Models and modelling for process limits in metal forming

Volk, Wolfram; Groche, Peter; Brosius, Alexander; Ghiotti, Andrea; Kinsey, Brad L.; Liewald, Mathias; Madej, Łukasz; Min, Junying; Ye, Jun

doi:10.1016/j.cirp.2019.05.007

Cited by 68 publications

(32 citation statements)

References 202 publications

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“…The complex 3D material flow that occurs during bulk forming processes requires very accurate FE models for its prediction. Especially, the prediction of the residual stress state of the final part requires an accurate material model that should be able to take into account all relevant phenomena [32]. The cost for the parameter identification for these models is often very high [32].…”

Section: Difficulties Related To the Analysis Of The Formation Of Resmentioning

confidence: 99%

“…Especially, the prediction of the residual stress state of the final part requires an accurate material model that should be able to take into account all relevant phenomena [32]. The cost for the parameter identification for these models is often very high [32]. For many processes, the modelling of the kinematic hardening behaviour is required for an accurate residual stress prediction.…”

Section: Difficulties Related To the Analysis Of The Formation Of Resmentioning

confidence: 99%

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Strategies for residual stress adjustment in bulk metal forming

et al. 2021

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The family of bulk forming technologies comprises processes characterised by a complex three-dimensional stress and strain state. Besides shape and material properties, also residual stresses are modified during a bulk metal forming process. The state of residual stresses affects important properties, like fatigue behaviour and corrosion resistance. An adjustment of the residual stresses is possible through subsequent process steps such as heat treatments or mechanical surface modification technologies, like shot peening and deep rolling. However, these additional manufacturing steps involve supplementary costs, longer manufacturing times and harmful effects on the product quality. Therefore, an optimized strategy consists in a targeted introduction of residual stresses during the forming processes. To enable this approach, a fundamental understanding of the underlying mechanisms of residual stress generation in dependence of the forming parameters is necessary. The current state of the art is reviewed in this paper. Strategies for the manipulation of the residual stresses in different bulk forming processes are classified according to the underlying principles of process modification.

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Section: Difficulties Related To the Analysis Of The Formation Of Resmentioning

confidence: 99%

Section: Difficulties Related To the Analysis Of The Formation Of Resmentioning

confidence: 99%

Strategies for residual stress adjustment in bulk metal forming

et al. 2021

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“…In this investigation, the model serves to predict the final geometry of the tube in the process design phase, especially with regard to buckling. According to Volk et al [20], accuracy and precision of a model are important for process design, while model execution time or flexibility are of much less importance. An accurate model must deliver an output close to the output of the real process [21].…”

Section: Fe-model For the Roll Forming Processmentioning

confidence: 99%

Roll forming of a high strength AA7075 aluminum tube

Suckow

Schroeder

Groche

2021

Prod. Eng. Res. Devel.

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The presented paper provides a modelling strategy for roll forming of a high strength AA7075 aluminum tube. Roll forming allows the cost-effective production of large quantities of long profiles. Forming of high strength aluminum brings challenges like high springback and poor formability due to the low Young’s modulus, low ductility and high yield strength. Forming processes with high strength aluminum, such as the AA7075 alloy, therefore require a detailed process design. Three different forming strategies, one double radius strategy and two W-forming strategies are discussed in the paper. The paper addresses the question whether common roll forming strategies are appropriate for the challenge of roll forming of a high strength aluminum tube. For this purpose, different forming strategies are investigated numerically regarding buckling, longitudinal strain distribution and final geometry. While geometry is quite the same for all strategies, buckling and strain distribution differ with every strategy. The result of the numerical investigation is an open tube that can be welded into a closed tube in a subsequent step. Finally, roll forming experiments are conducted and compared with the numerical results.

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“…Authors [36] simplified method was utilized to get experimental FLDs for these sheet substances. ANN modeling of the task based on experimental outcomes is in fact expelled to foresee FLDs.…”

Section: Related Workmentioning

confidence: 99%

Withdrawn

2020

IJRTE

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Models and modelling for process limits in metal forming

Cited by 68 publications

References 202 publications

Strategies for residual stress adjustment in bulk metal forming

Strategies for residual stress adjustment in bulk metal forming

Roll forming of a high strength AA7075 aluminum tube

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