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Advanced Manufacturing Processes of Metal Forming

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Metals and Alloys".

Deadline for manuscript submissions: closed (20 February 2024) | Viewed by 11033

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Dr. Anna Dziubińska

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Guest Editor

Metal Forming and Casting Department, Faculty of Mechanical and Industrial Engineering, Warsaw University of Technology, 85 Narbutta, 02-524 Warsaw, Poland
Interests: metal forming; die forging; lightweight metal alloys; metal forming of metallic biomaterials; plastic forming of metal composites
Special Issues, Collections and Topics in MDPI journals

Prof. Dr. Wojciech Presz

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Guest Editor

Metal Forming and Casting Department, Faculty of Mechanical and Industrial Engineering, Warsaw University of Technology, 85 Narbutta, 02-524 Warsaw, Poland
Interests: metal forming; microforming; microjoining; vibration assisted forming, surface phenomena; UFG materials for microforming
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

It is a great honor and privilege to be involved as guest editors of a Special Issue of Materials focusing on advanced manufacturing processes of metal forming, and to invite you to contribute a research paper or review to this Special Issue.

Metal forming is one of the most common technological methods used in the manufacturing of metal products. It is characterized by the fact that the metal is plastically deformed to give it the desired geometry and physical and chemical properties. The change in physical and chemical properties mainly consists in changing the structure, mechanical properties, and surface topology of the metal product. There are a number of metal-forming methods for modifying the structure and properties of metals in the desired direction. Due to the increasing demand for high-quality products and the rapid development of science and technology, advanced metal-forming technologies have been successfully developed in recent years. Significant progress can be seen in traditional metal-forming methods, such as die forging, extrusion, punching, drawing, rolling, pressing, etc. Additionally, unconventional metal-forming methods are being developed, such as SPD incremental forming, CONFORM extrusion, KOBO extrusion, innovative processes for forming flanges in hollow products by moving sleeve extrusion, the rapid tube hydroforming method, drawing using ultrasound, forming on an electromagnetic press, forming on a multi-slide press, plastic microforming processes assisted by low-frequency vibration energy and ultrasonic vibration, innovative forging rolling processes, etc.

This Special Issue aims to present the latest works in the research and development of advanced manufacturing processes of metal forming. It is our pleasure to invite you to submit a manuscript to this Special Issue. Full papers, communications, and reviews are welcome for submission.

Dr. Anna Dziubińska
Prof. Dr. Wojciech Presz
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

manufacturing processes
metal forming
traditional metal-forming processes
unconventional metal-forming processes
metals and their alloys
lightweight metal alloys
microstructure
mechanical properties

Related Special Issue

Advanced Manufacturing Processes of Metal Forming (2nd Edition) in Materials

Published Papers (10 papers)

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Research

15 pages, 6125 KiB

Open AccessArticle

Experimental Investigation of Current Intensity and Feed Speed in Electrically Assisted Necking and Thickening of 5A02 Aluminum Alloy Tubes

by Yubin Fan, Xuefeng Xu, Ruichen Tao, Ming Luo, Xiaodong Li, Liming Wei, Shitian Wu, Jie Xiao and Xiang Zeng

Materials 2024, 17(4), 771; https://doi.org/10.3390/ma17040771 - 06 Feb 2024

Viewed by 526

Abstract

In order to further explore the forming limits of thin-wall tube necking and thickening, and obtain sufficient thickness of the tube in the thickening area, local electric pulse-assisted forming experiments were carried out to study the effects of current intensity and feed speed on the necking and thickening forming of thin-wall tube. The experimental results show that with the increase in current intensity, the temperature in the forming area of the tube increases, and the forming load for necking and thickening decreases. However, with the increase in feed speed, the overall forming load for necking and thickening increases in general, and the smaller feed speed is more conducive to forming. Taking into account the forming efficiency and electrode loss, the corresponding forming process window is obtained for the manufacturing of good parts. That is, during the necking stage, the current intensity shall not be less than 300 A, and the feed speed shall not exceed 10 mm/min. During the thickening stage, the current intensity should not be less than 1400 A, and the feed speed should not exceed 1 mm/min. The target part is finally formed, with an average wall thickness of 5.984 mm in the thickening zone and a thickening rate of 303.2%. Full article

(This article belongs to the Special Issue Advanced Manufacturing Processes of Metal Forming)

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19 pages, 9915 KiB

Open AccessArticle

Dynamic Mechanical Properties and Modified Johnson-Cook Model Considering Recrystallization Softening for Nickel-Based Powder Metallurgy Superalloys

by Chen Ling, Xiaoping Ren, Xuepeng Wang, Yinghao Li, Zhanqiang Liu, Bing Wang and Jinfu Zhao

Materials 2024, 17(3), 670; https://doi.org/10.3390/ma17030670 - 30 Jan 2024

Viewed by 618

Abstract

The material undergoes high temperature and high strain rate deformation process during the cutting process, which may induce the dynamic recrystallization behavior and result in the evolution of dynamic mechanical properties of the material to be machined. In this paper, the modified Johnson-Cook (J-C) model for nickel-based powder metallurgy superalloy considering dynamic recrystallization behavior in high strain rate and temperature is proposed. The dynamic mechanical properties of the material under different strain rates and temperature conditions are obtained by quasi-static compression test and split Hopkinson pressure bar (SHPB) test. The coefficients of the modified J-C model are obtained by the linear regression method. The modified model is verified by comparison with experimental and model prediction results. The results show that the modified J-C model proposed in this paper can accurately describe the mechanical properties of nickel-based powder metallurgy superalloys at high temperatures and high strain rates. This provides help for studying the cutting mechanism and finite element simulation of nickel-based powder metallurgy superalloy. Full article

(This article belongs to the Special Issue Advanced Manufacturing Processes of Metal Forming)

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15 pages, 4127 KiB

Open AccessEditor’s ChoiceArticle

Analysis of the Effect of Skew Rolling Parameters on the Surface Roughness of C60 Steel Products Using ML Methods

by Konrad Lis

Materials 2023, 16(22), 7136; https://doi.org/10.3390/ma16227136 - 12 Nov 2023

Viewed by 772

Abstract

This paper presents results from experimental and numerical studies of the skew rolling process used to shape axisymmetric products made of C60-grade steel. An experimental study was carried out to investigate the effect of process parameters described by the forming angle α, the skew angle θ, the reduction ratio δ, and the jaw chuck velocity V_u on the surface roughness Ra of the forgings. Stepped forgings made of C60-grade steel were rolled. Based on numerical calculations, a machine learning regression model was developed that uses process parameters to predict the surface roughness of produced parts. The random forest model was found to be the most effective based on the determined metrics (MAE, RMSE, R²). A more detailed analysis of this model was performed using the SHAP library. The application of ML methods will enable optimization of skew rolling through appropriate selection of process parameters affecting improvement in product quality. Full article

(This article belongs to the Special Issue Advanced Manufacturing Processes of Metal Forming)

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12 pages, 3571 KiB

Open AccessArticle

Microcapsules in Fiber Metal Laminates for Self-Healing at the Interface between Magnesium and Carbon Fiber-Reinforced Epoxy

by Monika Ostapiuk

Materials 2023, 16(19), 6524; https://doi.org/10.3390/ma16196524 - 01 Oct 2023

Cited by 1 | Viewed by 787

Abstract

The paper presents issues regarding self-healing isophorone diisocyanate (IPDI) microcapsules applied in fiber metal laminates (FMLs) based on magnesium AZ31 and a carbon-reinforced polymer composite. The aim of this work is to analyze the morphology of the produced PU/PUa microcapsules containing IPDI and their behavior in a self-healing layer in FMLs. By means of SEM, it was confirmed that the microcapsules (MCs) had a narrow size distribution. Therefore, the developed MCs, having sizes ranging from 10 to 35 µm, might contribute to an improved self-healing coating, which benefits from the advantages of both small and larger-sized MCs. The positive result of the work is that there is a possibility to improve the properties of FMLs with added MCs, i.e., in corrosion and mechanical phenomena. Full article

(This article belongs to the Special Issue Advanced Manufacturing Processes of Metal Forming)

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14 pages, 10485 KiB

Open AccessArticle

Enhanced Mechanical Properties of QAl9-4 Aluminum Bronze for High-Speed-Rail Brake Systems with a Pulsed Magnetic Field

by Yujun Hu, Hongjin Zhao, Yinghui Zhang, Bing Zhang and Kefu Hu

Materials 2023, 16(17), 5905; https://doi.org/10.3390/ma16175905 - 29 Aug 2023

Viewed by 763

Abstract

To improve the mechanical properties and wear resistance of QAl9-4 aluminum bronze alloy parts of high-speed rail brake calipers, the solid aluminum bronze alloy was treated with a pulsed magnetic field in which the magnetic induction intensity was 3T at room temperature. After that, a tensile test and a friction and wear test were carried out on the alloy. The results indicate that the magnetic field promotes the movement of low-angle grain boundaries less than 2° and splices to form subcrystals or fine crystals, which reduces the mean grain size of the alloy. The disordered dislocation changed into a locally ordered dislocation line, the dislocation distribution became uniform, and the dislocation density increased, which simultaneously improved the alloy’s tensile strength and elongation. The elongation increased by 10.2% compared with that without the magnetic field. The increase in strength can provide strong support for the wear-resistant hard phase, and the enhancement of plasticity can increase the alloy’s ability to absorb frictional vibration. Therefore, it was hard for cracks to form and extend, and the specimen’s average friction coefficient was reduced by 22.05%. The grinding crack width and depth decreased, the wear debris became more uniform and fine, and the alloy’s wear resistance increased. Full article

(This article belongs to the Special Issue Advanced Manufacturing Processes of Metal Forming)

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15 pages, 7558 KiB

Open AccessArticle

Study on the Effect of the Pre-Forming of 22MnB5 Steel in Indirect Hot Stamping

by Ziming Tang, Zhengwei Gu, Yi Li, Xin Li, Ge Yu and Lingling Yi

Materials 2023, 16(10), 3739; https://doi.org/10.3390/ma16103739 - 15 May 2023

Cited by 3 | Viewed by 1129

Abstract

Based on the indirect hot-stamping test system, the effect of pre-forming on the microstructure evolution (grain size, dislocation density, martensite phase transformation) and mechanical properties of the blank in indirect hot stamping is systematically studied using ultra-high-strength steel 22MnB5. It is found that the average austenite grain size slightly decreases with the increase in pre-forming. After quenching, the martensite also becomes finer and more uniformly distributed. Although the dislocation density after quenching slightly decreases with the increase in pre-forming, the overall mechanical properties of the quenched blank are not greatly affected by pre-forming under the combined effect of the grain size and dislocation density. Then, this paper discusses the effect of the pre-forming volume on part formability in indirect hot stamping by manufacturing a typical beam part. According to the numerical simulations and experimental results, when the pre-forming volume increases from 30% to 90%, the maximum thickness thinning rate of the beam part decreases from 30.1% to 19.1%, and the final beam part has better formability and more uniform thickness distribution results when the pre-forming volume is 90%. Full article

(This article belongs to the Special Issue Advanced Manufacturing Processes of Metal Forming)

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20 pages, 22192 KiB

Open AccessArticle

Investigation of a New Screw Press Forming Process for Manufacturing Connectors from ZK60 Magnesium Alloy Preforms

by Anna Dziubinska

Materials 2023, 16(9), 3467; https://doi.org/10.3390/ma16093467 - 29 Apr 2023

Cited by 4 | Viewed by 1078

Abstract

This article discusses a new technology of forming connector forgings from ZK60 magnesium alloy preforms by die forging on a screw press. The purpose of the study was to evaluate the feasibility of using preforms cast from the ZK60 magnesium alloy to forge a connector forging with improved mechanical properties compared to those obtained by casting. It also aimed to establish whether this new forging method has the potential for replacing the multi-stage forging process conducted on hydraulic presses used for high-strength Mg alloys. A numerical analysis of the proposed approach was performed by the finite element method, applying the popular DEFORM computer software for simulating forming processes. The numerical results confirmed that the developed method produces parts with the desired shape. The numerical results also provided information regarding the behavior of the workpiece’s material and the screw press forging process, including the distributions of strains and temperatures, the Cockcroft–Latham damage criterion, and energy required to form connector forgings. The proposed screw press forging process for producing ZK60 alloy connectors from cast preforms was verified by experimental tests. The connector forgings produced from the ZK60 magnesium alloy were then subjected to qualitative tests. Full article

(This article belongs to the Special Issue Advanced Manufacturing Processes of Metal Forming)

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20 pages, 21934 KiB

Open AccessArticle

The Correlation of LVI Parameters and CAI Behaviour in Aluminium-Based FML

by Piotr Podolak, Magda Droździel-Jurkiewicz, Patryk Jakubczak and Jarosław Bieniaś

Materials 2023, 16(8), 3224; https://doi.org/10.3390/ma16083224 - 19 Apr 2023

Viewed by 850

Abstract

An experimental analysis of mechanical behaviour for aluminium-based fibre metal laminates under compression after impact was conducted. Damage initiation and propagation were evaluated for critical state and force thresholds. Parametrization of laminates was done to compare their damage tolerance. Relatively low-energy impact had a marginal effect on fibre metal laminates compressive strength. Aluminium–glass laminate was more damage-resistant than one reinforced with carbon fibres (6% vs. 17% of compressive strength loss); however, aluminium–carbon laminate presented greater energy dissipation ability (around 30%). Significant damage propagation before the critical load was found (up to 100 times the initial damaged area). Damage propagation for assumed load thresholds was minor in comparison to the initial damage size. Metal plastic strain and delaminations are dominant failure modes for compression after impact. Full article

(This article belongs to the Special Issue Advanced Manufacturing Processes of Metal Forming)

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27 pages, 20128 KiB

Open AccessArticle

The New Technology of Die Forging of Automotive Connecting Rods from EN AB-71100 Aluminium Alloy Cast Preforms

by Anna Dziubinska

Materials 2023, 16(7), 2856; https://doi.org/10.3390/ma16072856 - 03 Apr 2023

Cited by 2 | Viewed by 1698

Abstract

This article presents a new technology for forming automotive connecting rod forgings by means of die forging from cast performs from EN AB-71100 (EN AB-AlZn10Si8Mg) aluminum alloy. A premise was made that the production process would be carried out on forging presses. The process of forming connecting rod forgings was analyzed considering different deformation rates related to the type of machine used: a crank press and a screw press. The billet in the form of in-house designed, shaped preforms cast into sand molds with two variants of geometry was used in the process. The numerical analysis of the new process was carried out on the basis of the finite element method using Deform 3D, the simulation software for metal forming. The simulations were conducted in the spatial deformation conditions, considering the full thermomechanical analysis. Based on the simulations, certain important findings concerning the novel process were acquired, including the distribution of stress, deformation, temperatures, cracking criterion and energy parameters. The results of numerical tests confirmed the possibility of producing defect-free forgings of connecting rods from EN AB-71100 aluminum alloy on forging presses by means of the proposed technology. The proposed process of forging using crank and screw presses was verified in the course of tests conducted in industrial conditions. The properly formed connecting rod forgings were subjected to quality tests in terms of their structure and mechanical properties. Full article

(This article belongs to the Special Issue Advanced Manufacturing Processes of Metal Forming)

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22 pages, 12328 KiB

Open AccessArticle

Theoretical Analysis and Verification on Plastic Deformation Behavior of Rocket Nozzle Using a Novel Tube Upsetting-Bulging Method

by Yizhe Chen, Shilong Zhao, Hui Wang, Jun Li and Lin Hua

Materials 2023, 16(4), 1680; https://doi.org/10.3390/ma16041680 - 17 Feb 2023

Cited by 9 | Viewed by 1957

Abstract

The rocket nozzle is one of the core components to ensure the safe flight of rockets. To overcome the problems of multi-step forming, the occurrence of defects, and severe plastic deformation in traditional technology, a novel forming method named tube upsetting-bulging (TUBG) is put forward. With the support of internal pressure, a tube is deformed with an upsetting and bulging process at the same time. The tube is thickened at the small end and thinned at the large end. A nozzle with sharply varying diameters can be obtained. A theoretical model of TUBG that considers wrinkles and rupture is built. The influence factors of internal pressure during TUBG are discussed. Experiments and simulation works are conducted to analyze the plastic deformation process of TUBG. Results show that mechanical properties and geometrical parameters have an obvious influence on critical internal pressure. The proposed theoretical model can be used to predict a forming zone without wrinkles, rupture, and severe strain values. A well-formed nozzle can be obtained using the predicted forming zone, which verifies the correctness of the theoretical analysis. It can be found that TUBG is a novel potential method to fabricate rocket nozzles with high efficiency and quality without defects. Full article

(This article belongs to the Special Issue Advanced Manufacturing Processes of Metal Forming)

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