Journal of Materials Processing Technology最新文献_第4页

Investigation on deformation and strengthening mechanisms of Al-Zn-Mg-Cu alloy under a hybrid process of cryogenic incremental sheet forming and bake-hardening treatment 低温增量薄板成形和焙烧硬化处理混合工艺下铝锌镁铜合金的变形和强化机理研究

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2024-10-03 DOI: 10.1016/j.jmatprotec.2024.118619

Yanle Li, Tingyu Ge, Jilai Wang, Feifei Liu, Fangyi Li

Incremental sheet forming process is featured with high flexibility and short manufacturing cycle, which has great potential in customized forming of complex components. However, the formability of high-strength aluminum alloy is still needs to be improved. In this paper, an efficient cryogenic incremental sheet forming (CISF) process combined with bake-hardening (BH) treatment is proposed to achieve excellent formability and strength for Al-Zn-Mg-Cu alloy. First, the effect of different cryogenic temperatures on the formability of Al-Zn-Mg-Cu alloy is investigated and the mechanism of plasticity enhancement during cryogenic incremental sheet forming was revealed. The fracture forming limit lines constructed from different components show a significant increase in the formability of as-quenched Al-Zn-Mg-Cu at −170°C. Specially, when forming cone component with variable wall angle at −170℃, the ultimate forming height is increased by 70.4 % compared with 25℃. The microstructure shows that dislocation cross-slip is suppressed at cryogenic temperatures, and the large number of subgrain structure and uniformly distributed dislocations reflect the improved deformation uniformity at cryogenic temperatures. Second, the effect of cryogenic incremental sheet forming on the strength of Al-Zn-Mg-Cu is explored. The vertical forming force can be increased by 37.4 % at −170°C compared to 25°C, and the components have higher post-forming strength. Moreover, the strengthening response of the components after the combination of cryogenic incremental sheet forming and bake-hardening treatments is investigated. The cryogenic specimens exhibited a rapid bake-hardening response compared to the room temperature specimens. The yield strength increased by 15.4 % to 387.2 MPa after 40 mins of bake-hardening treatment at 180°C. It has been shown that precipitation strengthening and dislocation strengthening are the main strengthening mechanisms during cryogenic incremental sheet forming and bake-hardening treatments. This study reveals the dual enhancement effect during the cryogenic incremental sheet forming process, and proposes an efficient approach which combines cryogenic incremental sheet forming with bake-hardening treatment to manufacture high-performance components.

增量式板材成形工艺具有灵活性高、制造周期短的特点，在复杂部件的定制成形方面具有巨大潜力。然而，高强度铝合金的成形性仍有待提高。本文提出了一种结合烘烤硬化（BH）处理的高效低温增量板材成形（CISF）工艺，以实现铝-锌-镁-铜合金的优异成形性和强度。首先，研究了不同低温对 Al-Zn-Mg-Cu 合金成形性的影响，并揭示了低温增量薄板成形过程中塑性增强的机理。由不同成分构建的断裂成形极限线显示，在 -170°C 下，淬火后的 Al-Zn-Mg-Cu 的成形性显著提高。特别是，在-170℃条件下成形具有可变壁角的锥形成分时，极限成形高度比 25℃时增加了 70.4%。微观结构显示，低温下位错交叉滑移受到抑制，大量的亚晶粒结构和均匀分布的位错反映了低温下变形均匀性的改善。其次，探讨了低温增量薄片成形对 Al-Zn-Mg-Cu 强度的影响。与 25°C 相比，-170°C 时的垂直成型力可提高 37.4%，且部件具有更高的成型后强度。此外，还研究了结合低温增量板材成形和烘烤硬化处理后部件的强化响应。与室温试样相比，低温试样表现出快速的烘烤硬化反应。在 180°C 下经过 40 分钟的烘烤硬化处理后，屈服强度提高了 15.4%，达到 387.2 兆帕。研究表明，析出强化和位错强化是低温增量薄片成形和烘烤硬化处理过程中的主要强化机制。这项研究揭示了低温增量板材成形过程中的双重强化效应，并提出了一种将低温增量板材成形与烘烤硬化处理相结合来制造高性能部件的有效方法。

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引用次数: 0

An extended mesoscaled M-K model for predicting discrete ultimate strains and evaluating the effect of normal stress on forming limits 用于预测离散极限应变和评估法向应力对成形极限影响的扩展中观 M-K 模型

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2024-10-03 DOI: 10.1016/j.jmatprotec.2024.118609

Haiyang Wang , Gang Chen , Peng Zhang , Chuanjie Wang

Due to the size effect, the formability of metal sheets diminishes and the ultimate strain points exhibit a more discrete distribution. This poses a huge challenge to the process design and manufacture of microparts. This paper presents a modified mesoscopic scale forming limit model based on the M-K model. The model extends the forming limit curve (FLC) into forming limit bands to predict the discrete nature of the ultimate strain. In addition, a method for applying normal stresses to increase the forming limit of thin metal sheets is proposed. The effects of normal stresses on surface roughening and flow stresses in thin metal sheets were evaluated and quantified by uniaxial tensile experiments under normal stresses. The results show that the normal stress suppresses the increase of surface roughness and improves the work hardening rate. The effect of normal stresses on forming limits was obtained using a constructed model. The results show that the predictions of the proposed model are able to include almost all the ultimate strain points. The forming limit bands are more inclusive and safer than the single forming limit curve. In addition, the forming limits of thin plates under normal stresses are significantly increased, which is attributed to the suppression of surface roughening and the increase of strain hardening index. The forming limit bands proposed in this paper provide a more reliable form of forming limit assessment for thin metal plates. The proposed method of applying normal stresses provides a robust and inexpensive process route to address the challenge of poor formability of thin metal sheets.

由于尺寸效应，金属板的可成形性降低，极限应变点的分布更加分散。这给微型零件的工艺设计和制造带来了巨大挑战。本文提出了一种基于 M-K 模型的改进型中观尺度成形极限模型。该模型将成形极限曲线 (FLC) 扩展到成形极限带，以预测极限应变的离散性。此外，还提出了一种施加法向应力以提高金属薄板成形极限的方法。通过法向应力下的单轴拉伸实验，评估并量化了法向应力对金属薄片表面粗化和流动应力的影响。结果表明，法向应力抑制了表面粗糙度的增加，提高了加工硬化率。利用构建的模型得出了法向应力对成形极限的影响。结果表明，所建模型的预测几乎包含了所有极限应变点。与单一的成形极限曲线相比，成形极限带更具包容性和安全性。此外，薄板在法向应力作用下的成形极限显著提高，这归因于表面粗化的抑制和应变硬化指数的提高。本文提出的成形极限带为金属薄板的成形极限评估提供了一种更可靠的形式。本文提出的施加法向应力的方法为解决金属薄板成形性差的难题提供了一条稳健而廉价的工艺路线。

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引用次数: 0

Tailored porosity in additive manufacturing of 7075 aluminum alloy for crack suppression and high strength 在 7075 铝合金的增材制造过程中定制孔隙率，以实现裂纹抑制和高强度

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2024-10-02 DOI: 10.1016/j.jmatprotec.2024.118620

Tian-Shu Liu , Feng Qiu , Siwei Du , Jinlong Su , Hong-Yu Yang , Peng Chen , Fern Lan Ng , Youxiang Chew , Qi-Chuan Jiang , Chaolin Tan

Laser-directed energy deposition (LDED) additive manufacturing of 7075 aluminum (Al) alloy is highly challenging due to the inherent poor printability and high cracking tendency. Here, we disclose a new approach to suppress cracking in LDED-processed 7075 Al alloy by engineered porosity (about 1.14 %). The crack-free 7075 Al alloy was achieved by slightly sacrificing the densification. Further increasing the density of the material by increasing laser energy input leads to cracking. The mechanisms of minor pores in alleviating cracks are mainly reflected in three aspects: (i) pores disrupt the epitaxial growth of columnar grains; (ii) free-form surfaces surrounding pores could release the accumulated residual stress, and (iii) more dislocations near pore drive nucleation of near equiaxed grains. The LDED-processed crack-free 7075 Al alloy after heat treatment shows an ultimate tensile strength of 464 ± 12 MPa and break elongation of 9.7 ± 1.2 %, attaining a good strength-ductility synergy among many additively manufactured 7075 Al alloys in the current literature. Unlike the mainstream additive manufacturing of metallic materials, which pursues high densification to attain high-performance components, this work demonstrates the positive roles of pores in the additive manufacturing of cracking-sensitive materials. The findings of this work highlight new insights regarding the balance between pores and cracks for better manufacturability and higher mechanical performance of materials.

由于 7075 铝合金固有的打印性差和高开裂倾向，激光定向能量沉积（LDED）增材制造具有很高的挑战性。在此，我们揭示了一种新方法，通过设计孔隙率（约 1.14%）来抑制 LDED 加工 7075 铝合金中的裂纹。这种无裂纹的 7075 Al 合金是通过略微牺牲密度实现的。通过增加激光能量输入进一步提高材料密度会导致开裂。微小孔隙缓解裂纹的机理主要体现在三个方面：(i) 孔隙破坏了柱状晶粒的外延生长；(ii) 孔隙周围的自由形态表面可以释放累积的残余应力；(iii) 孔隙附近更多的位错推动了近等轴晶粒的成核。经 LDED 加工的无裂纹 7075 Al 合金在热处理后显示出 464 ± 12 MPa 的极限抗拉强度和 9.7 ± 1.2 % 的断裂伸长率，在现有文献中的众多添加剂制造 7075 Al 合金中实现了良好的强度-性能协同。与追求高密度化以获得高性能部件的主流金属材料增材制造不同，这项工作证明了孔隙在裂纹敏感材料增材制造中的积极作用。这项工作的发现凸显了有关孔隙与裂纹之间平衡的新见解，从而提高材料的可制造性和机械性能。

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引用次数: 0

Improving wear resistance and machining performance of diamond tools in ferrous metals cutting: A review 提高黑色金属切削中金刚石工具的耐磨性和加工性能：综述

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2024-09-30 DOI: 10.1016/j.jmatprotec.2024.118618

Chaosheng Song , Daohui Xiang , Bo Zhao , Qinglong An , Xuekun Li , Dazhong Wang , Feng Jiao , Guofu Gao , Xiaobin Cui

Cutting ferrous metals, such as mold steel, with diamond tools is a critical issue that urgently needs to be solved in the field of precision machining. In cutting ferrous metals, diamond tools experience severe chemical wear, such as graphitization, diffusion reactions, and oxidation reactions, resulting in machining results far below the expected level. This review analyzes the cutting mechanism of diamond tools in ferrous metal machining and analyzes the wear mechanism of diamond tools at two levels: experimental investigation and molecular dynamics simulation. In addition, problems in existing research on their cutting mechanism are critically discussed. Concerning the serious chemical wear phenomenon of diamond tools, we focus on green manufacturing as the starting point and conduct an in-depth discussion on chemical vapor deposition (CVD) coating technology, cryogenic cooling technology, microquantity lubrication (MQL) technology, and ultrasonic vibration technology. We also introduce the latest progress in the application of the above technologies. Finally, focusing on the advantages and limitations of several inhibition technologies, synergistic effects between them were explored, demonstrating their effective inhibition of tool wear and significant improvements in machining efficiency. Finally, a concise summary of the described content and insights into the future development direction of this field are provided.

使用金刚石工具切削模具钢等黑色金属是精密加工领域亟待解决的一个关键问题。在切削黑色金属时，金刚石工具会经历严重的化学磨损，如石墨化、扩散反应和氧化反应，导致加工效果远低于预期水平。本综述分析了黑色金属加工中金刚石工具的切削机理，并从实验研究和分子动力学模拟两个层面分析了金刚石工具的磨损机理。此外，还对其切削机理的现有研究中存在的问题进行了批判性讨论。针对金刚石工具严重的化学磨损现象，我们以绿色制造为切入点，对化学气相沉积（CVD）涂层技术、低温冷却技术、微量润滑（MQL）技术和超声振动技术进行了深入探讨。我们还介绍了上述技术的最新应用进展。最后，重点介绍了几种抑制技术的优势和局限性，探讨了它们之间的协同效应，证明了它们能有效抑制刀具磨损，显著提高加工效率。最后，对所述内容进行了简要总结，并对该领域的未来发展方向提出了见解。

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引用次数: 0

Investigating the friction stir additively manufactured AA2024 build and the influence of material flow in enhancing the inter-surface bonding 研究搅拌摩擦添加式制造的 AA2024 构件以及材料流动对增强表面间结合力的影响

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2024-09-27 DOI: 10.1016/j.jmatprotec.2024.118611

Pilli Jaya Teja, Rahul Jain

Friction Stir Additive Manufacturing (FSAM) is a solid-state joining process that operates below the material’s melting point, avoiding the drawbacks of fusion-based methods. In FSAM, inter-surface bonding is crucial for the build strength and is influenced by material flow at the interface. This study examines the influence of flat-faced (square) and smooth (threaded conical) pins, along with rotational speed, on the material flow, using Al-clad as a tracer. It also analyses the microstructure, micro-texture, mechanical properties of the builds, and the role of the forging force in FSAM. Defect-free builds were achieved with a forging force above 7000 N. The threaded conical pin caused upward migration of Al-clad, while the square pin led to fragmentation and distribution, offering excellent inter-surface bonding. Refined grain structures (∼5 µm) were observed in the top layers. The highest tensile strengths were 392 MPa in the weld direction (80 % build efficiency) with the threaded conical pin, and 358 MPa in the build direction (75 % build efficiency) with the square pin. Strong γ-fiber in ODFs indicates better ductility, with up to 60 % improvement in elongation. The current research shall guide the selection of appropriate process parameters and, in turn, reduce trial-and-error during manufacturing aluminum alloys through friction stir additive manufacturing.

摩擦搅拌快速成型技术（FSAM）是一种固态连接工艺，其工作温度低于材料的熔点，避免了熔融方法的缺点。在 FSAM 中，表面间的结合对制造强度至关重要，并受到界面上材料流动的影响。本研究以覆铝板为示踪剂，研究了扁平（方形）和光滑（螺纹锥形）销钉以及旋转速度对材料流动的影响。研究还分析了铸件的微观结构、微观纹理、机械性能以及锻造力在 FSAM 中的作用。锻造力超过 7000 牛时，铸件无缺陷。带螺纹的锥形销钉会导致覆铝板向上移动，而方形销钉则会导致覆铝板破碎和分布，从而提供出色的表面间结合。在顶层观察到细化的晶粒结构（∼5 µm）。螺纹锥形销在焊接方向的最高拉伸强度为 392 兆帕（成型效率为 80%），方形销在成型方向的最高拉伸强度为 358 兆帕（成型效率为 75%）。ODF 中的强γ 纤维表明延展性更好，伸长率最多可提高 60%。当前的研究将为选择合适的工艺参数提供指导，进而减少通过搅拌摩擦快速成型制造铝合金过程中的试错。

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引用次数: 0

Efficient evolution mechanism of electrolytic gas products from laser-assisted electrolyte jet machining 激光辅助电解质喷射加工产生的电解气体产物的高效演化机制

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2024-09-27 DOI: 10.1016/j.jmatprotec.2024.118617

Mingxin Yu , Liqun Du , Baoguo Du , Fenglai Wang , Ce Zhang , Dong Li

Efficient evolution of electrolytic gas products is one of the mechanisms for increased material removal rate in laser-assisted electrolyte jet machining. However, the evolution mechanism of electrolytic gas products with multiple energy fields in laser-assisted electrolyte jet machining is not clear. In order to quantitatively characterize the laser-assisted facilitation of the evolution of electrolytic gas products, a gas quantification and detection device was designed and built in this paper. Compared to traditional electrolyte jet machining, laser-assisted electrolyte jet machining of 2024-T3 aluminum alloy increased the gas production by 52 % in 180 s. For the anode, the surface modification induced by laser texturing reduces the oxygen evolution potential and surface free energy and promotes gas nucleation and detachment. In addition, laser-induced conductive plasma can enhance transient currents for electrolyte jet machining and cause machining vibrations. The cathodic gas discharge phenomenon was characterized in conjunction with interelectrode gap visualization experiments and cathodic nozzle damage. Experimental results show that cathodic gas discharge depends on strong electric field and high laser pulse fluence. In summary, laser temperature rise, anode surface modification, laser-induced plasma, plasma recoil and cathode gas discharge can all contribute to the evolution of electrolytic gas products.

在激光辅助电解质射流加工中，电解气体产物的高效演化是提高材料去除率的机制之一。然而，激光辅助电解质射流加工中多能量场电解气体产物的演化机制尚不清楚。为了定量表征激光辅助促进电解气体产物演化的过程，本文设计并制造了一种气体定量检测装置。与传统的电解液喷射加工相比，激光辅助电解液喷射加工 2024-T3 铝合金在 180 秒内增加了 52% 的产气量。对于阳极，激光纹理加工引起的表面改性降低了氧演化势能和表面自由能，促进了气体成核和脱离。此外，激光诱导的导电等离子体可增强电解液喷射加工的瞬态电流，并引起加工振动。结合电极间隙可视化实验和阴极喷嘴损伤，对阴极气体放电现象进行了表征。实验结果表明，阴极气体放电取决于强电场和高激光脉冲通量。总之，激光温升、阳极表面改性、激光诱导等离子体、等离子体反冲和阴极气体放电都会导致电解气体产物的演变。

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引用次数: 0

Synthesis of small-sized spherical Fe-based amorphous powders with insulating nanolayer from ribbon electrodes 用带状电极合成带有绝缘纳米层的小尺寸球形铁基非晶粉末

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2024-09-26 DOI: 10.1016/j.jmatprotec.2024.118610

Chekai Liu , Xueqian Yu , Ran Li , Ting Zhang , Tao Zhang

With growing demand for high-frequency electronic components in modern 5 G and ongoing 6 G communication networks, advanced soft-magnetic composites (SMCs) are crucial in diverse applications of electronic products and power systems. A novel spark erosion approach using ribbon electrodes was developed to produce fine Fe-based amorphous powders with high sphericity (99.5 %) and controllable particle sizes (D₅₀ ≤ 5.9 μm). The use of ribbon electrode leads to a significant enhancement of powder production efficiency, approximately four times than that achieved using bulk electrodes employed in conventional spark erosion. An oxygen-rich nanolayer was formed in-situ on the powder surface with high resistivity, eliminating the subsequent complex insulating treatment in traditional SMCs production. The SMCs made of our small-sized spherical insulated powders demonstrated stable permeability at high frequency, relatively high saturation magnetization, and low core losses. These performances meet the urgent soft-magnetic requirements essential for the miniaturization and high-frequency applications of electronic devices. The novel spark erosion method for preparation of fine spherical amorphous and crystalline powders with excellent soft-magnetic properties holds paramount importance for the manufacturing of high-performance SMCs as advanced electronic components.

随着现代 5 G 和未来 6 G 通信网络对高频电子元件的需求日益增长，先进的软磁复合材料（SMC）在电子产品和电力系统的各种应用中至关重要。我们开发了一种使用带状电极的新型火花侵蚀方法，用于生产具有高球形度（99.5%）和可控粒度（D50 ≤ 5.9 μm）的精细铁基无定形粉末。使用带状电极可显著提高粉末生产效率，约为传统火花侵蚀中使用的块状电极的四倍。粉末表面原位形成的富氧纳米层电阻率高，省去了传统 SMC 生产中复杂的后续绝缘处理。由我们的小尺寸球形绝缘粉末制成的 SMC 在高频下具有稳定的磁导率、相对较高的饱和磁化率和较低的磁芯损耗。这些性能满足了电子设备小型化和高频应用对软磁的迫切要求。利用新型火花侵蚀法制备具有优异软磁特性的精细球形非晶和结晶粉末，对于制造高性能 SMC 先进电子元件具有极其重要的意义。

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引用次数: 0

Mechanisms in the machinability improvement of Inconel 718 superalloy through ultra-high-speed grinding 通过超高速磨削提高铬镍铁合金 718 超级合金可加工性的机理

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2024-09-25 DOI: 10.1016/j.jmatprotec.2024.118614

Hao Liu, Huili Han, Qinghong Jiang, Bi Zhang

Inconel 718 (IN718) superalloy is a typical difficult-to-machine material characterized by low thermal conductivity and severe work hardening. Ultra-high-speed machining (UHSM) exhibits characteristics of material embrittlement and the skin effect of machining damage, which may address the above dual machining issues. This paper investigates the speed effect on the formation of machined surface and, for the first time, achieves ultra-high-speed grinding of IN718 superalloy at a speed up to 240 m/s. The grinding forces and surface integrity across various speed ranges are examined in detail. Multiple techniques are employed to characterize and analyze the subsurface microstructure. The results demonstrate that brittle-mode removal of IN718 superalloy occurs at a grinding speed exceeding 190 m/s, effectively mitigating work hardening and heat generation resulting from intensified plastic deformation. Furthermore, the machining speed influences the formation mechanism of recrystallization layer, gradually transitioning from discontinuous dynamic recrystallization (dDRX) domination to continuous dynamic recrystallization (cDRX) domination with an increase in grinding speed. Meanwhile, multifold nano-twins with a wide range of 4–5 nm form within tens of nanometer grains under UHSM conditions, further altering the subsurface microstructure. These findings provide valuable scientific insights for enhancing the machinability of other difficult-to-machine materials.

Inconel 718 (IN718) 超耐热合金是一种典型的难加工材料，其特点是导热率低和加工硬化严重。超高速加工（UHSM）具有材料脆化和加工损伤集肤效应的特点，可以解决上述双重加工问题。本文研究了速度对加工表面形成的影响，并首次实现了以高达 240 m/s 的速度对 IN718 超合金进行超高速磨削。本文详细研究了不同速度范围内的磨削力和表面完整性。采用多种技术对表面下微观结构进行表征和分析。结果表明，在磨削速度超过 190 米/秒时，IN718 超耐热合金会发生脆性模式去除，从而有效减轻了塑性变形加剧所导致的加工硬化和发热。此外，加工速度还影响再结晶层的形成机制，随着磨削速度的增加，再结晶层逐渐从不连续动态再结晶（dDRX）为主过渡到连续动态再结晶（cDRX）为主。同时，在 UHSM 条件下，数十纳米晶粒内形成了 4-5 纳米宽范围的多倍纳米孪晶，进一步改变了表面下的微观结构。这些发现为提高其他难加工材料的可加工性提供了宝贵的科学启示。

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引用次数: 0

A forming method of variable-diameter tubes straightforward from sheet metals 由金属板直接制成可变直径管材的成型方法

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2024-09-25 DOI: 10.1016/j.jmatprotec.2024.118613

Zhiheng Zhang , Tianxia Zou , Dayong Li , Yinghong Peng , Hua Xiao , Lei Shi

Variable-diameter metallic tubes are extensively used in many industrial applications. They are generally made of pre-formed raw tubes by using the existing processing methods, during which obvious non-uniformity in tube wall thickness inevitably occurs. In this work, a novel method is proposed to form variable-diameter tubes directly from sheet metals by means of the roll-stamp forming technique. A three-pass roll-stamp forming process and corresponding die blocks are designed and implemented to form a demonstrative conical tube. The finite element model of the roll-stamp forming process is established and forming quality is quantitatively evaluated. The initial blank configuration, which is the most important factor for process design, is determined by combining machine learning and multi-objective optimization. The forming experiment is performed, and the conical tube is successfully formed with no significant thinning/thickening of tube wall. The influences of forming direction and conical ratio on the forming process are numerically investigated. The proposed roll-stamp technique provides a novel and effective approach to manufacturing variable-diameter tubes.

变径金属管广泛应用于许多工业领域。一般来说，它们都是采用现有的加工方法将原始管材预先成型而成，在加工过程中不可避免地会出现明显的管壁厚度不均匀现象。在这项工作中，我们提出了一种新方法，利用辊压成型技术直接从金属板上成型可变直径的管材。设计并实施了三道辊压成形工艺和相应的模块，以成形示范性锥形管。建立了辊压成形工艺的有限元模型，并对成形质量进行了定量评估。通过机器学习和多目标优化相结合，确定了工艺设计中最重要的初始坯料配置。进行了成形实验，成功成形了锥形管，管壁没有明显的减薄/增厚。数值研究了成型方向和锥度比对成型过程的影响。所提出的轧辊冲压技术为制造变径管提供了一种新颖而有效的方法。

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引用次数: 0

Prediction of micro/meso scale forming limit for metal foils using a simple criterion 使用简单标准预测金属箔的微/介质鳞片成形极限

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2024-09-25 DOI: 10.1016/j.jmatprotec.2024.118612

Lihuang Zheng, Bao Meng, Min Wan

Accurately forecasting the forming limit of metal foils is essential in their micro-forming due to the appearance of necking failure easily. In order to accurately and easily forecast the forming limit of metal foils influenced by size effect, an idea for failure modeling of metal foils using the mechanism that different fracture modes of metal foils are related to shear bands is presented in this work. Based on the idea, a simple ductile failure criterion that considers the maximum shear stress and grain size effect but excludes the stress triaxiality is proposed, motivated by the demand to decrease the complexity of parameter calculation tests in micro-forming failure prediction. The proposed criterion and another criterion called as the μ-DF2022 model are applied to capture the forming limit curves of various thick copper and 304 stainless steel foils with different grain sizes to verify its advantage and performance, and the corresponding mechanisms of their prediction capabilities are also elucidated. Furthermore, the proposed and μ-DF2022 models are applied to forecast the limit drawing ratio of a 304 stainless steel foil to further show its performance and advantage in real micro-forming. The applications show that the proposed failure criterion effectively forecasts the forming limit of metal foils between equi-biaxial tension and uniaxial tension influenced by size effect. Moreover, the prediction accuracies using the proposed model and the μ-DF2022 model are comparable, whereas the proposed model does not require complex micro equi-biaxial tension tests, which are typically unavailable to many engineers and researchers, to calibrate its material parameters. Therefore, it is recommended to utilize the proposed criterion to capture the forming limit of metal foils in micro-forming. This work advances the forming limit modeling method of metal foils and provides insight into the application of uncoupled ductile failure criteria in the micro-forming of metal foils, which contributes to the development of their optimal micro-forming processes.

由于金属箔很容易出现缩颈失效，因此准确预测金属箔的成型极限对其微成型至关重要。为了准确、简便地预测受尺寸效应影响的金属箔成形极限，本文提出了一种利用金属箔的不同断裂模式与剪切带相关的机理建立金属箔失效模型的想法。基于这一想法，提出了一个简单的韧性破坏准则，该准则考虑了最大剪切应力和晶粒尺寸效应，但排除了应力三轴性，其动机是降低微成型破坏预测中参数计算试验的复杂性。应用所提出的准则和另一种称为μ-DF2022 模型的准则来捕捉不同晶粒尺寸的各种厚铜箔和 304 不锈钢箔的成形极限曲线，以验证其优势和性能，并阐明其预测能力的相应机制。此外，还应用提出的模型和 μ-DF2022 模型预测了 304 不锈钢箔的极限拉伸比，进一步显示了其在实际微成形中的性能和优势。应用结果表明，所提出的失效准则能有效预测金属箔在等轴拉伸和受尺寸效应影响的单轴拉伸之间的成形极限。此外，使用提出的模型和 μ-DF2022 模型的预测精度相当，而提出的模型不需要复杂的微型等轴拉伸试验来校准其材料参数，因为许多工程师和研究人员通常无法利用这些试验。因此，建议利用所提出的准则来捕捉金属箔在微成形中的成形极限。这项工作推进了金属箔的成形极限建模方法，并为非耦合韧性破坏准则在金属箔微成形中的应用提供了启示，有助于开发其最佳微成形工艺。

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