hot isostatic pressing, the constitutive model of Abouaf and co-workers was implemented into a finite element analysis. An optimal design technique based on the evaluation schemes of the design sensitivity was used to acquire the desired final shape of a powder compact. Experimental data of 316L stainless steel powder showed that the optimally designed container allowed near-net-shape forming of the desired powder compact during hot isostatic pressing.

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Xia, Yuhang, Zeran Hou, Jinjun Tan, Wenyao Wang, Nan Guo, and Junying Min. "An Experimental Study on the Frictional Behavior of Ultrathin Metal Sheets at Elevated Temperatures." Materials 17, no. 12 (June 19, 2024): 3009. http://dx.doi.org/10.3390/ma17123009.

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Hot forming is an effective approach for improving the formability of ultrathin metal sheets, such as those made of stainless steel and pure titanium. However, the increased friction coefficient between the tool and the high-temperature metal sheet negatively affects material flow during hot forming, potentially resulting in severe local thinning or even cracking. This study explores the frictional behavior of 0.1 mm thick ferritic stainless steel (FSS) and commercially pure titanium (CP-Ti) sheets at elevated temperatures. A friction testing apparatus was developed to measure the friction coefficients of these metal sheets from room temperature (25 °C) up to 600 °C. The friction coefficient of the FSS sheet increased monotonically with temperature, whereas that of the CP-Ti sheet first increased and then decreased. Post-friction testing microscopic examination demonstrated that built-up edges formed on the surfaces of the friction blocks when rubbed against the stainless steel, contributing to the higher friction coefficients. This study provides a foundation for understanding frictional behavior during the hot forming of ultrathin metal sheets.

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Ko, Dae-Cheol, Dae-Hoon Ko, Jae-Hong Kim, and Joon-Hong Park. "Development of a partition panel of an Al6061 sheet metal part for the improvement of formability and mechanical properties by hot forming quenching." Advances in Mechanical Engineering 9, no. 2 (February 2017): 168781401769121. http://dx.doi.org/10.1177/1687814017691213.

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In this study, the hot forming quenching process was investigated to improve the deficiencies that arise in materials subjected to conventional cold stamping, such as low formability and undesirable mechanical properties. The hot forming quenching process was mainly discussed in terms of formability and mechanical properties in this study and was first evaluated by preliminary tests. To examine formability, an evaluation was conducted using hot-tensile and hemispherical-dome stretching tests at temperatures of 350°C and 450°C, respectively. In addition, the mechanical properties of the formed part were predicted using quench factor analysis, which was based on the cooling temperature during the die quenching process. These preliminary test results were then used to predict the formability and hardness of the partition panel of an automotive part, where the analytical results indicated high performance of the hot forming quenching process, in contrast to conventional forming. Finally, the hot forming quenching experiment of the partition panel was carried out to validate the predicted results and the obtained formability and hardness values were compared with conventional forming at room temperature using T4 and T6 heat-treated sheets. The analytical and experimental results indicate that the hot forming quenching process is a very effective method for obtaining desirable formability and mechanical properties in the forming of aluminum sheets.

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Tisza, Miklós. "Hot Forming of Boron Alloyed Manganese Steels." Materials Science Forum 885 (February 2017): 25–30. http://dx.doi.org/10.4028/www.scientific.net/msf.885.25.

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The automotive industry always had a determining role in the whole economy. In sheet metal forming both the material and the technological developments are strongly affected by the development tendencies in car manufacturing. One of the main trends in today’s car manufacturing is to apply light weight construction principles to meet the increased customers’ demand and legal requirements. In this respect, application of high strength steels is regarded as one of the most promising possibilities. Applying high strength steels has a very positive response for many requirements: increasing strength results in the application of thinner sheets leading to significant mass reduction and simultaneously to lower consumption and less harmful emissions however it also leads to formability problems. Hot press forming is one of the most successful solutions to overcome these difficulties. In this paper, a general overview of hot press forming processes will be summarised.

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Sun, Wenhui, and Cuiping Yang. "Simulation of Cross Wedge Rolling and Hot Extrusion-Combined Forming Process for Axle Sleeve." Metals 13, no. 6 (May 25, 2023): 1017. http://dx.doi.org/10.3390/met13061017.

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In this paper, an axle sleeve is formed through a combined cross wedge rolling (CWR) and hot extrusion process, and the combined forming process is simulated via finite element analysis software Deform-3D. The forming mechanism is revealed by analyzing the stress and strain distribution, the temperature variation and the metal flow law of the workpiece during CWR and hot extrusion. Combined with CWR and hot extrusion forming experiments, the feasibility of a combined rolling and extrusion process to produce an axle sleeve is verified. It has been proven that the outer steps of the axle sleeve produced through the rolling extrusion composite process are well formed, the flange extrusion cavity is full, the metal streamline is continuous, the axis of the inner hole does not easily deviate, the product quality is good and the production efficiency is high.

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Alexandrov, S., P. T. Wang, and R. E. Roadman. "A fracture criterion of aluminum alloys in hot metal forming." Journal of Materials Processing Technology 160, no. 2 (March 2005): 257–65. http://dx.doi.org/10.1016/j.jmatprotec.2004.06.029.

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Tang, J., A. K. Tieu, and Z. Y. Jiang. "Modelling of oxide scale surface roughness in hot metal forming." Journal of Materials Processing Technology 177, no. 1-3 (July 2006): 126–29. http://dx.doi.org/10.1016/j.jmatprotec.2006.04.105.

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Tieu, Anh Kiet, Shanhong Wan, Ning Kong, Qiang Zhu, and Hongtao Zhu. "Excellent melt lubrication of alkali metal polyphosphate glass for high temperature applications." RSC Advances 5, no. 3 (2015): 1796–800. http://dx.doi.org/10.1039/c4ra12028k.

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Zhu, Xiao Xing, Bao Yu Wang, and Zheng Huan Hu. "Numerical Simulation and Experiment of Hot Roll Forming Large Module Gear." Applied Mechanics and Materials 456 (October 2013): 86–89. http://dx.doi.org/10.4028/www.scientific.net/amm.456.86.

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To compare with the other gear manufacturing methods, the hot roll forming process is applied in forming large module gear. The hot gear rolling theory is realized by modeling in Solidworks and Deform-3D, the finite element model (FEM) that coupled deformation and heat transfer was established, and the FE model velocity boundaries were set by converting the workpiece rotation into the revolution speed of the roller. The total displacement of metal flow, folding angel of teeth, effect strain and the temperature distribution of the part were obtained in the whole process of hot gear rolling, also the rolling force was predicted by simulation. The simulation results reveal the forming mechanism, and the rolling experiments were carried out with self-designed rolling mill, which verify that the hot roll forming large gear is feasible.

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Wang, Shyi Chin. "Briefing of CSC and its R & D Activities for Metal Forming." Key Engineering Materials 626 (August 2014): 576–82. http://dx.doi.org/10.4028/www.scientific.net/kem.626.576.

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China Steel Corporation was founded in 1971 being the largest integrate steel mill in Taiwan. After several stages of expansion projects, its crude steel production has reached 16.5 million tons annually. CSC has made consistent efforts on its technology innovation mainly carried out by two R & D departments. One of the major tasks of its R & D activities is to establish the advanced technologies for the manufacturing better steels and aluminum alloys as well as product application technology for downstream users. This presentation will mainly brief the research activities of CSC in the field of metal forming including rolling, sheet metal forming and thermal mechanical simulations carried out at Gleeble 3800. Work rolls with continuously variable crown (CVC) were applied to produce hot-rolled strips having precise profile and flatness. Lubrication rolling technology with high speed steel rolls was developed to diminish the wearing of work rolls at hot strip mills. The campaign life of rolling cycle was greatly prolonged. Computer-aided engineering (CAE) simulation technology of sheet metal forming has been established which proved to be an effective way to deal with the sever spring back and breakage of the cold forming of high strength steel automobile parts. Hot stamping has also been developed to support the technology innovation of CSC’s downstream customers. Flow stress and microstructure evolution during hot rolling for aluminum alloys were investigated using a Gleeble 3800 simulator. Both high strength AA5182 for can end and low earing AA3104 for can body aluminum sheets have been successfully developed.

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Szeliga, Danuta, Natalia Czyżewska, Konrad Klimczak, Jan Kusiak, Paweł Morkisz, Piotr Oprocha, Maciej Pietrzyk, and Paweł Przybyłowicz. "Sensitivity analysis, identification and validation of the dislocation density-based model for metallic materials." Metallurgical Research & Technology 118, no. 3 (2021): 317. http://dx.doi.org/10.1051/metal/2021037.

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Microstructure evolution model based on the differential equation describing evolution of dislocations was proposed. Sensitivity analysis was performed and parameters with the strongest influence on the output of the model were revealed. Identification of the model coefficients was performed for various metallic materials using inverse analysis for experimental data. The model was implemented in the finite element code and simulations of various hot forming processes were performed.

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Bulzak, Tomasz, Janusz Tomczak, and Zbigniew Pater. "A comparative analysis of hot and cold flashless forging of a stepped shaft using vertically-parted dies." International Journal of Advanced Manufacturing Technology 116, no. 7-8 (July 10, 2021): 2521–30. http://dx.doi.org/10.1007/s00170-021-07542-0.

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AbstractFlashless forging is classified as a precise metal forming technology. The main advantages of this technology are the reduction of the flash allowance and the shortening of the manufacturing time by eliminating the flash trimming operation. The article presents the process of one-step forging of a stepped shaft made of aluminum with the use of split dies. The process was carried out in cold and hot metal-forming conditions. The forging process was analyzed numerically using the Simufact Forming 15.0 software. The geometrical parameters of the obtained product were analyzed, and the distribution of effective strain, temperature, and the standardized cracking criterion was determined. The process force parameters were also determined. Numerical tests were verified in real conditions with the use of a specially designed device for forging in vertical split dies. Comparison of hot and cold forging in vertical split dies is presented. The comparative analysis results have demonstrated that the hot forging process has more advantages than the cold forging process. The hot forging process ensures higher accuracy of forged parts.

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Wang, Wei, Yu Liu, Peng Fei Wen, and Jun Tong. "Numerical Simulation on the Shape of Stamping Part about Hot Forming and Quenching." Applied Mechanics and Materials 328 (June 2013): 450–56. http://dx.doi.org/10.4028/www.scientific.net/amm.328.450.

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With the application of ultra high strength steel in vehicle manufacturing field, the hot forming method which is used to form the high strength sheet at high temperature and cool rapidly in dies to obtain the final part has been studied extensively. In this paper, The FE model that contained thermal mechanical-microstructure and strain model represented by a mixture law for hot forming was discussed, and further been applied to hot forming and quenching process simulation of 22MnB5 metal sheet of U-shape constant section part. The computed results of final part shape and hardness after cooled in air, in water without dies and cooled within dies were compared respectively.

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Farzin, Mahmoud, Reza Jafari Nedoushan, and Mohammad Mashayekhi. "Simulation of Hot Sheet Metal Forming Processes Based on a Micro-Structural Constitutive Model." Key Engineering Materials 473 (March 2011): 556–63. http://dx.doi.org/10.4028/www.scientific.net/kem.473.556.

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A constitutive model is proposed for simulations of hot forming processes. Dominant mechanisms in hot forming including inter-granular deformation, grain boundary sliding and grain boundary diffusion are considered in the constitutive model. A Taylor type polycrystalline model is used to predict inter-granular deformation. Previous works on grain boundary sliding and grain boundary diffusion are extended to drive three dimensional macro stress-strain rate relationships for each mechanism. In these relationships, the effect of grain size is also taken into account. It is shown that for grain boundary diffusion, stress-strain rate relationship obeys the Prandtl-Reuss flow rule. The proposed model is used to simulate step strain rate tests and the results are compared with experimental data. It is concluded that the model can be used to predict flow stress for various grain sizes and strain rates. The proposed model can be directly used in simulation of hot forming processes and as an example the bulge forming process is simulated and the results are compared with experimental data.

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Wang, Ming Wei, and Li Wen Zhang. "FE Simulation of Vacuum Hot Bulge Forming Process of BT20 Ti-Alloy Cylindrical Workpiece." Key Engineering Materials 392-394 (October 2008): 366–69. http://dx.doi.org/10.4028/www.scientific.net/kem.392-394.366.

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The vacuum hot bulge forming has been used in aerospace industry to manufacture cylindrical workpiece with improved mechanical properties and reduced fabrication cost. Vacuum hot bulge forming is based on the material soften and the stress relaxation theory. Different from other metal forming techniques, deformation of the workpiece takes place well below yield point and the amount of plastic deformation is directly relaxed to heating temperature and holding time. In this paper, a two-dimension thermo-mechanical coupled finite element model was developed. In this model, nonlinear radiation heat transfer and thermal physical properties of material depending on temperature were considered. This paper carried out numerical simulation of vacuum hot bulge forming of BT20 Ti-alloy cylindrical workpiece by using finite element software MSC.Marc. The temperature field, deformation field and stress field of hot bulge forming of BT20 Ti-alloy cylindrical workpiece were calculated. Numerical simulation results were accorded with experimental ones, which provided for the practice production as theory bases.

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Lee, Ho Sung, Jong Hoon Yoon, and Joon Tae Yoo. "An Experimental Study on Elevated Temperature Biaxial Bulge Test." Advanced Materials Research 430-432 (January 2012): 539–42. http://dx.doi.org/10.4028/www.scientific.net/amr.430-432.539.

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By using biaxial bulge test, it is possible to predict sheet metal forming behavior during hot forming process. The purpose of this study is to obtain materials parameters for elevated temperature forming condition during biaxial bulge test of a nickel base superalloy in hemispherical die. At constant gas pressure, the strain rate in which the metal sheet experiences varies and therefore the strain rate sensitivity can be obtained in a single loading. Biaxial bulge tests on superalloy metal sheet were performed and results are in satisfactory agreement with uniaxial test results at elevated temperature.

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Pleshivtseva, Yuliya, Stepan Korshikov, and Evgenjj Makarov. "Problem Oriented Simulation of Heating Stage in Technological Chain for Metal Hot Forming." Applied Mechanics and Materials 698 (December 2014): 203–8. http://dx.doi.org/10.4028/www.scientific.net/amm.698.203.

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Most high duty parts used in various fields of productions are forged parts made of steel. The conventional forging process chains include an induction heating systems and hot forming equipment. The large amount of consumed energy and an excess of material (flash) are the main factors motivating necessity to optimize the industrial technologies of metal hot forming. A significant economical effect can be achieved through optimization of heating modes and design parameters of induction heaters on the basis of modern optimal control theory for distributed parameters systems. The aim of the presented research is a problem-oriented simulation of induction heating stage in the forging chain. 2D ANSYS model provides FEM analysis of interrelated electromagnetic, temperature and thermal stress fields during induction heating of a steel cylindrical billet before its hot forming. The model has interface adapted to optimization procedures; it provides more options for variation of the heating system parameters or billet geometry and material properties, and for evaluating the process optimization abilities.

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Schell, Lukas, and Peter Groche. "Challenges in Tribometry for Warm and Hot Sheet Metal Forming of High Strength Aluminum with Tool Lubrication." Defect and Diffusion Forum 414 (February 24, 2022): 95–102. http://dx.doi.org/10.4028/p-lq0q96.

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For conventional sheet metal forming at room temperature, numerous tribometers were developed in the 20th century. At the present state of the art, unsolved issues for tribometry remain for temperature-supported forming processes of high strength aluminum (e.g. EN AW-7075), in which the sheet is heated to temperatures between 200 and 480 °C. The tribological design of these processes remains a major challenge, which needs to be addressed by investigations with adapted tribometers. In this study, a recently adapted strip drawing test for aluminum warm and hot forming is presented – including a newly developed strip heating unit, a die lubrication system and a die tempering system for efficient tribological testing. The contribution is completed with both, experimental results and a numerical investigation of temperature gradients in the strip drawing test. Finally, it is discussed whether transient process conditions of non-isothermal forming processes with die lubrication should be considered in tribometers for warm and hot sheet metal forming.

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Le, Khanh Dien, Tan Hung Nguyen, Ngoc Huy Tran, Thanh Son Le, Huy Bich Nguyen, and Thanh Nam Nguyen. "A Research of the Precision of Titanium Sheet Formed by Hot Incremental Sheet Forming Method." Key Engineering Materials 749 (August 2017): 154–60. http://dx.doi.org/10.4028/www.scientific.net/kem.749.154.

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Single Point Incremental Forming (SPIF) is a recent technology of forming sheet in several decades. Nowadays, SPIF technology is still continued to be studied, applied and ameliorated in sheet manufacturing in industry. However one of the difficulties of the technology is the forming angle is still small (smaller than 800 according the properties of metal sheets). This paper recommends a measure of increasing the plasticity of the sheet by heating in time of forming by SPIF technology. Naturally, the plasticity of metal sheet increases by the temperature of the material in forming process with its limitation and constraint. The paper represents the effect of heating metal sheet through the empirical process of SPIF technology directed by the design of experiment (DOE). The analyses of the results of experimental process is applied to show the effect of heating to the precision of Titanium sheet. Finally, some private opinions about the heating in SPIF are also mentioned as a very tiny contribution of the research for the new technology.

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Hou, Ying Ke. "Experimental Study on Surface Damage in Forming of Galvanized Steel Sheets." Advanced Materials Research 221 (March 2011): 674–78. http://dx.doi.org/10.4028/www.scientific.net/amr.221.674.

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U-channel forming tests were performed to investigate the surface damage behavior of hot-dip galvanized (GI), galvannealed (GA) and electrogalvanized (EG) steels in sheet metal forming (SMF). Experimental results indicate that the surface topographies of galvanized steels are roughening with the number of forming in sheet metal forming (SMF) and the types and mechanisms of surface damages of the three coatings are different. And tool hardness has great effects on surface damages of the GI and GA steels while the influence of tool hardness on surface damage of EG steel is negligible.

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Wu, Pengfei, Baoyu Wang, J. Lin, Bin Zuo, Zhi Li, and Jing Zhou. "Investigation on metal flow and forming load of bi-metal gear hot forging process." International Journal of Advanced Manufacturing Technology 88, no. 9-12 (June 9, 2016): 2835–47. http://dx.doi.org/10.1007/s00170-016-8973-x.

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Almadani, Mohammad, Ahmet Guner, Hany Hassanin, and Khamis Essa. "Hot-Air Contactless Single-Point Incremental Forming." Journal of Manufacturing and Materials Processing 7, no. 5 (October 5, 2023): 179. http://dx.doi.org/10.3390/jmmp7050179.

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Single-point incremental forming (SPIF) has emerged as a time-efficient approach that offers increased material formability compared to conventional sheet-metal forming techniques. However, the physical interaction between the forming tool and the sheet poses challenges, such as tool wear and formability limits. This study introduces a novel sheet-forming technique called contactless single-point incremental forming (CSPIF), which uses hot compressed air as a deformation tool, eliminating the requirement for physical interaction between the sheet and a rigid forming tool. In this study, a polycarbonate sheet was chosen as the case-study material and subjected to the developed CSPIF. The experiments were carried out at an air temperature of 160 °C, air pressure of 1 bar, a nozzle speed of 750 mm/min, and a step-down thickness of 0.75 mm. A Schlieren setup and a thermal camera were used to visualize the motion of the compressed hot air as it traveled from the nozzle to the sheet. The results showed that the CSPIF technique allowed for the precise shaping of the polycarbonate sheet with minimal springback. However, minor deviations from the designed profile were observed, primarily at the starting point of the nozzle, which can be attributed to the bending effects of the sample. In addition, the occurrence of sheet thinning and material buildup on the deformed workpiece was also observed. The average surface roughness (Ra) of the deformed workpiece was measured to be 0.2871 microns.

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Yang, Haifeng, Jingbin Hao, Haoda Wang, and Mengsen Ding. "Fabrication of a Hot-Embossing Metal Micro-Mold through Laser Shock Imprinting." Materials 16, no. 14 (July 19, 2023): 5079. http://dx.doi.org/10.3390/ma16145079.

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As a technology for polymer surface fabrication, roll-to-roll hot embossing has been widely used because of its advantages, such as its low cost and high efficiency. However, the metal micro-mold is a major factor that determines the hot embossing of the polymer. In this study, a new metal micro-mold manufacturing method is proposed. The metal micro-mold is produced using laser shock imprinting (LSI) on the surface of metal foil. It has the characteristics of good thermal stability and high strength. During our LSI experiment, the strength of the mold increased after laser shocking. In this study, copper foils of different thicknesses were selected for LSI experiments. Through the analysis of the profile and forming depth of the microstructure, combined with the numerical simulation of the forming mechanism of copper foils with different thicknesses using ABAQUS software(Abaqus 2021), a copper foil with a flat back was selected as the final metal micro-mold. On this basis, copper molds with different microstructure shapes were created. Then, the mold was used in the hot-embossing experiment to manufacture the microstructure on the surface of polyethylene terephthalate (PET) and to study the fidelity and integrity of the molded microstructure. The deformation resistance of the copper mold under hot-embossing conditions was verified through a nano-indentation experiment. The final results show that the metal micro-mold produced via LSI had a high accuracy and molding stability and has potential applications in the field of roll-to-roll hot embossing.

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Li, Zhengfang, Bin Wu, Yanping Sun, Mingxiu Shen, Zhengyuan Gao, Zhiguo An, and Shihong Lu. "Improvement of arc burn defect of initial contact loss of electric hot incremental sheet forming." Mechanics & Industry 23 (2022): 11. http://dx.doi.org/10.1051/meca/2022012.

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Electric hot incremental sheet forming, which is used to form hard-to-form sheet metal, is viewed as the one of rapid prototyping manufacturing technologies. However, the non-uniform stress distribution of forming regions would cause an initial contact loss phenomenon between the tool and the sheet, and an electric arc burn of the part surface is obtained due to the contact loss. In this work, a control method of axial pressure response was proposed to judge the stability of the initial contact between forming the tool and the sheet. A power supply on-off device was designed for electric hot incremental forming, and the calculation model of the initial axial force was established during deformation. Meanwhile, two response pressure values were proposed to control the power supply starting and the current intervention and to ensure the stability of the power supply during the forming process. In addition to this, the axial force and the surface of part were analyzed further in electric hot incremental sheet forming.

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Shvets, Ludmila, and Kateryna Chmykh. "ANALYTICAL RESEARCH METHODS OF HOT DEFORMATION OF METALS." ENGINEERING, ENERGY, TRANSPORT AIC, no. 3(118) (December 23, 2022): 95–100. http://dx.doi.org/10.37128/2520-6168-2022-3-12.

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Hot processing of metals by pressure has a number of positive qualities: the constituent parts of the metal are distributed more evenly than before processing; grain sizes decrease, which leads to improved mechanical properties; the metal becomes denser. Pressure-treated metals have a fibrous structure. The hot working process is one of the types of metal forming processes and it takes place at temperatures higher than the recrystallization temperature. During hot deformation, the metal is also strengthened (hot defamation), but it is completely removed in the process of recrystallization. With it, the plasticity of the metal is higher, and the resistance to deformation is approximately 10 times lower than during cold deformation. Most metals have a recrystallization temperature that is half or one-third of the melting temperature of the metal. Therefore, we can say that when the metal is plastically deformed above the recrystallization temperature, but below the burning point, this is a hot process of metal deformation. Elastic and then plastic deformation occur under the influence of external forces on the material. Pressure treatment of metals is possible due to their plasticity. A sign of elastic deformation is its reversibility, that is, its disappearance after removal of the load. The physical essence of elastic deformation is explained by the slight relative displacement of atoms in the crystal lattice, which return to their previous positions after the load is removed. There are such methods of hot processing as: hot rolling, hot forging, hot stamping, hot drawing.

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Yang, Song, Jie Zhao, Yankang Tian, and Yi Qin. "A pilot prototype production line for the hot-forming of aluminium alloy sheets with fast contact-cooling and multi-point tooling." MATEC Web of Conferences 401 (2024): 01010. http://dx.doi.org/10.1051/matecconf/202440101010.

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This paper reports the study of the process chain for sheet metal forming using multi-point tooling for stamping at elevated temperatures and developing a complete production line integrating heating, intermediate fast-cooling, forming and aging. It aims to deliver a high-efficient and cost-effective sheet-metal forming technology with improved process capability and flexibility for the forming of high-strength sheet metal parts. Multi-point tooling sets are employed to test the flexibility of hot/warm-forming the lightweight high-strength metal sheets with fast tooling reconfigurability. The intermediate cooling with high cooling rates was achieved with a contact cooling system recently developed at the University of Strathclyde. With this pilot line, the aluminium sheets heated to the solution heat treatment (SHT) temperature were subjected to the intermediate cooling prior to forming with multi-point tooling. The cooling step is fast and controllable, with different cooling rates tested. The tests conducted on the pilot line demonstrated significant enhancement of the forming limit and manufacturing flexibility.

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YU, Z. Q., Y. K. HOU, S. H. LI, Z. Q. LIN, and W. G. ZHANG. "SURFACE DAMAGE BEHAVIOR OF GALVANIZED STEEL SHEETS IN FORMING PROCESS UNDER TENSION-BENDING." International Journal of Modern Physics B 24, no. 30 (December 10, 2010): 5877–84. http://dx.doi.org/10.1142/s0217979210057481.

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The surface damage behaviors of different galvanized steel sheets were investigated under the condition of tension-bending. The U-channel forming tests were performed for HDGI (hot-dip galvanized) and HDGA (hot-dip galvannealed) steels. Experimental results indicate that HDGI steel shows better damage resistance than HDGA steel in sheet metal forming. Scratching is the main surface damage in the forming of HDGI steel while exfoliating and scratching of coating are two types of surface damage for HDGA steel. And tool hardness and surface topography have crucial effects on part surface damage in the forming of the two kinds of galvanized steels. Different surface treatments should be applied to the forming tools in the forming of HDGI and HDGA steels for better surface qualities of products.

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Kaneko, Masao, Akira Yanagisawa, Masato Imamura, and Takeo Nakagawa. "Forming of Hot Dipped Sheet Shaving Metal Fibers by Brazing Method." Journal of the Japan Society of Powder and Powder Metallurgy 41, no. 9 (1994): 1089–94. http://dx.doi.org/10.2497/jjspm.41.1089.

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Saby, Michel, Pierre-Olivier Bouchard, and Marc Bernacki. "A geometry-dependent model for void closure in hot metal forming." Finite Elements in Analysis and Design 105 (November 2015): 63–78. http://dx.doi.org/10.1016/j.finel.2015.07.003.

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Bouvard, D., and E. Ouedraogo. "A simulation material for modelling the hot-forming of metal powders." Powder Technology 46, no. 2-3 (April 1986): 255–62. http://dx.doi.org/10.1016/0032-5910(86)80034-1.

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Journal articles on the topic 'Hot metal forming'

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