Search results for "Sheet metal"
showing 10 items of 141 documents
An anomalous wave formation at the Al/Cu interface during magnetic pulse welding
2020
This paper reports an anomalous wave formation at an Al/Cu bimetallic interface produced by magnetic pulse welding. The mechanism of the anomalous wave formation is investigated using both metallurgical characterization and the interface kinematics. It reveals that the anomalous wave is formed with the combination of the intermediate zone and the interdiffusion zone with a thickness of 70 nm, wherein the intermediate zone is caused by the local melting due to the high shear instability, and the interdiffusion zone is formed below the melting point of aluminum combined with ultrahigh heating and cooling rates of about 10^13 °C s^−1. A multiphysics simulation of impact welding has been perfor…
Variable-charge method applied to study coupled grain boundary migration in the presence of oxygen
2009
International audience; One of the important differences between simulation and experiments in grain boundary (GB)-dominated metallic structures is the lack of impurities such as oxygen in computational samples. A modified variable-charge method [Elsener A, Politano O, Derlet PM, Van Swygenhoven H. Modell Simul Mater Sci Eng 2008;16:025006] based on the Streitz and Mintmire approach [Streitz FH, Mintmire JW. Phys Rev B 1994;50:11996] is used to study coupled GB motion in an Al bicrystal with a [1 1 2] symmetrical tilt GB in the presence of substitutional O, and compared with the stick–slip process identified by Cahn and Mishin [Cahn JW, Mishin Y, Suzuki A. Acta Mater 2006;54:4953]. It is found…
Mechanical and metallurgical characterization of AA6082-T6 sheet-bulk joints produced through a linear friction welding based approach
2020
In the last decades, new flexible manufacturing processes have been developed to face the demands, by many industrial fields, for highly customized complex functional parts. The peculiar design of these components often overcomes conventional sheet metal and bulk metal forming processes capabilities. In order to face this issue, new hybrid techniques, capable of exploit key advantages of different processes, have to be developed. In this study, a method to obtain sheet-bulk joints, based on the Linear Friction Welding process, is proposed. The feasibility of the technique was investigated through an experimental campaign carried out with varying pressure and oscillation frequency using AA60…
Geometrical deviation of end-of-life parts as a consequence of reshaping by single point incremental forming
2021
AbstractPutting in place circular economy strategies is an urgent challenge to face. In this scenario, manufacturing processes play a relevant role as efficient material reuse enabler. Scientists have to make an effort either to find new process or to rethink old process to reprocess end-of-life (EoL) component to recover both material and functions. In this paper, single point incremental forming (SPIF) process is used for reshaping sheet metal EoL components. The entire process chain was replicated including both deep drawing process (to imitate the end-of-life component) as well as SPIF operations (to obtain the reshaped components). The geometrical deviation as a consequence of SPIF ope…
Re-forming end-of-life components through single point incremental forming
2020
Abstract Applying Circular Economy strategies is mandatory to face material demand while minimizing the environmental impact. Manufacturing processes are to be thought as means to enable material/component reuse strategies. This paper presents the suitability of Single Point Incremental Forming (SPIF) to re-form End-of-life sheet metal components. Deep drawing followed by SPIF process on aluminium alloys were carried out to simulate reforming processes chain. The resulting thinning and strain distributions were experimentally analysed for different configurations. The research proves that the local action and enhanced formability nature of SPIF allow non-homogeneously thinned and reduced fo…
Effect of the mutual position between weld seam and reinforcement on the residual stress distribution in Friction Stir Welding of AA6082 skin and str…
2016
Abstract In the paper, a numerical and experimental study was carried out to highlight the effect of the distance d between the weld seam and the reinforcement on the residual stress distribution in Friction Stir Welded AA6082-T6 structures. An L-shaped profile was welded to a sheet metal with varying tool rotation and distance d from the weld seam. The Cut Compliance method was used to determine the resulting longitudinal residual stress. A dedicated FE model for FSW was set up, validated and utilized to predict the longitudinal residual stress in the assembled part. The analysis allowed the identification of a few design guidelines in order to reduce the detrimental effects of the residua…
A Pareto optimal design approach for simultaneous control of thinning and springback in stamping processes
2009
One of the most relevant research issues in automotive field is focused on the reduction of stamped parts weight also increasing their strength. In this way, a strong research effort is developed on high strength steels which are widely utilized and they require a proper springback control. Springback reduction in sheet metal forming is a typical goal to be pursued which is conflicting with thinning reduction for instance. Thus, such problems can be considered as multi-objective ones characterized by conflicting objectives. What is more, nowadays, a great interest would be focused on the availability of a cluster of possible optimal solutions instead of a single one, particularly in an indu…
Enhancement of mechanical properties of FSWed AA7075 lap joints through in-situ fabrication of MMC
2017
Abstract Friction Stir Processing (FSP) has been demonstrated feasible to create local Metal Matrix Composites (MMCs) in light alloys matrix. In this research, local MMCs were produced contextually to the weld using Friction Stir Welding (FSW). SiC particles were added to AA7075 lap joints by creating a proper groove on the top surface of the bottom sheet. Different welds were produced with increasing number of tool passes. The effect of the multiple passes was investigated through shear tests, macro and micro observations, average grain size and microhardness measurements. The welded joints were compared to a reference weld produced with no reinforcements. It was found that poor mixing bet…
Magnetic field-assisted single-point incremental forming with a magnet ball tool
2021
Abstract This paper describes magnetic field-assisted single-point incremental forming (M-SPIF) with a Nd-Fe-B magnet ball tool. In M-SPIF, the tool driven by magnetic force plastically deforms a sheet. The polarity of the magnet tool helps to make the magnetic force (i.e., forming force) more controllable. In creating a truncated cone, the direction of the magnetic force gradually points more outward as the process progresses, and material is forced outwards from the cone center, increasing thinning in M-SPIF, while the cone center remains undeformed in traditional SPIF. Moreover, M-SPIF creates less localized plastic strain than traditional SPIF while forming the desired geometry.
Meta-heuristic Algorithms for Nesting Problem of Rectangular Pieces
2017
Abstract Nesting problems consist of placing multiple items onto larger shapes finding a good arrangement. The goal of the nesting process is to minimize the waste of material. It is common to assume, as in the present work, that the stock sheet has fixed width and infinite height, since in the real world a company may have to cut pieces from a roll of material. The complexity of such problems is often faced with a two-stage approach, so-called “hybrid algorithm”, combining a placement routine and a meta-heuristic algorithm. Starting from a given positioning sequence, the placement routine generates a non-overlapping configuration. The encoded solution is manipulated and modified by the met…