Computational Methods in Manufacturing Processes

A special issue of Metals (ISSN 2075-4701).

Deadline for manuscript submissions: closed (31 December 2019) | Viewed by 17798

Special Issue Editors

Department of Civil and Environmental Engineering, Technical University of Catalonia, UPC BarcelonaTech, 08034 Barcelona, Spain
Interests: computational mechanics; computational plasticity; contact mechanics; coupled thermomechanical problems; finite element method
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Laboratoire de Tribologie et Dynamique des Systèmes, Écully, France
Interests: computational mechanics; computational methods in manufacturing processes; nonlinear multi-physical models; FEM and XFEM; nitriding and carbo-nitriding processes; spot welding (SPW) processes; friction stir welding (FSW) processes; fusion welding processes (MAG); additive manufacturing (AM) processes
Special Issues, Collections and Topics in MDPI journals
Department of Aerospace and Mechanical Engineering, University of Liege, B-4000 Liege, Belgium
Interests: computational mechanics; contact mechanics and numerical tribology; nonlinear coupled thermomechanical models; FEM, PFEM and DEM; impact simulation; metal forming simulation including roll forming; friction stir welding (FSW) processes and additive manufacturing (AM) processes
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

“Computational Modeling in Manufacturing Processes” has been a very active field of research in the last few decades. Significant advances in this field have been the result of interdisciplinary multi-physics and multiscale research in related fields of computational mechanics, constitutive material models, and mathematical analysis. Additionally, during this period, industry has shown a growing interest in incorporating numerical techniques as a valuable tool for design and process optimization.

This Special Issue on “Computational Modeling in Manufacturing Processes” intends to collect the last developments in the field, written by well-known researchers who have contributed significantly in the computational modeling and numerical simulation of different material manufacturing processes.

Topics addressed in this Special Issue may include, but are not limited to:

  • Computational modelling
  • Numerical simulation
  • Finite Elements
  • Stabilization methods
  • Thermomechanical formulations
  • Material properties
  • Metallurgical characterization
  • Numerical methods
  • Industrial applications
  • Additive Manufacturing (AM) processes
  • Friction Stir Welding (FSW) processes
  • Casting processes
  • Rolling processes
  • Sheet Metal Forming (SMF) processes

Prof. Carlos Agelet de Saracibar
Prof. Eric Feulvarch
Prof. Jean-Philippe Ponthot
Guest Editors

Manuscript Submission Information

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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

  • computational models
  • constitutive models
  • mathematical models
  • numerical simulation
  • finite element methods
  • manufacturing processes
  • additive manufacturing
  • friction stir welding

Published Papers (4 papers)

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Research

16 pages, 5637 KiB  
Article
Analysis of Sheet Metal Forming (Stamping Process): A Study of the Variable Friction Coefficient on 5052 Aluminum Alloy
by Shasha Dou and Jiansheng Xia
Metals 2019, 9(8), 853; https://doi.org/10.3390/met9080853 - 03 Aug 2019
Cited by 35 | Viewed by 5131
Abstract
Under a boundary lubrication regime, the effect of sliding velocity and normal loads on the friction coefficient in the sheet metal stamping process was investigated using a pin-on-disk sliding wear test. Software was used to analyze both the data generated and the friction [...] Read more.
Under a boundary lubrication regime, the effect of sliding velocity and normal loads on the friction coefficient in the sheet metal stamping process was investigated using a pin-on-disk sliding wear test. Software was used to analyze both the data generated and the friction coefficient; in addition, a variable friction model based on different velocities and normal loads was also initiated. Under different experimental conditions and numerous influences, both the analysis and microtopography examination of sheet metal helped to obtain the mechanism influence on the friction coefficient. Through further analysis of the microtopography of sheet metal, the law of the surface roughness of sheet metal after grinding with stamping die was established. The model was established to simulate the thickness distribution and spring-back of U-bend parts using ABAQUS software. The results show that the friction coefficient values between the sheet metal and the stamping die generally decrease with increasing sliding velocity and normal loads, and the decreasing tendency slows down under a higher sliding velocity and normal load. Furrow wear and abrasive wear are the main wear mechanisms, with slight sticking wear under the boundary lubrication; the surface roughness after grinding with stamping die generally increases with increasing normal loads and decreasing sliding velocity. The predicted results of thickness distribution with a constant friction coefficient of 0.1 and with the variable friction coefficient model are more consistent with the actual measured values, but the predicted accuracy of spring-back in the variable friction coefficient model is higher than that of the constant friction coefficient model. Full article
(This article belongs to the Special Issue Computational Methods in Manufacturing Processes)
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14 pages, 17965 KiB  
Article
Simulation and Experiment of Manufacturing Process for Structural Aluminum Parts with Hard to Plastic Forming
by Chul Kyu Jin
Metals 2019, 9(2), 207; https://doi.org/10.3390/met9020207 - 10 Feb 2019
Viewed by 3988
Abstract
A process comprising a hot extrusion process and a warm forging process was designed to form an umbrella-shaped aluminum structural component with a high degree of difficulty for the plastic forming method. A circular cylindrical part was extruded with a hot extrusion process, [...] Read more.
A process comprising a hot extrusion process and a warm forging process was designed to form an umbrella-shaped aluminum structural component with a high degree of difficulty for the plastic forming method. A circular cylindrical part was extruded with a hot extrusion process, and then an embossing part was produced with a warm forging process. The formability and the maximum load required for forming were then determined using a forming analysis program. The hot extrusion process was executed at 450 °C under the extrusion speed at 6 mm/s, while the warm forging process was executed at 260 °C under the forging speed at 150 mm/s. The simulation results showed that the load required for hot extrusion was 1019 ton, while the load required for the warm forging was 534 ton. The umbrella-shaped part was manufactured by using a 1600 ton capacity press. The graphite lubricant was coated on the mold as well as the material. A forming experiment was performed under the same condition with the simulation condition. The portion where extrusion was done became elliptical with the α-Al phase elongated towards extrusion direction. Whereas, the α-Al phase became circular in the forged portion. The tensile strength value was found as 345 MPa, while elongation rate was 12%. Meanwhile, Vickers hardness value at the extruded portion was 105 HV, and it was 110 HV at the forged portion. Full article
(This article belongs to the Special Issue Computational Methods in Manufacturing Processes)
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8 pages, 1042 KiB  
Article
Elastic Properties of FeCr20Ni8Xn (X = Mo, Nb, Ta, Ti, V, W and Zr) Austenitic Stainless Steels: A First Principles Study
by Yuchen Dou, Hong Luo and Jing Zhang
Metals 2019, 9(2), 145; https://doi.org/10.3390/met9020145 - 29 Jan 2019
Cited by 7 | Viewed by 3679
Abstract
Austenitic stainless steels suffer from intergranular corrosion and stress corrosion cracking when exposed to elevated temperature (500–800 °C). Under these environments, Cr-carbides and Cr-carbontrides precipitate at the grain boundaries, which results in the formation of Cr-depleted zone. In practice, alloying elements could be [...] Read more.
Austenitic stainless steels suffer from intergranular corrosion and stress corrosion cracking when exposed to elevated temperature (500–800 °C). Under these environments, Cr-carbides and Cr-carbontrides precipitate at the grain boundaries, which results in the formation of Cr-depleted zone. In practice, alloying elements could be added into austenitic stainless steels to modify the precipitation processes. Besides the precipitation processes, the elastic properties of the iron matrix would be influenced. Using the exact muffin-tin orbitals (EMTO) method, the solute effects on the elastic properties of FeCr20Ni8 austenitic stainless steels were studied. Based on the simulated shear modulus (G) and bulk modulus (B), we proposed a design map for FeCr20Ni8 based alloys, aiming to provide a basis for the design of high-performance austenitic stainless steels. Full article
(This article belongs to the Special Issue Computational Methods in Manufacturing Processes)
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20 pages, 9373 KiB  
Article
Application of a GTN Damage Model Predicting the Fracture of 5052-O Aluminum Alloy High-Speed Electromagnetic Impaction
by Fei Feng, Jianjun Li, Peng Yuan, Qixian Zhang, Pan Huang, Hongliang Su and Rongchuang Chen
Metals 2018, 8(10), 761; https://doi.org/10.3390/met8100761 - 25 Sep 2018
Cited by 18 | Viewed by 4273
Abstract
An increasing demand exists within the automotive industry to utilize aluminum alloy sheets because of their excellent strength-weight ratio and low emissions, which can improve fuel economy and reduce environmental pollution. High-speed automobile impactions are complicated and highly nonlinear deformation processes. Thus, in [...] Read more.
An increasing demand exists within the automotive industry to utilize aluminum alloy sheets because of their excellent strength-weight ratio and low emissions, which can improve fuel economy and reduce environmental pollution. High-speed automobile impactions are complicated and highly nonlinear deformation processes. Thus, in this paper, a Gurson-Tvergaard-Needleman (GTN) damage model is used to describe the damage behavior of high-speed electromagnetic impaction to predict the fracture behavior of 5052-O aluminum alloy under high-speed impaction. The parameters of the GTN damage model are obtained based on high-speed electromagnetic forming experiments via scanning electron microscopy. The high-speed electromagnetic impaction behavior process is analyzed according to the obtained GTN model parameters. The shape of the high-speed electromagnetic impaction in the numerical simulations agrees with the experimental results. The analysis of the plastic strain and void volume fraction distributions are analyzed during the process of high-speed impact, which indicates the validity of using the GTN damage model to describe or predict the fracture behavior of high-speed electromagnetic impaction. Full article
(This article belongs to the Special Issue Computational Methods in Manufacturing Processes)
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