Abstract Lightweight design is one of the current key drivers to reduce energy consumption vehicles. Design methodologies for lightweight components, strategies utilizing materials with favorable specific properties and hybrid are used increase performance parts automotive applications. In this paper, various forming processes produce light described. Material discussed, covering manufacturing components like fiber–metal, polymer–metal metal–metal composites, which can be in subsequent deep...

The uniform pressure electromagnetic actuator (UPEA) is an innovative tool design for forming applications. In this article its suitability magnetic pulse welding demonstrated. To facilitate the process design, a simple mathematical model based on analytical equations describing behavior of system and mechanical workpieces under impulse loads presented in manuscript. goal to predict workpiece velocity considering input energy, equipment setup characteristics as well properties workpiece....

The residual stress state of a sheet metal component manufactured by forming has significant influence on the mechanical properties, and thus determines time until fails, especially for dynamic loads. origin resulting incrementally formed parts with regard to mechanisms shearing, bending, normal is still under investigation. relationship between process parameters, mechanisms, complex part geometry single point incremental (SPIF) presented in this publication. For purpose, validated...

Magnetic pulse welding (MPW) is often categorized as a cold technology, whereas latest studies evidence melted and rapidly cooled regions within the joining interface. These phenomena already occur at very low impact velocities, when heat input due to plastic deformation comparatively where jetting in kind of distinct material flow not initiated. As another source, this study investigates cloud particles (CoP), which ejected result high speed impact. MPW experiments with different collision...

The prevailing residual stress state in a formed metal component highly affects its mechanical properties. single point incremental forming (SPIF) process allows flexible adjustment of the parameters during to influence state. A selective induction compressive stresses can improve product properties, such as fatigue strength. effect dominant mechanisms on manufactured is analyzed. Linear grooves are into aluminum alloy 5083 sheets and their resulting measured by means X-ray diffraction...

The V-die bending of a carbon-fiber-reinforced thermoplastic laminate bonded to thin cover layers made microalloyed steel was investigated. Such hybrid semifinished products are gaining importance in transport-related lightweight designs. Experiments were conducted for different forming temperatures and dwell times determine suitable process parameters. punch radius varied evaluate its influence on the springback/negative springback fiber–metal (FML). results, which good accordance with...

Abstract Magnetic pulse welding (MPW) is a solid-state process that bonds similar and dissimilar metals using high velocity collision. In this paper, effects of impact velocity, target tube thickness, mandrel inclusion on the interfacial morphology were investigated through tubular parts, Al6060T4 (flyer) to Cu-ETP (target), by electromagnetic compression. The hypothesis tested in research “well-supported target,” i.e., either thick or support mandrel, allows for vortices be created at...

Abstract Process-induced residual stresses significantly influence the mechanical properties of a formed component. A polymer pad is used as flexible die in two-point incremental forming to induce compressive component during process. Experimental and numerical results illustrate stress superposition on properties. It shown that active support, using geometry-independent polyurethane die, causes beneficial tool side compared tensile induced by single-point process without such supporting die.

The roll-slide-drawing process enables tailoring of profile cross-sections at arbitrary axial positions with short transition zones high industrial throughput rates. combines rolling using rotating dies non-axisymmetric complex geometries and subsequent drawing a constant cross-section geometry. For initially round tubes, limits notches lengths are derived analytically. These removed through the novel approach starting oval or rectangular shaped as demonstrated experimentally. Developed...

Abstract Multimaterial design with a combination of solid and foam structures offers promising avenue for reducing component weight while enhancing their functionalities. However, the complexity multistage manufacturing processes poses significant challenges to adopting such approaches. To address these challenges, this paper introduces an innovative concept known as Electromagnetic Forming Injection Foaming (EFIF), which integrates injection molding, forming, foaming into single hybrid...

The stamping of fiber metal laminates (FMLs) at thermoforming temperature the thermoplastic matrix is investigated. studied FML types consist a unidirectional carbon fiber-reinforced core that attached to cover layers either made steel or magnesium alloy. An analytical model established in order predict process forces during forming, which are blankholder force required make covers yield plastically, punch force, and corresponding load distribution on individual (outer layer, inner layer)....

Additive manufacturing as a process for producing semi-finished parts subsequent forming operation has not been investigated yet. This paper examines the behavior of an additively manufactured monolithic sheet metal in three point bending. An approach numerical simulation is proposed, with results material characterization Hastelloy X. The anisotropic implemented Hill (1948) yield criterion. reveal that it possible to characterize employing testing procedures commonly used technologies and...

Abstract Incremental sheet-bulk metal forming (iSBMF) enables the manufacture of functional lightweight components featuring a load-adapted shape with high material efficiency. The flexibility incremental process allows for modification strain path through adjustment tool motion while maintaining final product geometry. These modifications generate both different hardening and damage evolution. In this paper, numerical experimental investigation paths is carried out to identify their impact...

The possibility of applying CMR-B-scalar sensors made from thin manganite films exhibiting the colossal magnetoresistance effect as a fast-nondestructive method for evaluation quality magnetic pulse welding (MPW) process is investigated in this paper. This based on field magnitude measurements vicinity tools and joining parts was tested during electromagnetic compression MPW an aluminum flyer tube with steel parent. testing setup used investigation allowed simultaneous measurement...

Abstract A new process combination route consisting of additive manufacturing (AM) with a subsequent forming operation is proposed. The has the opportunity to increase efficiency AM up 360%. Stainless steel 316L sheets different core structures (similar sandwich sheets) are produced by AM, characterized, and formed in die bending operation. characteristics this novel semi-finished product can be accurately predicted numerical simulation. discussed detail compared conventional parts terms...