Advanced Metal Forming and Smart Manufacturing Processes

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Mechanical Engineering".

Deadline for manuscript submissions: 30 March 2024 | Viewed by 16115

Special Issue Editors

School of Chemical and Metallurgical Engineering, University of the Witwatersrand, Johannesburg 2000, South Africa
Interests: titanium alloys; dental alloys; welding
Special Issues, Collections and Topics in MDPI journals
Faculty of Engineering and the Built Environment; School of Chemical and Metallurgical Engineering, University of the Witwatersrand, Johannesburg 2000, South Africa
Interests: physical metallurgy of dilute and complex concentrated alloys; cold spray technologies; rational alloy design
Department of Mining, Materials and Petroleum Engineering, Jomo Kenyatta University of Agriculture and Technology, Nairobi 00100, Kenya
Interests: metal forming; wire-arc additive manufacturing; finite element simulation; welding metallurgy; fatigue; creep failure analysis

Special Issue Information

Dear Colleagues,

Material forming processes remain one of the oldest routes for achieving microstructural control and shaping of structural components. However, research and development of forming processes have continued to evolve due to the need to minimize processing costs, eliminate defects in components, enhance production efficiency and develop techniques that are compatible with modern manufacturing processes like additive manufacturing. One of the notable developments in forming processes in the last few decades is the introduction of finite element simulations which has helped save experimental cost and processing time in the metal processing industries. With the emergence of industry 4.0 and the dire need for sustainable manufacturing practices, new advances are evolving in the material-forming and smart manufacturing ecosystem. Consequently, this Special Issue invites innovative contributions from authors on the recent advances in the shaping of metallic alloys and metal matrix composites. Contributions that extend the current understanding of the various mechanisms influencing deformation processes and microstructural control at different length and time scales are highly desirable. In addition, original research articles, brief communications, and review articles on thermomechanical processing and microstructural evolution, machining, hybrid manufacturing, new experimental testing techniques, and micro and macroscale modeling of deformation conditions are invited.

We have the great pleasure of inviting you to contribute research article(s) to this Special Issue.

Dr. Michael Oluwatosin Bodunrin
Dr. Desmond Klenam
Dr. Japheth Obiko
Guest Editors

Manuscript Submission Information

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Keywords

  • hot deformation
  • finite element simulation
  • machining
  • forging
  • rolling
  • extrusion
  • superplastic forming
  • microstructural evolution
  • constitutive modelling
  • smart manufacturing, severe plastic deformation
  • metamorphic manufacturing

Published Papers (14 papers)

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Research

15 pages, 5465 KiB  
Article
Finite Element Simulation and Experimental Verification of Circular Tube Nosing through Conical Dies
by Walid M. Shewakh and Ibrahim M. Hassab-Allah
Appl. Sci. 2024, 14(6), 2337; https://doi.org/10.3390/app14062337 - 11 Mar 2024
Viewed by 351
Abstract
The process of tube nosing is a delicate art that involves forming the end of a tubular part without causing any collapse, buckling, or wrinkling. A recent study has delved into the different modes of failure that can occur during this process and [...] Read more.
The process of tube nosing is a delicate art that involves forming the end of a tubular part without causing any collapse, buckling, or wrinkling. A recent study has delved into the different modes of failure that can occur during this process and has determined the limits of tube nosing through the use of plasticity and thin/thick-walled tube theories. A finite element simulation was developed to replicate the cold-nosing process using conical dies to validate these theories. The results were compared to experimental outcomes for mild steel, hard steel, and annealed aluminium tubes to ensure accuracy. Through this analysis, we identified and confirmed the modes of failure that can restrict the plastic deformation for the tube nosing process. The outcomes were compared to analytical expressions and showed excellent agreement with the experiments, proving that these expressions provide a reliable reference guide for predicting the limits of the tube-nosing process. The FE simulation method also accurately models critical buckling stresses, nosing loads, and failure modes. Full article
(This article belongs to the Special Issue Advanced Metal Forming and Smart Manufacturing Processes)
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12 pages, 5017 KiB  
Article
Application-Oriented Data Analytics in Large-Scale Metal Sheet Bending
by Mariluz Penalva, Ander Martín, Cristina Ruiz, Víctor Martínez, Fernando Veiga, Alain Gil del Val and Tomás Ballesteros
Appl. Sci. 2023, 13(24), 13187; https://doi.org/10.3390/app132413187 - 12 Dec 2023
Viewed by 664
Abstract
The sheet-metal-forming process is crucial in manufacturing various products, including pipes, cans, and containers. Despite its significance, controlling this complex process is challenging and may lead to defects and inefficiencies. This study introduces a novel approach to monitor the sheet-metal-forming process, specifically focusing [...] Read more.
The sheet-metal-forming process is crucial in manufacturing various products, including pipes, cans, and containers. Despite its significance, controlling this complex process is challenging and may lead to defects and inefficiencies. This study introduces a novel approach to monitor the sheet-metal-forming process, specifically focusing on the rolling of cans in the oil-and-gas sector. The methodology employed in this work involves the application of temporal-signal-processing and artificial-intelligence (AI) techniques for monitoring and optimizing the manufacturing process. Temporal-signal-processing techniques, such as Markov transition fields (MTFs), are utilized to transform time series data into images, enabling the identification of patterns and anomalies. synamic time warping (DTW) aligns time series data, accommodating variations in speed or timing across different rolling processes. K-medoids clustering identifies representative points, characterizing distinct phases of the rolling process. The results not only demonstrate the effectiveness of this framework in monitoring the rolling process but also lay the foundation for the practical application of these methodologies. This allows operators to work with a simpler characterization source, facilitating a more straightforward interpretation of the manufacturing process. Full article
(This article belongs to the Special Issue Advanced Metal Forming and Smart Manufacturing Processes)
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18 pages, 5461 KiB  
Article
Design of the Production Technology of a Bent Component
by Radek Čada and Tomáš Pektor
Appl. Sci. 2023, 13(24), 13033; https://doi.org/10.3390/app132413033 - 06 Dec 2023
Viewed by 530
Abstract
This paper concerns the design of the technology for the production of the part by bending and also the design of the forming tool for a small number of pieces of the produced part. The part in question was the oscillating tool blade [...] Read more.
This paper concerns the design of the technology for the production of the part by bending and also the design of the forming tool for a small number of pieces of the produced part. The part in question was the oscillating tool blade to cut soft materials. The aim was to design economically advantageous technology to produce this blade without spot welding from two parts, preferably from one semi-finished product. A suitable material for the part and its new shape were designed. Calculations were made for the smallest recommended internal bending radius, the largest allowable bending radius, the smallest length of the bending arm, and the angle of springback after bending. The component’s shape and a suitable blank were determined. A low-cost bending tool was designed. Dynaform simulations were used to analyse deformation, material thickness after bending, and formability. Analyses showed that the designed bending manufacturing process is safe. The bending tool and then the cutting blade test pieces were produced to verify the tool’s functionality. The procedure for designing the manufacturing process and the forming tool presented in the paper can be applied in cases where it is necessary to design a suitable technology to produce a small number of parts by forming to achieve a minimum cost per piece of the manufactured part. Full article
(This article belongs to the Special Issue Advanced Metal Forming and Smart Manufacturing Processes)
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19 pages, 4771 KiB  
Article
Biocompatibility and Degradation of Fe-Mn-5Si Alloy after Equal-Channel Angular Pressing: In Vitro and In Vivo Study
by Olga Rybalchenko, Natalia Anisimova, Natalia Martynenko, Georgy Rybalchenko, Andrey Belyakov, Igor Shchetinin, Elena Lukyanova, Olga Chernogorova, Arseniy Raab, Natalia Pashintseva, Evgeny Kornyushenkov, Gulalek Babayeva, Darina Sokolova, Mikhail Kiselevskiy and Sergey Dobatkin
Appl. Sci. 2023, 13(17), 9628; https://doi.org/10.3390/app13179628 - 25 Aug 2023
Cited by 1 | Viewed by 1011
Abstract
An attempt to improve the functional characteristics of a degradable Fe-Mn-5Si shape memory alloy by means of structure refinement by equal-channel angular pressing (ECAP) was made. In the course of ECAP, an austenitic ultrafine-grained structure was obtained. In shear bands with a thickness [...] Read more.
An attempt to improve the functional characteristics of a degradable Fe-Mn-5Si shape memory alloy by means of structure refinement by equal-channel angular pressing (ECAP) was made. In the course of ECAP, an austenitic ultrafine-grained structure was obtained. In shear bands with a thickness of 301 ± 31 nm, twins 11 ± 1 nm in size were formed. Due to the resulting structure, the tensile strength was doubled up to 1419 MPa, and the yield strength was increased up to 1352 MPa, four times higher compared with the annealed state. Dynamic indentation tests revealed a decrease in Young’s modulus by more than 2.5 times after ECAP compared to values measured in the annealed state. The results of the study of hemolytic and cytotoxic activity in vitro, as well as the local and systemic reactivity of the body of laboratory animals after implantation of the test samples indicate the biocompatibility of the alloy after ECAP. Biocompatibility, high specific strength and low modulus of elasticity open prospects for Fe-Mn-5Si alloy after ECAP to be used for the production of degradable implants that can effectively provide the fastening function in osteoreconstruction. Full article
(This article belongs to the Special Issue Advanced Metal Forming and Smart Manufacturing Processes)
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14 pages, 33631 KiB  
Article
Increasing the Wear Resistance of Structural Alloy Steel 38CrNi3MoV Subjected to Isothermal Hardening and Deep Cryogenic Treatment
by Serhii Bobyr, Pavlo Krot, Eduard Parusov, Tetiana Golubenko and Olena Baranovs’ka
Appl. Sci. 2023, 13(16), 9143; https://doi.org/10.3390/app13169143 - 10 Aug 2023
Cited by 1 | Viewed by 698
Abstract
In the production of critical parts for various machines and mechanisms, expensive structural steels are used alloyed with chromium, nickel, molybdenum, and vanadium. In practice, the wear resistance of parts, especially under severe operating conditions, may be insufficient due to uneven microstructure and [...] Read more.
In the production of critical parts for various machines and mechanisms, expensive structural steels are used alloyed with chromium, nickel, molybdenum, and vanadium. In practice, the wear resistance of parts, especially under severe operating conditions, may be insufficient due to uneven microstructure and the content of retained austenite. Therefore, increasing the operational stability of various products made of alloy steels is an important task. The purpose of this work is to investigate the effect of isothermal hardening from the intermediate (γ+α)-area and the duration of deep cryogenic treatment on the structure formation and frictional wear resistance of 38CrNi3MoV steel. The isothermal hardening promotes the formation of the required multiphase microstructure of 38CrNi3MoV steel. The influence of the duration of deep cryogenic treatment on the microhardness, amount of retained austenite, fine structure parameters, and friction wear of 38CrNi3MoV steel are established. Complex heat treatment of 38CrNi3MoV steel, according to the proposed mode, makes it possible to achieve a significant decomposition of retained austenite to martensite, which leads to an increase in frictional wear resistance of ~58%. Full article
(This article belongs to the Special Issue Advanced Metal Forming and Smart Manufacturing Processes)
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15 pages, 5712 KiB  
Article
CNN-Based Ti-6242 Impeller Forging Process Design for Uniform Strain Distribution
by Kyungmin Kim, Yosep Kim, Youngkyu Ju, Insu Son and Naksoo Kim
Appl. Sci. 2023, 13(14), 8272; https://doi.org/10.3390/app13148272 - 17 Jul 2023
Viewed by 932
Abstract
In this study, we propose a systematic process design method using a convolutional neural network (CNN) for the uniform strain distribution of a Ti-6242 impeller during forging. A convolutional neural network (CNN) is a machine learning algorithm optimized for processing grid-like data, such [...] Read more.
In this study, we propose a systematic process design method using a convolutional neural network (CNN) for the uniform strain distribution of a Ti-6242 impeller during forging. A convolutional neural network (CNN) is a machine learning algorithm optimized for processing grid-like data, such as images, by identifying patterns within the data. To achieve the design goal with a simple process, we propose a methodological process in which the initial billet passes through three steps: upsetting, preform forging, and target impeller forging. We used the CNN model in the upsetting and preforming steps to enable our proposed design method to be applied to various impeller shapes. We trained a CNN model with two different types of datasets: one to derive the preform shape suitable for the target impeller forging and another to determine the shape of the initial billet that was upset for impeller preform forging. The proposed forging process resulted in a reduction in the mean strain, strain standard deviation, and maximum strain by up to 38.6%, 52.5%, and 59.7%, respectively, compared with the impeller forging processes proposed in previous studies. Consequently, the strain of the forged product was been homogenized, thereby reducing the possibility of defects. This process design method can be used in fields such as aerospace that require high-quality forging. Full article
(This article belongs to the Special Issue Advanced Metal Forming and Smart Manufacturing Processes)
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15 pages, 6412 KiB  
Article
Tensile Stress Evolution Outside Deformation Zone of Cold Rolled Strip
by Kangwu Zhang, Dongcheng Wang, Yanghuan Xu and Hongmin Liu
Appl. Sci. 2023, 13(11), 6781; https://doi.org/10.3390/app13116781 - 02 Jun 2023
Viewed by 614
Abstract
To determine the exact distribution of tensile stress in a cold rolled strip, tensile stress evolution caused by lateral uneven velocity distribution outside the deformation zone of the strip is examined. The finite difference method is employed to solve the problem. Different factors, [...] Read more.
To determine the exact distribution of tensile stress in a cold rolled strip, tensile stress evolution caused by lateral uneven velocity distribution outside the deformation zone of the strip is examined. The finite difference method is employed to solve the problem. Different factors, including the strip width and the form and amplitude of the initial stress distribution on the stress evolution, are analyzed. On the one hand, to improve the calculation speed, a “Gaussian” curve is proposed to fit the results calculated by the finite difference method. Simulation results show that the stress evolution calculated by the fitting equation is in good agreement with that obtained by the finite difference method. On the other hand, to verify the exactness of the model, an experiment is conducted, and the comparison between the calculated results and experimental values is discussed. Full article
(This article belongs to the Special Issue Advanced Metal Forming and Smart Manufacturing Processes)
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17 pages, 9052 KiB  
Article
Comparative Study on Hot Metal Flow Behaviour of Virgin and Rejuvenated Heat Treatment Creep Exhausted P91 Steel
by Shem Maube, Japheth Obiko, Josias Van der Merwe, Fredrick Mwema, Desmond Klenam and Michael Bodunrin
Appl. Sci. 2023, 13(7), 4449; https://doi.org/10.3390/app13074449 - 31 Mar 2023
Viewed by 1073
Abstract
This article reports on the comparative study of the hot deformation behaviour of virgin (steel A) and rejuvenated heat treatment creep-exhausted (steel B) P91 steels. Hot uniaxial compression tests were conducted on the two steels at a deformation temperature range of 900–1050 °C [...] Read more.
This article reports on the comparative study of the hot deformation behaviour of virgin (steel A) and rejuvenated heat treatment creep-exhausted (steel B) P91 steels. Hot uniaxial compression tests were conducted on the two steels at a deformation temperature range of 900–1050 °C and a strain rate range of 0.01–10 s−1 to a total strain of 0.6 using Gleeble® 3500 equipment. The results showed that the flow stress largely depends on the deformation conditions. The flow stress for the two steels increased with an increase in strain rate at a given deformation temperature and vice versa. The flow stress–strain curves exhibited dynamic recovery as the softening mechanism. The material constants determined using Arrhenius constitutive equations were: the stress exponent, which was 5.76 for steel A and 6.67 for steel B; and the apparent activation energy, which was: 473.1 kJ mol−1 for steel A and 564.5 kJmol−1 for steel B. From these results, steel A exhibited better workability than steel B. Statistical parameters analyses showed that the flow stress for the two steels had a good correlation between the experimental and predicted data. Pearson’s correlation coefficient (R) was 0.97 for steel A and 0.98 for steel B. The average absolute relative error (AARE) values were 7.62% for steel A and 6.54% for steel B. This study shows that the Arrhenius equations can effectively describe the flow stress behaviour of P91 steel, and this method is applicable for industrial metalworking process. Full article
(This article belongs to the Special Issue Advanced Metal Forming and Smart Manufacturing Processes)
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14 pages, 5420 KiB  
Article
The Effect of Cutting Tool Geometry on Surface Integrity: A Case Study of CBN Tools and the Inner Surface of Bearing Rings
by Lenka Cepova, Robert Cep, Leszek Chalko, Stepanka Dvorackova, Miroslav Trochta, Miroslaw Rucki, Libor Beranek, Ondrej Mizera and Volodymyr Chyshkala
Appl. Sci. 2023, 13(6), 3543; https://doi.org/10.3390/app13063543 - 10 Mar 2023
Cited by 1 | Viewed by 1207
Abstract
In this paper, a practical issue of the application of cubic boron nitride (CBN) cutting tools for the machining of steel 100Cr6 thin-walled bearing rings is addressed. Three geometries of the commercially available CBN cutting inserts were tested at different machining parameters. The [...] Read more.
In this paper, a practical issue of the application of cubic boron nitride (CBN) cutting tools for the machining of steel 100Cr6 thin-walled bearing rings is addressed. Three geometries of the commercially available CBN cutting inserts were tested at different machining parameters. The effect of geometry was assessed in terms of surface integrity, considering 2D profile parameters, 3D topography of the surface, and residual stresses in the surface layer. The results were sometimes contradictory, since the same cutting inserts provided the largest and the lowest values of the topography parameters, dependent on different cutting conditions. In general, CBN cutting inserts with XCEL geometry ensured the smallest profile parameters Ra and Rz, and the spatial parameters of Smr1 exhibited the largest values among all tested tools, suggesting reduced wear resistance. Residual stresses analysis did not reveal any inacceptable or potentially dangerous surface layer state after machining. Full article
(This article belongs to the Special Issue Advanced Metal Forming and Smart Manufacturing Processes)
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13 pages, 3175 KiB  
Article
On the Uniaxial Compression Testing of Metallic Alloys at High Strain Rates: An Assessment of DEFORM-3D Simulation
by Michael Bodunrin, Japheth Obiko and Desmond Klenam
Appl. Sci. 2023, 13(4), 2686; https://doi.org/10.3390/app13042686 - 19 Feb 2023
Cited by 4 | Viewed by 1695
Abstract
In this study, the challenges associated with conducting high-strain rate uniaxial compression testing experiments are highlighted. To address these challenges, DEFORM-3D simulation was explored as an alternative approach to experimental testing. Previously established constitutive constants obtained from experimental low strain rate uniaxial compression [...] Read more.
In this study, the challenges associated with conducting high-strain rate uniaxial compression testing experiments are highlighted. To address these challenges, DEFORM-3D simulation was explored as an alternative approach to experimental testing. Previously established constitutive constants obtained from experimental low strain rate uniaxial compression testing of three titanium (α + β) alloys were used as input codes. From the results, the peak flow stress values obtained from the DEFORM-3D simulation were close to the values obtained experimentally at low (0.1 to 10/s) and high (20 and 50/s) strain rates. For the alloys considered in this study, a discrepancy of ~20% in the peak flow stress was obtained at a 10/s strain rate. The difference in peak flow stress for strain rates less than 10/s or higher (20 and 50/s) is within acceptable limits. The limitations of using DEFORM-3D simulations for high strain rate uniaxial compression testing are highlighted. Full article
(This article belongs to the Special Issue Advanced Metal Forming and Smart Manufacturing Processes)
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18 pages, 7194 KiB  
Article
Flow Behavior and Microstructure of Hot-Worked Fe-30.9Mn-4.9Al-4.5Cr-0.4C and Fe-21.3Mn-7.6Al-4.3Cr-1C Low-Density Stainless Steels
by Takatso Komane, Nthabiseng Maledi, Desmond Klenam, Josias van der Merwe and Michael Bodunrin
Appl. Sci. 2023, 13(4), 2310; https://doi.org/10.3390/app13042310 - 10 Feb 2023
Viewed by 1110
Abstract
Two as-cast low-density steels grades (austenite-based duplex Fe-30.9Mn-4.9Al-4.5Cr-0.4C and austenitic Fe-21.3Mn-7.6Al-4.3Cr-1C) with an initial dendritic microstructure were subjected to hot working conditions to understand the influence of deformation parameters on flow behavior and microstructural evolution. The alloys were produced using electric arc melting, [...] Read more.
Two as-cast low-density steels grades (austenite-based duplex Fe-30.9Mn-4.9Al-4.5Cr-0.4C and austenitic Fe-21.3Mn-7.6Al-4.3Cr-1C) with an initial dendritic microstructure were subjected to hot working conditions to understand the influence of deformation parameters on flow behavior and microstructural evolution. The alloys were produced using electric arc melting, and their phase constituents were determined using optical microscopy and X-ray diffraction analysis. This was then corroborated with the phase predicted from Thermo-Calc simulation. The as-cast alloys were machined to 10 × 10 × 7 mm specimen configurations for rectangular axial testing on the Gleeble 3500 thermomechanical simulator. The samples were deformed to a total strain of 0.5 at different deformation temperatures (800, 900, and 1000 °C) and strain rates (0.1 and 5 s−1). Thereafter, a hardness test was conducted on the deformed samples, and post-deformed microstructures were analyzed using optical and scanning electron microscopes. The results showed that the alloys’ dendritic structures were effectively transformed at temperatures below 1000 °C regardless of the strain rate. At all deformation conditions, the peak flow stress of Fe-21.3Mn-7.6Al-4.3Cr-1C alloy was at least 50% higher than that of Fe-30.9Mn-4.9Al-4.5Cr-0.4C alloy owing to the higher carbon content in the austenitic low-density stainless steel. The hardness of all the deformed samples was superior to that of the as-cast samples, which indicates microstructural reconstitution and grain refinement in the alloys. Dynamic recrystallization, dynamic globularization, and dynamic recovery influenced the softening process and the microstructural changes observed in the alloys under different deformation conditions. Full article
(This article belongs to the Special Issue Advanced Metal Forming and Smart Manufacturing Processes)
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17 pages, 9440 KiB  
Article
Microstructure and Fatigue Performance of Ti6Al4V Produced by Laser Powder Bed Fusion after Post-Heat Treatment
by Yulong Yang, Meng Zhao, Hong Wang, Kai Zhou, Yangdong He, Yuyi Mao, Deqiao Xie, Fei Lv and Lida Shen
Appl. Sci. 2023, 13(3), 1828; https://doi.org/10.3390/app13031828 - 31 Jan 2023
Cited by 3 | Viewed by 1638
Abstract
With the development of additive manufacturing (AM), the Ti-6Al-4V alloy manufactured by laser powder bed fusion (LPBF) is becoming more widely studied. Fatigue fracture is the main failure mode of such components. During LPBF processing, porosity defects are unavoidable, which hinders the exploration [...] Read more.
With the development of additive manufacturing (AM), the Ti-6Al-4V alloy manufactured by laser powder bed fusion (LPBF) is becoming more widely studied. Fatigue fracture is the main failure mode of such components. During LPBF processing, porosity defects are unavoidable, which hinders the exploration of the relationship between fatigue performance and microstructure. In this study, a laser remelting method was used to reduce porosity defects inside the Ti-6Al-4V alloy. Three annealing treatments (AT) and three solution-aging treatments (SAT) were used to study the effect of the two-phase zone (α + β) microstructure on fatigue life and fatigue crack growth behavior. Fatigue life and crack growth rate (CGR) curves were obtained, and fatigue fracture surface and crack growth fracture surface were analyzed. The results show that microstructure influences fatigue life but has little effect on CGR. Compared with the as-built specimen, the fatigue life of the AT and SAT specimens increased significantly at 850℃ by 101 and 63.7 times, respectively. The thickness of the α lath and the location of crack nucleation together affect the fatigue life. In the stable growth stage, the layered microstructure of α colonies is the most resistant to crack growth. Full article
(This article belongs to the Special Issue Advanced Metal Forming and Smart Manufacturing Processes)
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19 pages, 16958 KiB  
Article
Robust Design of Deep Drawing Process through In-Line Feedback Control of the Draw-In
by Luigi Tricarico and Maria Emanuela Palmieri
Appl. Sci. 2023, 13(3), 1717; https://doi.org/10.3390/app13031717 - 29 Jan 2023
Cited by 4 | Viewed by 1894
Abstract
In the deep drawing process, the scatter of the friction coefficient between blank and tool interfaces as well as of the material properties between blank positions in the coil or between different coils significantly influences the part quality. These uncontrollable fluctuations increase the [...] Read more.
In the deep drawing process, the scatter of the friction coefficient between blank and tool interfaces as well as of the material properties between blank positions in the coil or between different coils significantly influences the part quality. These uncontrollable fluctuations increase the risk of waste. To avoid this problem, currently, the new era of Industry 4.0 aims at developing control algorithms able to in-line adjust process parameters and always meet the part quality requirements. Starting from this context, in this study a method for process control during the punch stroke is proposed. It assumes the blank draw-in in specific points as the control variable, while the blank holder force is adopted as an in-line adjustable process parameter. The approach was implemented for the deep drawing of a T-shaped component, using a blank in DC05 steel with a thickness of 0.75 mm. The results show that the measurement of blank draw-in is a representative index of the component quality, which in this study is evaluated in terms of formability (thinning) and cosmetic (surface deflections) defects. Once the optimal condition and the corresponding blank draw-in were identified, the feedback control algorithm was able to increase or reduce the blank holder force according to whether the recorded draw-in was higher or lower than the optimal one. Full article
(This article belongs to the Special Issue Advanced Metal Forming and Smart Manufacturing Processes)
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9 pages, 2477 KiB  
Article
Predicting the Effect of Processing Parameters on Caliber-Rolled Mg Alloys through Machine Learning
by Jinyeong Yu, Seung Jun Oh, Seunghun Baek, Jonghyun Kim and Taekyung Lee
Appl. Sci. 2022, 12(20), 10646; https://doi.org/10.3390/app122010646 - 21 Oct 2022
Cited by 2 | Viewed by 1173
Abstract
The multi-pass caliber rolling (MPCR) of Mg alloy has attracted much attention due to its engineering and manufacturing advantages. The MPCR process induces a unique microhardness variation, which has only been predicted using a finite element analysis thus far. This study employed machine [...] Read more.
The multi-pass caliber rolling (MPCR) of Mg alloy has attracted much attention due to its engineering and manufacturing advantages. The MPCR process induces a unique microhardness variation, which has only been predicted using a finite element analysis thus far. This study employed machine learning as an alternative method of microhardness prediction for the first time. For this purpose, two machine-learning approaches were evaluated: the artificial neural network (ANN) approach and that aided by generative adversarial networks (GANs). These approaches predicted microhardness variation in the most difficult case (i.e., after the final-pass MPCR deformation). The machine-learning approaches provided a good prediction for the center area of the cross-section, because the prediction was relatively easy due to the small deviation in microhardness. In contrast, the ANN failed to anticipate the shifted hardness variation in the side sections, leading to a low predictability. Such an issue was effectively improved by integrating the GAN with the ANN. Full article
(This article belongs to the Special Issue Advanced Metal Forming and Smart Manufacturing Processes)
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