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Advances in Design and Manufacturing in Die Casting and Metal...
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Advances in Design and Manufacturing in Die Casting and Metal Forming

A special issue of Machines (ISSN 2075-1702). This special issue belongs to the section "Material Processing Technology".

Deadline for manuscript submissions: 30 June 2025 | Viewed by 2957

Special Issue Editors

Dr. Alberto Vergnano

E-Mail Website
Guest Editor
Enzo Ferrari Department of Engineering, University of Modena and Reggio Emilia, Modena, Italy
Interests: actuation systems and control for autonomous driving of vehicles; simulation based design; design and optimization methods of multi-physics systems and foundry equipment; human-intelligent system integration; design and prototyping of ADAS systems for comfort and safety; integrated simulation methods (virtual commissioning) of mechatronic systems; methods for energy saving in robotic systems; design for X; design for manufacturing and design for assembly; design for recycle; design for re-manufacturing
Prof. Dr. Paolo Veronesi

E-Mail Website
Guest Editor
Enzo Ferrari Department of Engineering, University of Modena and Reggio Emilia, Via P. Vivarelli 10, 41125 Modena, Italy
Interests: metallurgy; thermal applications of microwaves to metals; electromagnetic modeling; composite materials and refractory materials
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The final performance of products as well as their economic and environmental sustainability result from the integrated design of parts and related manufacturing processes. In particular, die casting and metal forming manufacturing are pivotal processes that are integral to the production of parts in, for example, the automotive, construction, aerospace, and electronics industries, amongst others. This is becoming more and more important nowadays, seeking resource efficiency towards near net shape production. Recent advances in design methods, simulation techniques, process modeling, material science, and tooling technology have led to remarkable improvements in product quality, efficiency, and sustainability. This Special Issue aims to highlight the latest research and developments in die casting and metal forming manufacturing, along with part design and optimization by taking into account manufacturability constraints, providing a platform for researchers and practitioners to disseminate their latest findings and innovations in these fields. Of particular interest are original contributions that demonstrate a successful application for improvement in resource efficiency.

Research topics that are of interest for this Special Issue include, but are not limited to, the following:

  • Novel die casting techniques and technologies;
  • Advanced forming processes and techniques;
  • Resource efficiency;
  • Energy saving;
  • Integrated part and process design;
  • Process modeling, simulation, and optimization;
  • Industry 4.0 applications;
  • Advanced materials and alloys;
  • Tooling design and innovations;
  • Surface treatment and finishing of die equipment;
  • Quality control and inspection methodologies;
  • Surface engineering and coatings; 
  • Case studies and applications in specific industries.

Prof. Dr. Alberto Vergnano
Prof. Dr. Paolo Veronesi
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. Machines 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 2400 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

  • die casting
  • metal forming manufacturing
  • integrated part and manufacturing process design
  • resource efficiency
  • net shape production
  • manufacturing equipment design
  • design by simulation
  • optimization techniques

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Further information on MDPI's Special Issue polices can be found here.

Published Papers (4 papers)

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Research

14 pages, 7651 KiB  
Article
Optimization of Motor Rotor Punch Wear Parameters Based on Response Surface Method
by Shaobo Wen, Ran She, Zhendong Zhao and Yipeng Gong
Machines 2024, 12(10), 671; https://doi.org/10.3390/machines12100671 - 25 Sep 2024
Viewed by 545
Abstract
To reduce the wear of the motor rotor punching punch and ensure the efficiency is the highest in actual production, the finite element analysis software Deform-3Dv11 is used to simulate the punch wear based on the Archard model theory. With punch wear as [...] Read more.
To reduce the wear of the motor rotor punching punch and ensure the efficiency is the highest in actual production, the finite element analysis software Deform-3Dv11 is used to simulate the punch wear based on the Archard model theory. With punch wear as the response target and punch speed, punch clearance, and punch edge fillet as the main factors, 17 groups of response surface Box–Behnken test designs are established, as well as a quadratic polynomial regression model between the main factors and the response. The results revealed that: the influence of various parameters on punch wear is in the order of punch edge fillet C > punch clearance B > punch speed A; the order of the interactive influence of various factors is as follows: punch speed and punch edge fillet AC > punch speed and punch clearance AB > punch clearance and punch edge fillet BC. The optimal blanking process combination obtained by using Design-Expert13 software is as follows: blanking speed 50 mm/s, blanking clearance 0.036 mm, and die cutting edge rounded corner 0.076 mm; the predicted response surface value is 6.95 × 10−12 mm. Through simulation verification, the actual optimized simulation value is 6.93 × 10−12 mm, with an absolute relative error of 2.5% for the predicted response value. Moreover, the optimized simulation value is reduced by 30.4% compared to the one before optimization, effectively reducing the punch wear of the motor rotor punching forming and providing a theoretical foundation for further wear optimization. Full article
(This article belongs to the Special Issue Advances in Design and Manufacturing in Die Casting and Metal Forming)
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10 pages, 7927 KiB  
Article
Double-Sided Surface Structures with Undercuts on Cold-Rolled Steel Sheets for Interlocking in Hybrid Components
by Aron Ringel, Sindokht Shayan and David Bailly
Machines 2024, 12(8), 562; https://doi.org/10.3390/machines12080562 - 16 Aug 2024
Viewed by 414
Abstract
Weight reduction strategies are essential for the transportation sector to reduce greenhouse gas emissions or extend the range of electric vehicles. In the field of lightweight assembly strategies, multi-material design offers great potential. Joining materials typically used in the automotive sector, such as [...] Read more.
Weight reduction strategies are essential for the transportation sector to reduce greenhouse gas emissions or extend the range of electric vehicles. In the field of lightweight assembly strategies, multi-material design offers great potential. Joining materials typically used in the automotive sector, such as aluminum and steel, brings challenges as conventional processes such as fusion welding are unsuitable. Therefore, new technologies can extend the design options. In previous studies, a mechanical interlocking between cold-rolled surface structures with undercuts on a steel sheet and die-cast aluminum was presented. This method has now been extended to double-sided structures for more complex applications with a joint on both sheet surfaces. Numerical simulations and validation experiments were performed to investigate the manufacturing of the double-sided structures. Furthermore, the influence of the alignment of the upper and lower structures in relation to each other on the resulting structural geometry and the rolling forces were analyzed. More advantageous geometric parameters, e.g., 24% larger undercuts, and approx. 24.1% lower forming forces at 20% height reduction were observed for a shifted alignment. However, significantly higher wear of the structured rollers occurred in the corresponding experiments. Full article
(This article belongs to the Special Issue Advances in Design and Manufacturing in Die Casting and Metal Forming)
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16 pages, 14166 KiB  
Article
Identification of Heat Transfer Parameters for Gravity Sand Casting Simulations
by Alberto Vergnano, Pietro Facondini, Nicolò Morselli, Paolo Veronesi and Francesco Leali
Machines 2024, 12(6), 414; https://doi.org/10.3390/machines12060414 - 17 Jun 2024
Viewed by 622
Abstract
Gravity sand casting simulations require accurate modelling of heat transfer phenomena to reliably evaluate the expected quality of the produced parts. Average model parameters can be easily retrieved from a validated database. However, these parameters are highly dependent on the specific sand used [...] Read more.
Gravity sand casting simulations require accurate modelling of heat transfer phenomena to reliably evaluate the expected quality of the produced parts. Average model parameters can be easily retrieved from a validated database. However, these parameters are highly dependent on the specific sand used and the actual forming process in the foundry. Furthermore, the heat transfer from the solidifying alloy to the mould surfaces is not precisely known, so simulation models usually use typical values for overall heat transfer coefficients. Most research works investigate individual parameters, whereas heat transfer phenomena largely arise from their interaction together. Therefore, the present work describes a combined experimental and computational method based on genetic algorithm techniques for determining the most important parameters for heat transfer in a sand mould. The experiments examine both virgin and reused sand, as these are alternatively used in the foundry for mould forming. The density, thermal conductivity, and specific heat capacity of the different sands are identified, along with heat transfer coefficients. The counterproof simulations demonstrate that the standard parameters are quite reliable for virgin sand. However, in the case of reused sand, the identified parameters lead to more reliable results. Full article
(This article belongs to the Special Issue Advances in Design and Manufacturing in Die Casting and Metal Forming)
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17 pages, 5327 KiB  
Article
Investigation on the Torsional–Flexural Instability Phenomena during the Bending Process of Hairpin Windings: Experimental Tests and FE Model Validation
by Valerio Mangeruga, Saverio Giulio Barbieri, Matteo Giacopini, Fabrizio Giuradei, Piermaria Vai and Chris Gerada
Machines 2024, 12(6), 396; https://doi.org/10.3390/machines12060396 - 10 Jun 2024
Viewed by 842
Abstract
Modern electric motors developed for the automotive industry have an ever higher power density with a relatively compact size. Among the various existing solutions to improve torque and power density, a reduction in the dimensions of the end-windings has been explored, aiming to [...] Read more.
Modern electric motors developed for the automotive industry have an ever higher power density with a relatively compact size. Among the various existing solutions to improve torque and power density, a reduction in the dimensions of the end-windings has been explored, aiming to decrease volume, weight, and losses. However, more compact end-windings often lead to complex shapes of the conductors, especially when preformed hairpin windings are considered. The rectangular cross-section of hairpin conductors makes them prone to deviating out of the bending plane during the forming process. This phenomenon, known as torsional–flexural instability, is influenced by the specific aspect ratio of the cross-section dimensions and the bending direction. This study focuses on understanding this instability phenomenon, aiming to identify a potential threshold of the cross-section aspect ratio. The instability makes it difficult to predict the final geometry, potentially compromising the compliance with the geometric tolerances. A finite element model is developed to analyse a single planar bend in a hairpin conductor. Various cross-section dimensions with different aspect ratios are simulated identifying those that experience instability. Moreover, an experimental campaign is conducted to confirm the occurrence of instability by testing the same single planar bending. The experimental data obtained are used to validate the finite element model for the tested dimensions. The aim is to provide designers with a useful tool to select hairpin geometries that are more suitable for the folding process, contributing to successful assembly and improving the overall design process of preformed hairpin conductors. Full article
(This article belongs to the Special Issue Advances in Design and Manufacturing in Die Casting and Metal Forming)
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