List of articles (by subject) metal forming
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Open Access Article
1 - Experimental Investigation of Maximum Achievable Convolution Height of Metallic Bellows in Hydroforming Process
Mehdi Safari Younes GhadiriThe manufacturing of metal bellows with high ratios of crown-to-root diameters is very sensitive to design parameters such as internal pressure inside the tube, axial force and movement, die-stroke length (distance of the dies) as well as the initial tube length. In thi MoreThe manufacturing of metal bellows with high ratios of crown-to-root diameters is very sensitive to design parameters such as internal pressure inside the tube, axial force and movement, die-stroke length (distance of the dies) as well as the initial tube length. In this paper, hydroforming process of a metallic bellows is investigated experimentally. For this purpose, the effects of internal pressure and die stroke on the maximum achievable convolution height and thickness distribution of hydroformed bellows is studied. The experiments are performed with different internal pressures such as 90, 110 and 130 bars and also in different die strokes such as 10, 12 and 14 mm. The results show that by increasing the die stroke, the range of allowable internal pressure to produce a metallic bellows without wrinkling or bursting decreases and manufacturing of the bellows becomes more difficult. It is extracted from results that with holding the die stroke value, very low internal pressures leads to wrinkling in the hydroformed bellows while very high internal pressures cause the excessive thinning. Also, it is concluded that by increasing both internal pressure and die stroke the convolution height of manufactured bellows is increased. It is proved that the maximum thickness reduction is occurred at the crown point of hydroformed bellows. Manuscript profile -
Open Access Article
2 - Impact of Loading Rate in Hot Tube Gas Forming of AA6063
Mastafa Rajaee Seyed Jamal Hosseinipour Hamed Jamshidi AvalIn this paper, the manufacturing of a cylindrical AA6063 step tube via hot metal gas forming (HMGF) process is studied both experimentally and numerically. The goal is to investigate the effect of loading rate on the specimen profile and thickness distribution. ABAQUS f MoreIn this paper, the manufacturing of a cylindrical AA6063 step tube via hot metal gas forming (HMGF) process is studied both experimentally and numerically. The goal is to investigate the effect of loading rate on the specimen profile and thickness distribution. ABAQUS finite element software is used for the numerical simulation. Experiments were carried out at 580°C in two conditions; first, without axial feeding and then with an axial feeding of 14 mm at a maximum pressure of 0.5 MPa. The studied parameters are the pressure rate and the axial feeding rate. The results show that in the non-axial feeding mode, the thickness distribution in the die cavity region was non-uniform and a rupture occurred at a pressure of 0.6 MPa. The reduction of the pressure rate has no significant effect on the rupture pressure. In the case of axial feeding, by choosing the pressure rate of 0.001 MPa/s and the axial feeding rate of 0.1 mm/s, wrinkling has been created in the specimens. However, at a pressure rate of 0.005 MPa/s and an axial feeding rate of 0.02 mm/s, the specimens are raptured. Under low pressure rate of 0.001 MPa/s and low axial feeding rate of 0.02 mm/s, the thickness in the die cavity area has decreased. A suitable die filling and thickness distribution are obtained at a pressure rate of 0.005 MPa/s and axial feeding rate of 0.1 mm/s. Manuscript profile -
Open Access Article
3 - Multi-Objective Optimization of Loading Paths for Double-Layered Tube Hydroforming using Finite Element Analysis
Hamed Ebrahimi Keshmarzi Ramin Hashemi Reza MadoliatOne of the most important studies in tube hydroforming process is optimization of loading paths. The primary purpose of this research is to maximize formability by detecting the optimal forming parameters. The most significant settings in the prosperity of tube hydrofor MoreOne of the most important studies in tube hydroforming process is optimization of loading paths. The primary purpose of this research is to maximize formability by detecting the optimal forming parameters. The most significant settings in the prosperity of tube hydroforming process, are internal pressure and end axial feed (i.e., load path). In this paper, a finite element analysis was performed for a double-layered tube hydroforming process using the ABAQUS/Explicit software. Then, the finite element model has been verified with published experimental data. Using design of experiments (DOE) working with the Taguchi method, 32 loading paths are designed for optimization. All 32 loading paths are modelled using the finite element method in ABAQUS/Explicit and the magnitudes of bulge height and the total thickness of tubes at the branch tip are obtained in each loading path. The regression analysis is carried out to estimate the tubes formability and obtain objective functions that are bulge height and the total thickness of tubes at the protrusion peak as functions of loading parameters (internal pressure and axial feed). For solving the multi-objective optimization problem, the non-dominated sorting genetic algorithm II (NSGA-II) is utilized and the optimum results were obtained from the Pareto optimal front. Finally, the optimized loading path was applied to the finite element model and better formability (3.4% increase in the bulge height) has been achieved in the results. Manuscript profile -
Open Access Article
4 - Optimal Design of Steppers in Single Step High Pressure Torsion (SIHPT) Process as a Novel SPD Method
Mehdi Eskandarzadeh Ghader Faraji A. Masoumi Ali KalakiSingle Step High Pressure Torsion (SIHPT) is a newly developed HPT based method for processing of materials which is capable of producing nanostructured long samples with characteristics comparable to conventional HPT process. While, conventional HPT can be applied only MoreSingle Step High Pressure Torsion (SIHPT) is a newly developed HPT based method for processing of materials which is capable of producing nanostructured long samples with characteristics comparable to conventional HPT process. While, conventional HPT can be applied only on thin samples; it is possible to produce nanostructured parts with about 10 cm long using SIHPT method. However, SIHPT needs some technical improvements in order to be used for production in industrial scale. One of key component of SIHPT is the steppers which help different sections of the sample to be twisted. This study investigates main parameters of Steppers including the corner radius, thickness and rotation speed. The experimental results revealed that for the lowest length of sample’s contact inside the Steppers (lower contact length) of 5mm; there is considerable slippage in pressures below 1GP. However, the amount of slippage decreases gradually by increasing the magnitude of the applied pressure and the amount of the lower contact length. Moreover, it found that the rotational speed influences the amount of slippage in low pressures (lower than 1 GPa) but not in high pressures. In addition, according to Finite Element (FE) analysis it was found that 1 mm corner radius of steppers is the optimal value for the SIHPT process. Manuscript profile -
Open Access Article
5 - Multi-Objective Optimization of the Stamping of Titanium Bipolar Plates for Fuel Cell
Vahid Modanloo Vali Alimirzaloo Majid ElyasiHigh demands of quality development in the industry especially automotive, necessitates multi-objective optimization of the manufacturing processes. Fuel cells are one of the most important sources of renewable energies that Bipolar Plates (BPPs) are their main componen MoreHigh demands of quality development in the industry especially automotive, necessitates multi-objective optimization of the manufacturing processes. Fuel cells are one of the most important sources of renewable energies that Bipolar Plates (BPPs) are their main components. Metallic BPPs are known as a suitable replacement of the graphite plates due to their lower weight and cost. Accordingly, this study employs Multi-Criteria Decision Making (MCDM) methods to determine the best forming condition in the stamping of titanium BPP. In the first step, the process is analyzed using the Finite Element (FE) simulation. Afterward, validation of the FE model is confirmed by performing the experiments using titanium ultra-thin sheet with a thickness of 0.1 mm. Subsequently, a set of tests with 15 experiments are assumed to be as alternatives. In addition, filling ratio, thinning ratio and forming load are considered as different criteria. In order to select the optimum condition considering three mentioned responses simultaneously, TOPSIS and VIKOR methods are applied. In addition, a weighting procedure combining AHP and Entropy approaches is used. Based on the weighting results, the highest and lowest weights were obtained for filling ratio (0.5398) and forming load (0.1632), respectively. Likewise, a Spearman’s rank equal to 0.9357 was obtained that demonstrates high compatibility between TOPSIS and VIKOR methods. Overall, the best (optimum) forming condition has obtained an experiment with a clearance of 0.2 mm, the speed of 3.5 mm/s, and friction coefficient as 0.2. Manuscript profile -
Open Access Article
6 - Fabrication of a Complicated Specimen with Two Point Incremental Forming Process
Mehdi Safari Jalal JoudakiManufacturing of complicated industrial components is one of the main challenges for mechanical engineers in sheet metal forming processes. Incremental sheet metal forming (ISMF) is used widely for forming complicated shapes by a single rotating tool. This paper examine MoreManufacturing of complicated industrial components is one of the main challenges for mechanical engineers in sheet metal forming processes. Incremental sheet metal forming (ISMF) is used widely for forming complicated shapes by a single rotating tool. This paper examines the experimental investigation of two-point incremental forming of a complicated specimen made of AA3105 aluminum alloy. The part shape consists of positive and negative cavities and the shape complexity limits the manufacturing process to two-point incremental forming process (TPIF). In addition, the effects of selected process parameters such as forming depth in each increment of process, tool rotational speed and various forming patterns on thickness distribution and thinning percentage of specimen are investigated. The forming pattern includes the sequence of forming the cavities (Internal/External pattern and External/Internal pattern). The main finding of the study can be expressed that the thinning ratio of manufactured specimen is increased with an increase in the forming depth in each increment of TPIF. Also, the higher rotational speed leads to a reduction in the thinning of the fabricated specimen. The results prove that the use of Internal/External forming pattern leads to reduction in the thinning of the manufactured specimen. Manuscript profile -
Open Access Article
7 - High-Velocity Compaction of Aluminum Powder by Gas Detonation Forming Technique
Tohid Mirzababaie Mostofi Mostafa Sayah Badkhor Hashem BabaeiIn this paper, a large-scale experimental study has been conducted in order to evaluate the high-velocity compaction of aluminum powder using Gas Detonation Forming (GDF) processing technique. In this series of experiments, the effect of the distribution of grain partic MoreIn this paper, a large-scale experimental study has been conducted in order to evaluate the high-velocity compaction of aluminum powder using Gas Detonation Forming (GDF) processing technique. In this series of experiments, the effect of the distribution of grain particle size, initial powder mass, and loading conditions on green density and strength of compacted products were thoroughly studied. The maximum relative green density and green strength of 97.6% and 17.9% were achieved. Group Method of Data Handling (GMDH)-type neural network in conjunction with Singular Value Decomposition (SVD) method was exerted to model the high-velocity compaction process of aluminum powder. The main objective of this idea is to demonstrate how two characteristics of the high-velocity compaction, namely, the relative green density and strength of products vary with the changing of significant parameters, involved in GDF processing technique. Manuscript profile -
Open Access Article
8 - Influences of Blank Holder Force in The Multi-Step Deep Drawing Process of Aluminum Sheets
Sajad Bakhtiari Seyed Jalal Hashemi Amir Hossein RoohiIn recent decades, the use of aluminium alloys is developed in the automotive industry with regard to the need for lightweight and anti-corrosion components, one of which is AA7075 Al alloy. In this study, the multi-step deep drawing process of AA7075 aluminium sheets u MoreIn recent decades, the use of aluminium alloys is developed in the automotive industry with regard to the need for lightweight and anti-corrosion components, one of which is AA7075 Al alloy. In this study, the multi-step deep drawing process of AA7075 aluminium sheets under various blank holder forces is investigated through a numerical simulation and is then validated with experimental results. Simulations were conducted by ABAQUS finite element software, and the influences of the blank holder force on the wrinkling height, rupture occurrence and thickness distribution of the sheet were studied. The optimum amount of blank holder force at each drawing step is determined so that the height of wrinkling, and the thinning percentage do not exceed the permissible value. Based on the results, the blank holder force magnitude should be considered descending during the four successive steps to achieve more uniform thickness distribution, and also the wrinkling height could be reduced by increasing the blank holder force in the analysed force range. The optimum amount of blank holder force in the four drawing steps was 28000, 2500, 1500 and 600 N, respectively. In general, the minimum thickness was created in the corner of the punch. The results also showed that an excessive increase in the blank holder force in order to eliminate the wrinkling caused the thinning percentage to increase. Finally, a good accordance between the experimental and numerical results was observed. Manuscript profile -
Open Access Article
9 - Hole-flanging of 2205 Dual-Phase Steel using Incremental Forming Process
Amir H. Roohi Seyed Jalal HashemiIn this study, hole-flanging of a dual-phase steel sheet is conducted using incremental forming approach. In this process, a hole with a certain diameter is pre-cut on a sheet. Then, this hole is transformed into a cylindrical flange shapes, by contacting the forming to MoreIn this study, hole-flanging of a dual-phase steel sheet is conducted using incremental forming approach. In this process, a hole with a certain diameter is pre-cut on a sheet. Then, this hole is transformed into a cylindrical flange shapes, by contacting the forming tool with the hole edges. During the process, the tool is moved in spiral paths. The parameters affecting the height and thickness distribution of the formed flange include axial step, radial step, and rotational speed of the tool. Results show that the axial step has the most significant effect on the process, among other parameters; when the axial step is tripled, the flange thickness increases by 19%. On the other hand, a decrease in the radial step decreases the flange edge thickness. When the radial step is tripled, the flange thickness increases by 8%, while the flange height decreases about 3%. Manuscript profile -
Open Access Article
10 - Experimental Investigation on Process Parameters of Dissimilar Double-Layered Wire Produced by Modified Friction Stir Extrusion Process
Masoud Yavari Nouri S. M. Hossein Seyedkashi Moosa SajedIn this paper, a new production method of aluminium/steel double-layered wire is proposed using a modified friction stir extrusion process. The core and coating were made of St37 steel and aluminium alloy, respectively. For extruded specimens, the effects of the main pr MoreIn this paper, a new production method of aluminium/steel double-layered wire is proposed using a modified friction stir extrusion process. The core and coating were made of St37 steel and aluminium alloy, respectively. For extruded specimens, the effects of the main process parameters including tool rotational speed and feed rate were investigated on adhesion strength and surface cracks. The tool rotational speed was studied at two levels of 300 and 600 rpm, and the feed rate at two levels of 4 and 12 mm/min. Pull-out test was carried out using a tensile test machine to evaluate the adhesion strength. Surface cracks were evaluated by the liquid penetrant test. The results suggest that the modified friction stir extrusion process can be used successfully to produce dissimilar double-layered wires. With the right combination of tool rotational speed and feed rate levels, a dissimilar double-layered wire can be produced with a high adhesion strength and good surface quality. No cracks were observed in specimens produced with the feed rate of 12 mm/min and rotational speed of 600 rpm. The maximum adhesion strength was 2867.13 N that was achieved with a tool rotational speed of 300 rpm and feed rate of 12 mm/min. Manuscript profile -
Open Access Article
11 - Stress and Strain Analysis in Cup Drawing Process for Different Materials using ANSYS Software
siva prasad kondapalli GURRAM RAVITEJASheet metal forming is widely used in automotive and aerospace industry. In this paper analysis of sheet metal forming process by deep drawing was discussed. Static analysis on the deep drawing operation was carried out to find the stresses, strains and total deformatio MoreSheet metal forming is widely used in automotive and aerospace industry. In this paper analysis of sheet metal forming process by deep drawing was discussed. Static analysis on the deep drawing operation was carried out to find the stresses, strains and total deformation of deep drawing cup. CAD models are generated using CATIA from the dimensions obtained by theoretical calculations and analysis is carried out using ANSYS software. The force required to develop the cup, deformation and defect like tearing, wrinkles etc. can be obtained through simulation. By using this method it is easy to make stress and strain analysis for different materials. From the analysis it is observed that Titanium has the maximum stress with standing ability when compared to copper and Aluminum. Manuscript profile -
Open Access Article
12 - Experimental Analysis of Effective Parameters on the Bowing Defect of Symmetrical U-Section in Roll Forming Production
Amin Poursafar Saeid Saberi Rasoul Tarkesh Esfahani Meisam Vahabi Javad Jafari FesharakiThe roll forming process plays a critical role in producing various sections used in industries. Also, the quality of these products is strongly affected by the thickness of the strip, the distance between stands, the section web, the flower pattern, and the plastic ani MoreThe roll forming process plays a critical role in producing various sections used in industries. Also, the quality of these products is strongly affected by the thickness of the strip, the distance between stands, the section web, the flower pattern, and the plastic anisotropy. Therefore, the influences of practical factors on the bowing defect of the symmetrical U-section are experimentally and mathematically characterized in the present research. The investigated material is DC03 (1.0347) steel. Different prediction models such as linear and non-linear model based on the general full-factorial design of experiment are used to predict the effect of following factors on the bowing defect. Accuracy of the analytical model was verified by comparing the output results with the practical data. Results show that the strip thickness of investigated material, the flower pattern, and the section web have the most significant effect on the bowing defect. Also, the anisotropic properties of the investigated material and the inter distance have the minor impact on the bowing defect, but the effect of material with considering the anisotropic properties on increasing the accuracy of process simulation results is very impressive and increases the accuracy of simulation results from 84% to 91%. Finally, the predicted bowing defect using the modified two-factor model was in 91% agreement with the experimental results. Manuscript profile -
Open Access Article
13 - Numerical Simulation of Hot Forging Process of KIA Car Brake’s Output Shaft
saeid Hashemian Peyman Mashhadi Keshtiban Abuzar Es'haghi OskuiThe present study investigates the production process by closed die forging method of one of the sensitive and safe parts of KIA car brake, which is affected by various mechanical and thermal stresses in its operating conditions; therefore, in the present research, the MoreThe present study investigates the production process by closed die forging method of one of the sensitive and safe parts of KIA car brake, which is affected by various mechanical and thermal stresses in its operating conditions; therefore, in the present research, the application of this forming method in the Iranian automotive industry has been discussed. In this study, an attempt was made using finite element analysis in ABAQUS software to determine the maximum force required for forging this part. In addition, the influence of various parameters such as the temperature of the part during the forming process, the coefficient of friction between the part and the die, as well as the strain rate have been investigated. The results indicated that the friction coefficient has a significant effect on the maximum required force, and the maximum values of the load increase with increasing the friction coefficient; but the remarkable result is that the effect of this coefficient is negligible from a value onwards. This point is consistent with the observations in practice. Besides, a strong dependence of the results on the loading speed was observed, and the required force has increased with increasing loading speed for reasons such as the strain hardening phenomenon. Also, the force required for forging has decreased with increasing the temperature, which is due to reduced material strength. This reduction from 900°C to 1000°C is less than 2%, while it is approximately 40% from 1000°C to 1100°C, which is consistent with the experimental reports. Manuscript profile -
Open Access Article
14 - Strength Improvement of Nano-Structured Titanium Processed by Parallel Tubular Channel Angular Pressing
Ali Amani Hamid Soleimanimehr Shahram Etemadi Haghighi Farid BiniyazanParallel Tubular Channel Angular Pressing (PTCAP), as a process of Severe Plastic Deformation (SPD), was employed for improving the strength of commercially pure Titanium (Grade 2). In the present research, the tubular samples of pure titanium were severely deformed by MoreParallel Tubular Channel Angular Pressing (PTCAP), as a process of Severe Plastic Deformation (SPD), was employed for improving the strength of commercially pure Titanium (Grade 2). In the present research, the tubular samples of pure titanium were severely deformed by one and two passes of PTCAP at the temperature of 450°C. It was found by the results of tensile tests that the yield and ultimate strengths increased by 24% and 29% after applying the second pass of PTCAP, respectively. It was also showed that the Vickers microhardness increased by 46%. Moreover, the micrographs illustrated that the average grain size decreased from ∼21 μm in the unprocessed condition to ∼143 nm after applying two PTCAP passes. Therefore, applying the technique of PTCAP was successful to produce the nano-structured titanium. Manuscript profile