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Metals
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Advances in Plastic Deformation Technologies
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Advances in Plastic Deformation Technologies

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Failure Analysis".

Deadline for manuscript submissions: closed (18 January 2023) | Viewed by 15197

Special Issue Editors

Dr. Igor Bobrovskij

E-Mail Website
Guest Editor
Togliatti State University, Tolyatti, Russian Federation
Interests: surface texture; burnishing; roughness; plastic deformation; honing
Dr. J. Antonio Travieso-Rodriguez

E-Mail Website
Guest Editor
Mechanical Engineering Department, Escola d’Enginyeria de Barcelona Est, Universitat Politècnica de Catalunya, Avinguda d’Eduard Maristany, 10–14, 08019 Barcelona, Spain
Interests: manufacturing; burnishing; surface integrity; additive manufacturing
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

One of the main impacts of material enhancement nowadays is largely determined by the quality of goods we buy and use in everyday life. Advanced finishing technologies play a key role in automotive, aerospace, and biomedical industries and are an integral part of mechanical engineering. One of the most important groups of finishing technologies is based on plastic deformation. Academic and industrial researchers employed in this field face many challenges. Despite an impressive progress achieved in both instrumentation and theory over past decades, a number of important issues are still to be addressed, such as:

  • How can we increase productivity and lower the production costs while maintaining the high quality of products?
  • How can we make use of the plastic deformation in the processing of products obtained using additive technologies?
  • What are the best materials to be used in the design of instruments?

Answering these questions is critically important for gaining deep and insightful understanding of both new processes such as, for example, incremental plastic deformation, shoot peening, nano-burnishing, wide burnishing, and low plasticity burnishing, as well as traditional ones such as extrusion, drawing, and bending.

The importance of the topics proposed for this Special Issue is well proven by the steadily growing number of articles on plastic deformation in the mainstream international journals over the past few years, and we hope that you, our esteemed colleagues, will make further important contributions to this quickly growing field with your high-quality research articles, communications and reviews.

It is our pleasure to invite you to submit your manuscript to this Special Issue!

Dr. Igor Bobrovskij
Dr. J. Antonio Travieso-Rodriguez
Guest Editors

Manuscript Submission Information

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

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

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

Keywords

  • plastic deformation
  • plasticity
  • extrusion
  • shot peening
  • burnishing
  • bending
  • surface
  • texture

Published Papers (7 papers)

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Editorial

Jump to: Research

3 pages, 208 KiB  
Editorial
Advances in Plastic Deformation Technologies
by J. Antonio Travieso-Rodríguez and Igor Bobrovskij
Metals 2023, 13(7), 1194; https://doi.org/10.3390/met13071194 - 27 Jun 2023
Viewed by 719
Abstract
Material enhancement plays an important role in everyday life due to its impacts on the quality of goods, which we, consumers, buy and use [...] Full article
(This article belongs to the Special Issue Advances in Plastic Deformation Technologies)

Research

Jump to: Editorial

15 pages, 5370 KiB  
Article
Impacts of Surface Texture and Nature of Friction on Energy-Force Efficiency of Surface Plastic Deformation during Burnishing
by Igor Bobrovskij, Nikolaj Bobrovskij, Alexander Khaimovich and J. Antonio Travieso-Rodriguez
Metals 2022, 12(10), 1568; https://doi.org/10.3390/met12101568 - 21 Sep 2022
Cited by 2 | Viewed by 1317
Abstract
Burnishing, the plastic deformation of the workpiece surface due to sliding contact with a tool called burnisher, is a finishing operation widely used in various industries. In this work, impacts of the initial surface roughness Ra of the workpiece being burnished, the nature [...] Read more.
Burnishing, the plastic deformation of the workpiece surface due to sliding contact with a tool called burnisher, is a finishing operation widely used in various industries. In this work, impacts of the initial surface roughness Ra of the workpiece being burnished, the nature of friction in the contact zone, and the clamping force on the stability and energy efficiency of burnishing have been investigated. Experiments have been conducted with and without lubricant, represented by low-viscosity deep-hydrogenated fraction of sour oils, at initial surface roughness Ra of 0.8 and 1.25 μm and variable (100–200 N) clamping force. A key process indicator, which largely controls mechanics of burnishing, the temperature in the tool-workpiece contact zone has been measured using natural thermocouple method. Microhardness of the workpiece surface after burnishing has also been measured. It has been shown that changes in the temperature of the tool-workpiece contact zone are proportional to the changes in the squared tool clamping force. This dependence appeared to be universal and equally applicable to burnishing with and without lubrication. Based on the analysis of the experimental data, a new criterion of the burnishing efficiency has been developed. The new criterion simplifies the choice of optimum operational parameters and helps in preventing adverse impacts of structural phase transformations in the workpiece surface layer that unavoidably lead to reduced product quality and operational reliability and in reducing tool wear, which is critically important in the case of dry burnishing. The obtained results show that the nature of friction accompanying the surface plastic deformation has a significant impact on the stability and energy efficiency of the burnishing process. While the clamping force is equally important for burnishing with and without lubrication, the initial roughness Ra has an impact on dry burnishing only. Application of minimum quantity lubrication (MQL) under experimental conditions typical for industrial burnishing is found to be favorable. In particular, it was shown that MQL not only enhances the stability of burnishing process and but also increases its energy efficiency by more than 20%. Full article
(This article belongs to the Special Issue Advances in Plastic Deformation Technologies)
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21 pages, 18668 KiB  
Article
Ball Burnishing of Friction Stir Welded Aluminum Alloy 2024-T3: Experimental and Numerical Studies
by Cyrus Amini, Ramón Jerez-Mesa, Jose Antonio Travieso-Rodriguez, Hojjat Mousavi, Jordi Lluma-Fuentes, Mohammad Damous Zandi and Soran Hassanifard
Metals 2022, 12(9), 1422; https://doi.org/10.3390/met12091422 - 28 Aug 2022
Cited by 3 | Viewed by 1780
Abstract
This paper deals with the improvement of the material surface state of friction stir welding paths modified in situ by plastic deformation through ball burnishing. The metallurgical and topological states of materials joined by this welding technique are typically detrimental to the ulterior [...] Read more.
This paper deals with the improvement of the material surface state of friction stir welding paths modified in situ by plastic deformation through ball burnishing. The metallurgical and topological states of materials joined by this welding technique are typically detrimental to the ulterior performance of the workpiece, and it is believed that ball burnishing can improve these states to enhance functioning. This study is divided into two phases. The first one is experimental and consists of welding aluminum AA2024-T3 plates while combining different tool rotations and welding speeds. Then, the welding line is deformed locally by ball burnishing. The improvement of the topology and deep hardness distribution is measured and discussed, and the evolution of mechanical properties is assessed through tensile tests. The second phase is oriented towards estimating the residual stresses by combining two pre-existing models of friction stir welding and burnishing developed by the same authors using ANSYS®. Friction stir welding experimentation and measurements show a decrease in the values of all measured mechanical properties compared to the original material. The dominant factor affecting the properties and texture of the materials is the rotational speed of the tool, with the rupture point in the tensile test located in the distinct zone with the lowest value of microhardness on the advancing side. The higher the ratio of the rotational speed to the welding speed, the lower the roughness value. Finally, ball burnishing is proven to be an effective method to enhance the surface integrity of friction stir welded joints in light of the results, achieving a reduction of 11% to 36% in average roughness and an increase of about 22% in hardness profile, along with an integrated numerical model estimation of a remarkable effect on compressive residual stresses in-depth on the retreating side of the welded samples. However, in some tests, this treatment reduced some characteristics (yield stress and failure strain). Full article
(This article belongs to the Special Issue Advances in Plastic Deformation Technologies)
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17 pages, 3721 KiB  
Article
Derivation of the Coefficients in the Coulomb Constant Shear Friction Law from Experimental Data on the Extrusion of a Material into V-Shaped Channels with Different Convergence Angles: New Method and Algorithm
by Igor Bobrovskij, Alexander Khaimovich, Nikolaj Bobrovskij, J. Antonio Travieso-Rodriguez and Fedor Grechnikov
Metals 2022, 12(2), 239; https://doi.org/10.3390/met12020239 - 27 Jan 2022
Cited by 4 | Viewed by 2622
Abstract
The combined Coulomb constant shear friction law is widely used in commercial and research software for the finite-element analysis (FEA) of metalworking and is naturally more flexible and hence, more relevant to real-life manufacturing than the individual Coulomb and constant shear friction laws. [...] Read more.
The combined Coulomb constant shear friction law is widely used in commercial and research software for the finite-element analysis (FEA) of metalworking and is naturally more flexible and hence, more relevant to real-life manufacturing than the individual Coulomb and constant shear friction laws. In this work, a new mathematical model of coefficients in the Coulomb constant shear friction law for extruding a metal through narrow V-shaped channels with small convergence angles has been developed and evaluated and compared with laboratory measurements. The extrusion of the model material (lead) through narrow V-shaped channels with small convergence angles varying from 0 to 3.5 degrees has been studied. The Coulomb friction coefficient µ and the constant friction factor m appear to be independent of the dimension ratio and are influenced mostly by roughness and range from µ = 0.363 (with lubricant) to µ = 0.488 (without lubricant) and from m = 0.726 (with lubricant) to 0.99 (without lubricant). The relative length dominated by the Coulomb friction law is less than 1%, and the Coulomb’s coefficient of friction can be approximated as ½ the constant shear friction factor for all tested cases. The developed method and algorithm can be used in both FEA of manufacturing processes and efficiency tests for lubricants used in metalworking. Full article
(This article belongs to the Special Issue Advances in Plastic Deformation Technologies)
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15 pages, 5779 KiB  
Article
Determination of Constitutive Equation and Thermo–Mechanical Processing Map for Pure Iridium
by Mi Zhou, Rui Hu, Jieren Yang, Chuanjun Wang and Ming Wen
Metals 2020, 10(8), 1087; https://doi.org/10.3390/met10081087 - 12 Aug 2020
Cited by 5 | Viewed by 2180
Abstract
Deformation behavior of pure iridium has been studied during thermal compression testing with the help of Gleeble-1500D in the temperature range of 1200 °C~1500 °C and strain rate range of 10−1 s−1~10−2 s−1. Resistance to deformation, microstructural [...] Read more.
Deformation behavior of pure iridium has been studied during thermal compression testing with the help of Gleeble-1500D in the temperature range of 1200 °C~1500 °C and strain rate range of 10−1 s−1~10−2 s−1. Resistance to deformation, microstructural evolution and hot workability of pure iridium have been used to analyze in detail. Frictional coefficient has been used to modify the experimental stress–strain curve of thermal compression test, and it has been found effective in reducing the influence of friction during thermo–mechanical testing. The hyperbolic sine constitutive equation of pure iridium has been established to give a material processing model for numerical simulation. A very high value of activation energy for iridium, 573 KJ/mol, clearly indicates that it is very hard to deform this material. The deformation mechanism of pure iridium is dependent upon temperature as well as strain rate. At low temperature and strain rate (temperature range of 1200 °C~1300 °C and strain rate range of 10−1 s−1~10−2 s−1), dynamic recovery is active while dynamic recrystallization becomes operative as temperature and stain rate are increased. On further increase in temperature and decrease in strain rate (temperature range of 1400 °C~1500 °C and strain rates of 10−2 s−1~10−3 s−1), abnormal grain growth takes place. On the basis of a constitutive model and processing map, suitable forming process parameters (temperature range of 1400 °C~1500 °C and strain rate range of 0.1 s−1~0.05 s−1) for pure iridium have been worked out. Full article
(This article belongs to the Special Issue Advances in Plastic Deformation Technologies)
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13 pages, 15663 KiB  
Article
Mechanical Strengthening in S235JR Steel Sheets through Vibration-Assisted Ball Burnishing
by Jordi Llumà, Giovanni Gómez-Gras, Ramón Jerez-Mesa, Jaume Rue-Mascarell and J. Antonio Travieso-Rodriguez
Metals 2020, 10(8), 1010; https://doi.org/10.3390/met10081010 - 28 Jul 2020
Cited by 9 | Viewed by 2938
Abstract
The superficial effect of hardening caused after vibration-assisted ball burnishing and its consequences in the tensile behavior of a carbon steel material are studied in this paper. As ball burnishing affects the material to hundredths of micrometers in depth through plastic deformation, the [...] Read more.
The superficial effect of hardening caused after vibration-assisted ball burnishing and its consequences in the tensile behavior of a carbon steel material are studied in this paper. As ball burnishing affects the material to hundredths of micrometers in depth through plastic deformation, the overall macro effect of this modification was studied. Different levels of preload and vibration amplitude were studied to address the described issue. The study was done in two phases. First of all, the depth to which ball burnishing affects the material was studied by performing Vickers indentation tests with different loads. It was proven that the effects of ball burnishing are best represented when a 0.05 kg load is used, as higher loads include more volume of core material in the measurement, hence hiding the effect of ball burnishing. In a second phase, the ball burnished specimens were subjected to tensile tests. It was proven that an increase of burnishing preload diminishes the ductile behavior of the material and increases its strength representative values, although the proportion of affected material in the cross-section of the specimen is reduced with regard to the whole surface. Additionally, as the preload increases, the effects of assistance through vibrations is reduced, and the effect of the static preload acquires more relevance in modifying the macroscopic mechanical properties of the steel alloy. Experiments using different amplitudes and new forces are encouraged to obtain more information about how the material can be modified optimally through vibration-assisted ball burnishing. Full article
(This article belongs to the Special Issue Advances in Plastic Deformation Technologies)
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15 pages, 3753 KiB  
Article
Enhancing Surface Topology of Udimet®720 Superalloy through Ultrasonic Vibration-Assisted Ball Burnishing
by Ramón Jerez-Mesa, Victoria Plana-García, Jordi Llumà and J. Antonio Travieso-Rodriguez
Metals 2020, 10(7), 915; https://doi.org/10.3390/met10070915 - 8 Jul 2020
Cited by 11 | Viewed by 2450
Abstract
This contribution reports the effects of an ultrasonic-vibration assisted ball burnishing process on the topological descriptors of nickel-based alloy Udimet®720. This material is of high interest for the transportation industry, and specifically for the aeronautical sector. Despite the acknowledged necessity to [...] Read more.
This contribution reports the effects of an ultrasonic-vibration assisted ball burnishing process on the topological descriptors of nickel-based alloy Udimet®720. This material is of high interest for the transportation industry, and specifically for the aeronautical sector. Despite the acknowledged necessity to finish this material to achieve excelling mechanical performances of parts, surface integrity enhancement by means of plastic deformation through ball burnishing has seldom been explored in previous references so far. In this paper, different surface descriptors are used to report how the topology changes after ultrasonic-assisted ball burnishing, and how burnishing conditions influence that change. The burnishing preload and the number of passes are the only influential factors on surface change, whereas the feed velocity of the tool and the strategy reveal not to be relevant on the result. Additionally, the extent to which the process successfully modifies the objective surfaces is highly divergent depending on the original scale of the treated surface. The assistance of the process with vibrations also shows that the resulting topologies are characterized by a periodical pattern of repetitive peaks and valleys that are extended on the surface with a higher frequency in comparison to the non-assisted process, which could influence in the functional deployment of workpieces treated through it, and could deliver an advantage with regard to its non-assisted homologous process. Full article
(This article belongs to the Special Issue Advances in Plastic Deformation Technologies)
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