In sheet metal forming industries, finite element simulations are commonly used for the process/tool design. An important factor for finite element modeling is mechanical property (flow stress curves and stress–strain relationships) of the sheet material. Hydroforming bulge and uniaxial tensile tests were performed on four different sheet metal alloys of industrial interest and the resulting flow stress curves determined using different analytical approaches developed by Hill, Panknin, Chakrabarty and Kruglov. To obtain flow stress curves, both the dome height and pressure were measured during the bulge tests. The effect of anisotropy and strain hardening characteristics were also investigated. The results show that biaxial loading provides flow stress properties at higher strain levels as compared to uniaxial loading. It was also concluded that an accurate flow curves can be obtained using Panknin’s bulge radius and Kruglov’s thickness calculation approaches.

Suitability of AA2024-T3 and AA5083-H111 aluminium sheet alloys for forming operations in room temperature were examined by using forming limit diagrams with different strain paths. In the experimental part, circular bulge, nongrooved tensile as well as grooved tensile specimens were used. This was done to simulate the following: (a) biaxial stretching region (positive range of minor strain), (b) uni-axial strain path and (c) strain path from uni-axial tension to plane strain region of the forming limit diagram, respectively. The effects of combined strain paths coupled with material anisotropy were taken into account in each stage. Tensile properties as well as formability parameters were correlated in accordance with the attained forming limit diagrams. Average plastic strain ratio and planar anisotropy, in addition to work hardening exponents of the samples, were calculated from the test data and the effects on the forming limit diagrams were discussed. Moreover, comparisons were made between experimental and theoretical forming limit diagrams. It is shown that experimental forming limit diagrams are in very good agreement with the theoretical predictions, particularly when BBC2000 yield criteria are used for the M-K model. In addition, theoretical prediction by using the Hill93-Swift model showed small deviation with the experimental forming limit diagrams. Finally, finite element simulations were carried out to investigate the numerical forming limit diagrams through an industrial sheet metal forming simulation software. It was consequently shown that, due to frictional effects resulting from hemispherical-shaped punch, the finite element results depicted small deviation compared to the experimental data.

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In this paper the processing steps for producing SOFC (Solid Oxide Fuel Cell) supports by means of PIM (Powder Injection Molding) technique were investigated. Injection molding parameters in this study were divided into pressure-related (injection pressure and packing pressure), temperature-related (nozzle temperature and mold temperature), and time-related (injection rate and holding time) parameters. Keeping the other parameters (pressure-related, temperature-related and time-related parameters) constant at an optimized value, the effects of each of the molding parameters above were investigated. The results show that the short shot, warpage, weld line and void are the most common defects in molded parts. According to the results the short shot could be seen in low values of injection pressure, injection rate, nozzle and mold temperature. Also, warpage could be seen in high values of mold temperature, injection and packing pressure. Poor weld line was another defect that could be seen in low values of injection pressure, injection rate, nozzle and mold temperature. Also the void was one of the most common defects that could be seen in high values of injection rate and nozzle temperatures. Finally, using optimized molding parameters, the molded parts underwent debinding and sintering processes. Based on the results of thermal shock tests and the porosity measurements of the sintered parts, these molded parts possessed relatively desirable characteristics.