scholarly journals Asymmetrical Rolling of Aluminum Alloys and Steels: A Review

Metals ◽  
2020 ◽  
Vol 10 (9) ◽  
pp. 1126 ◽  
Author(s):  
Gabriela Vincze ◽  
Fábio J.P. Simões ◽  
Marilena C. Butuc
Keyword(s):  
Aluminum Alloys ◽  
Low Cost ◽  
Angular Speed ◽  
Thickness Reduction ◽  
Speed Ratio ◽  
Metallic Materials ◽  
Asymmetric Rolling ◽  
Forming Process ◽  
Metal Forming Process ◽  
Pros And Cons

Asymmetric rolling is an attractive metal forming process due to its simplicity, low cost and capability to produce unique characteristics in materials. The asymmetry promoted by the process leads to a formation of a large collection of texture components and a refined structure which is capable to improve the mechanical behavior of metallic materials. The aim of this work is to present a perspective of the process and to construct the bases for future development and application of this technique. Thus, several aspects are addressed such as process methods (i.e., dissimilarity of the rolls diameters, rolls angular speed or friction conditions), the process parameters (i.e., total thickness reduction, thickness reduction per pass, peripheral speed ratio, rolling routes) and their effect on material properties, including texture and microstructure evolution, and mechanical properties. This review is focused on the experimental description of asymmetric rolling applied to aluminum alloys and steels. Although the asymmetric rolling application was mostly at a laboratory scale, there is a good perspective for its implementation in the industry. The pros and cons based on the up to date literature and authors’ experience are presented and discussed.

A Two-Pronged Approach for the Assessment of Springback Variability for Sheet Metal Forming Applications

2013 ◽  
Vol 554-557 ◽  
pp. 957-965 ◽  
Author(s):  
Jérémy Lebon ◽  
Guénhaël Le Quilliec ◽  
Rajan Filomeno Coelho ◽  
Piotr Breitkopf ◽  
Pierre Villon
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Numerical Models ◽  
Low Cost ◽  
Forming Process ◽  
Metal Forming Process ◽  
Small Random Perturbations ◽  
Complex Phenomena ◽  
Bending Under Tension

Springback assessment for sheet metal forming processes is a challenging issue which requires to take into account complex phenomena (physical non linearities and uncertainties). We highlight that the stochastic analysis of metal forming process requires both a high precision and low cost numerical models and propose a two-pronged methodology to address these challenges. The deep drawing simulation process is performed using an original low cost semi-analytical approach based on a bending under tension model with a good accuracy for small random perturbations of the physical and process parameters. The springback variability analysis is performed using an efficient stochastic metamodel, namely a sparse version of the polynomial chaos expansion.

scholarly journals Study On The Single Point Incremental Sheet Forming of AISI 321 Variable Wall Angle Geometry

2021 ◽  
Author(s):  
Muhammad Jawad Afzal ◽  
Asif Israr ◽  
Muhammad Soban Akram ◽  
Abdul Muqeet
Keyword(s):  
Low Cost ◽  
Single Point ◽  
Cnc Machine ◽  
Forming Process ◽  
Wall Angle ◽  
Metal Forming Process ◽  
Clamping System ◽  
Variable Wall ◽  
Aisi 321 ◽  
Wall Geometry

Abstract For rapid prototyping, design validation and small batch productions process with low tooling cost is preferred. Single Point Incremental Forming (SPIF) is a die-less sheet metal forming process which requires only low cost forming tool driven by CNC machine in a toolpath to form required geometry at room temperature from sheet blank clamped in a low cost and low stiffness clamping system. In this study, effect of process parameters such as tool radius, feed rate and lubrication are considered on the formability of the truncated profile of AISI 321 Variable Wall Geometry (VWA). Set parameters conditions with 2 level layers are optimized using numerical and statistical approach. Experimentation on the same setup is carried out by selecting the most, least and mid favorable solutions optimized on the basis of forming forces and stresses in the sheet. Geometrical accuracy, sheet thinning, and forming forces are compared analytically, numerically and experimentally addressing the inadequacy of analytically models for Variable Wall Angle Geometries.

scholarly journals Low-cost metal-forming process using an elastic punch and a reconfigurable multi-pin die

2018 ◽  
Vol 12 (3) ◽  
pp. 391-401 ◽  
Author(s):  
Ali Elghawail ◽  
Khamis Essa ◽  
Mohamed Abosaf ◽  
Abror Tolipov ◽  
Shizhong Su ◽  
...  
Keyword(s):  
Metal Forming ◽  
Low Cost ◽  
Forming Process ◽  
Metal Forming Process ◽  
Elastic Punch

scholarly journals PROCESS SIMULATION AND QUALITY EVALUATION IN INCREMENTAL SHEET FORMING

2011 ◽  
Vol 12 (3) ◽  
Author(s):  
Meftah Hrairi ◽  
Salah B. M. Echrif
Keyword(s):  
Wall Thickness ◽  
Metal Forming ◽  
Tool Path ◽  
Incremental Forming ◽  
Low Cost ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Metal Forming Process ◽  
Complex Parts

Single Point Incremental Forming (SPIF) is a promising sheet-metal-forming process that permits the manufacturing of small to medium-sized batches of complex parts at low cost. It allows metal forming to work in the critical ‘necking-to-tearing' zone which results in a strong thinning before failure if the process is well designed. Moreover, the process is complex due to the number of variables involved. Thus, it is not possible to consider that the process has been well assessed; several remaining aspects need to be clarified. The objective of the present paper is to study some of these aspects, namely, the phenomenon of the wall thickness overstretch along depth and the effect of the tool path on the distribution of the wall thickness using finite element simulations.Abstrak: Pembentukan Tokokan Mata Tunggal (Single Point Incremental Forming (SPIF)) merupakan satu proses pembentukan kepingan logam yang membolehkan pembuatan dalam jumlah yang kecil hingga sederhana, bahagian-bahagian yang kompleks pada kos yang rendah. Jika proses ini direka dengan baik, kaedah ini membolehkan pembentukan logam yang baik terhasil. Jika tidak, semasa peringkat zon kritikal ‘perleheran-ke-pengoyakan' menyebabkan penipisan keterlaluan yang boleh menyebabkan logam tersebut rosak. Tambahan pula, proses ini agak kompleks, kerana ia melibatkan beberapa pemboleh ubah. Maka, walaupun proses ini telah dinilaikan seeloknya; masih terdapat beberapa aspek lain yang perlu diperjelaskan. Objektif kertas ini dibentangkan adalah untuk mengkaji beberapa aspek tertentu, seperti, ketebalan dinding regangan berlebihan di sepanjang kedalaman dan kesan tool path (beberapa siri posisi koordinat untuk menentukan pergerakan alatan memotong ketika operasi memesin) terhadap pengagihan ketebalan dinding menggunakan simulasi unsur terhingga.

scholarly journals An Extensive Review on Advance Forming Methods

2020 ◽  
Vol 5 (1) ◽  
pp. 42-48
Author(s):  
Praveen Kumar ◽  
◽  
Tushar Gandhi ◽  
Vaibhav Chandra ◽  
Keyword(s):  
Low Cost ◽  
High Energy ◽  
Laser Forming ◽  
Forming Process ◽  
Major Work ◽  
New Methods ◽  
Metal Forming Process ◽  
Hydroforming Process ◽  
High Energy Absorption ◽  
Forming Methods

Giving it a shape and making it a useful component defines the process of forming. Years of research have given new methods to this process. In various industries like automobile and aeronautics, the goal is to achieve complicated shapes with properties like high energy absorption, high rigidity at a lower cost. These aspects can be achieved by Advance Forming Methods (AFM), major work is being done on the hydroforming process as this process provide shapes that otherwise require a greater number of processes. The idea of flexible forming is something where the efforts are reduced along with a number of trials by introducing rubber pads into the sheet metal forming process and the complexity of tool design automatically reduces. Other than these processes, the process of rapid prototyping which is incorporated in the laser forming process is being used in the fabrication of metallic components. The areas of work which is being done are to reduce the number of failures by optimizing the process parameters to achieve better results at a low cost

scholarly journals Laser Welding of High-strength Aluminium Alloys for the Sheet Metal Forming Process

Procedia CIRP ◽  
2014 ◽  
Vol 18 ◽  
pp. 203-208 ◽  
Author(s):  
J. Enz ◽  
S. Riekehr ◽  
V. Ventzke ◽  
N. Sotirov ◽  
N. Kashaev
Keyword(s):  
Laser Welding ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Aluminium Alloys ◽  
High Strength ◽  
Forming Process ◽  
Metal Forming Process

scholarly journals Co-Design of CVT-Based Electric Vehicles

Energies ◽  
2021 ◽  
Vol 14 (7) ◽  
pp. 1825
Author(s):  
Caiyang Wei ◽  
Theo Hofman ◽  
Esin Ilhan Caarls
Keyword(s):  
Cooling System ◽  
Design Method ◽  
Low Cost ◽  
Cost Effective ◽  
Speed Ratio ◽  
Air Flow Rate ◽  
Cost Of Ownership ◽  
Variable Transmission ◽  
Primary Focus ◽  
Design Freedom

For an electric vehicle (EV) with a continuously variable transmission (CVT), a novel convex programming (CP)-based co-design method is proposed to minimize the total-cost-of-ownership (TCO). The integration of the electric machine (EM) and the CVT is the primary focus. The optimized system with co-design reduces the TCO by around 5.9% compared to a non-optimized CVT-based EV (based on off-the-shelf components) and by around 2% compared to the EV equipped with a single-speed transmission (SST). By taking advantage of the control and design freedom provided by the CVT, the optimal CVT, EM and battery sizes are found to reduce the system cost. It simultaneously finds the optimal CVT speed ratio and air-flow rate of the cooling system reducing the energy consumption. The strength of co-design is highlighted by comparing to a sequential design, and insights into the design of a low-power EV that is energy-efficient and cost-effective for urban driving are provided. A highly integrated EM-CVT system, which is efficient, low-cost and lightweight, can be expected for future EV applications.

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