Sharif Digital Repository

Friction plays an important role in metal forming operations. Therefore, many techniques are developed for evaluation of friction in large deformation processes. Among them the "Barrel Compression Test" (BCT) is a very simple method that quantitatively evaluates the constant friction factor, m, simply by compressing a cylindrical specimen. BCT was analyzed by Avitzur [B. Avitzur, Metal Forming Processes and Analysis, McGraw-Hill, 1968] using the upper bound theory. Ebrahimi et al. [R. Ebrahimi, A. Najafizadeh, J. Mater. Process. Technol. 152 (2004) 136-143] suggested a method in order to make Avitzur's mathematical results applicable. However, they made an assumption in their work which... 

Welded sheets with different thicknesses are one of the interesting types of tailor-welded blanks (TWBs) that are widely used in metal-forming industries. In the present work, the formability behavior of different 1100-aluminum TWBs was studied. In this regard, the TWBs were made with different thickness ratios by using friction stir welding (FSW) at different welding rotational speeds (ω). The thickness ratios of 1.0, 1.3, and 1.7 were investigated where the thinner sheets had 1.5 mm thick for all conditions; i.e., the volume of welded material increased when the thickness ratio increased. Macrostructural observations, mechanical investigations, and sheet-forming limit tests were... 

An enhanced unfolding inverse finite element method (IFEM) is used together with an extended strain-based forming limit diagram (EFLD) to develop a fast and reliable approach to predict the feasibility of the deep drawing process of a part and determining where the failure or defects can occur. In the developed unfolding IFEM, the meshed part is properly fold out on the flat sheet and treated as a 2D problem to reduce the computation time. The large deformation relations, nonlinear material behavior and friction conditions in the blank holder zone are also considered to improve the accuracy and capability of the proposed IFEM. The extended strain-based forming limit diagram based on the... 

In this article, a robust algorithm for prediction of forming limit diagrams (FLD) has been presented. The presented model is based on the "Marciniak and Kuczynski" (M-K) theory. Solution to the system of equations has been obtained by applying the Newton's method. Since the Newton's method usually has nonconverging problem, a particular backtracking algorithm has been developed and applied. In this algorithm, a technique for step length selection in the frame of gradient descent method has been implemented. Also for the convergence criterion the so-called "Armijo" condition has been used. For verification of the results, BBC2000 yield function and Swift hardening law for AK steel metal have... 

In this paper residual stresses induced by butt metal arc gas welding (MAGW), in accordance with ASTM E837, are determined by hole drilling. The results are analyzed by probabilistic methods. Also, the effect of fatigue life on relaxation of welding residual stress is investigated. The specimens are tested to measure fatigue life and crack growth rates in accordance with ASTM E466 for force controlled amplitude axial fatigue testing. © 2008 Verlag Stahleisen GmbH, Düsseldorf  

Effort was made to characterise segregation tendency of mechanically stirred ZA27 alloy with back extrusion as a thixoforming process. At sufficiently high ram speeds, at which liquid phase flows forcefully, pooling of the heavy liquid phase owing to gravitational segregation contributes to homogeneity of back extruded products in terms of solid phase distribution, The amount of this contribution depends on the contact time of this liquid with solid skeleton during liquid exertion to the clearance. Hence, at high ram speeds, small rams which demand taller initial slugs are more efficient in minimising the segregation. However, in the case of low speed back extrusion tests, liquid impotency... 

Post-uniform deformation energy of materials is defined as absorbed energy per unit area after necking. The energy is constant for a material type and its experienced specific processing history and also depends on its mechanical parameters as workhardening exponent, strain rate sensitivity, post-necking extension and inhomogeneity factor. Different methods such as single and multiple tensile testing had been proposed in the literature to calculate tearing energy, but the effect of post-necking extension had not been expressed explicitly. A new model by implementing uniform and failure elongations with the combination of Unwin theory is introduced. Based on the model, it was shown that... 

The influence of sheet thickness on sheet metal forming limits is a controversial issue; while some investigations indicate the considerable influence of thickness on forming limit diagrams (FLDs), others suggest that it is of negligible importance. In the present work, it has been demonstrated that if the thickness-reduction process is chosen so as not to alter the micro structure of the material, the forming limits do not change with variations of thickness. A material which has extensive usage in sheet metal forming processes of automotive industry (St14) has been provided. The initial thickness of the sheet is 1.5mm and using grinding process (which does not alter the microstructure) the... 

The main drawback of the method proposed by Marciniak and Kuczynski for prediction of the limit strains in sheet metal forming processes is requirement of an experimental point of the forming limit curve (FLC) in order to calibrate the curve. The purpose of this work is to introduce a new method to calibrate the FLC using the M-K model in which no experimental data is needed. To achieve this goal, many experimental FLCs were collected from the literature and the values of the initial inhomogeneity factors were determined for them with trial and error aproach. Using these data, an empirical law was developed to predict the value of inhomogeneity factor. The resultant curves show good... 

In this paper, a new computational technique is presented based on the extended arbitrary Lagrangian-Eulerian finite element model (X-ALE-FEM) in plasticity forming of powder compaction. An arbitrary Lagrangian-Eulerian (ALE) technique is employed to capture the advantages of both Lagrangian and Eulerian methods and alleviate the drawbacks of the mesh distortion in Lagrangian formulation. In order to remove the limitation of the mesh conforming to the boundary conditions in this process, the extended finite element method (X-FEM) is implemented by incorporating discontinuous fields through a partition of unity method. The implementation of X-FEM technique in the framework of ALE model is... 

Intelligent deep-drawing is an instrumental research field in sheet metal forming. A set of 28 different experimental data have been employed in this paper, investigating the roles of die radius, punch radius, friction coefficients and drawing ratios for axisymmetric workpieces deep drawing. This paper focuses an evolutionary neural network, specifically, error back propagation in collaboration with genetic algorithm. The neural network encompasses a number of different functional nodes defined through the established principles. The input parameters, i.e., punch radii, die radii, friction coefficients and drawing ratios are set to the network; thereafter, the material outputs at two... 

This paper proposes an inverse isogeometric analysis to estimate the blank and predict the strain distribution in sheet metal forming processes. In this study, the same NURBS basis functions are used for drawing a final part and analysis of the forming process. In other words, this approach requires only one modeling and analysis representation, in contrast to inverse FEM. This model deals with minimization of potential energy, deformation theory of plasticity, and infinitesimal deformation relations with considering a new non-uniform friction model. One advantage of the presented methodology is that the governing equations are solved in two-dimensional space without concerning about... 

This current work considers the utilization of the completely Lagrangian technique, smoothed particle hydrodynamics to improve the 3D finite element model for numerical analysis of the friction stir welding (FSW) in the air and underwater conditions. This technique was primarily applied to simulate fluid motion because of various advantages compared to conventionally grid-based methods. Newly, its usage has been developed to analyze the metal-forming analysis. The temperature history, strain and stress distributions during the FSW process in the air, as well as underwater, were considered. Besides the cooling influence, the effect of traveling speed, friction coefficient, mesh size and the... 

An efficient isogeometric-based framework is presented to integrate optimum design and formability analysis of sheet metal forming processes. To assess the quality of the formed parts, several objective functions such as fracture, wrinkling, thickness variation, and stretching are studied. In this framework, geometric parameters of addendum surfaces and middle tools are considered as design variables, the objective functions are calculated using the recently developed one-step and multi-step inverse isogeometric methods, and the optimum design variables are obtained using the genetic global optimization algorithm. The major advantage of employing the inverse methods is to analyze the...