Bernard Rolfe

The Influence of Temperature on the Forming Behavior of Metal/Polymer Laminates in Sheet Metal Forming

The influence of temperature on the forming behavior of an aluminum/polypropylene/aluminum (APA) sandwich sheet was studied. Shear and tensile tests were performed to determine the mechanical properties of the laminate and the component materials as a function of process temperature. The forming limit diagram (FLD) of the laminate was established for two different temperatures, and its springback behavior was examined in four-point bend and channel bend tests. Cup forming tests were performed at various test temperatures to determine the limiting drawing ratio (LDR) and the tendency for wrinkling at these temperatures. Although there was only a minor influence of temperature on the mechanical properties and the FLD values of the laminate, the bend test results reveal that springback can be reduced by forming at higher temperature. The decreasing strength of the core material with rising process temperature led to an increased tendency of the laminate to wrinkle in the heated cup drawing tests.

The effect of skin passing on the material behavior of metal strip in pure bending and tension

The metal strip used in roll forming has often been preprocessed by (tension or roller) leveling or by skin-pass rolling, and as a consequence, may contain residual stresses. These stresses are not well observed by the tensile test, but could have a significant effect on the bending and springback behavior. With the advent of improved process design techniques for roll forming, including advanced finite element techniques, the need for precise material property data has become important. The major deformation mode of roll forming is that of bending combined with unloading and reverse bending, and hence property data derived from bend tests could be more relevant than that from tensile testing. This work presents a numerical study on the effect of skin passing on the material behavior of stainless steel strip in pure bending and tension. A two dimensional (2-D) numerical model was developed using Abaqus Explicit to analyze the affect of skin passing on the residual stress profile across a section for various working conditions. The deformed meshes and their final stress fields were then imported as pre-defined fields into Abaqus Standard, and the post-skin passing material behavior in pure bending was determined. The results show that a residual stress profile is introduced into the steel strip during skin passing, and that its shape and stress level depend on the overall thickness reduction as well as the number of rolling passes used in the skin passing process. The material behavior in bending and the amount of springback changed significantly depending on the skin pass condition.

Effects of Microstructure on the Variation of the Unloading Behavior of DP780 Steels

The nonlinear unloading behavior of three different commercial dual-phase steels (DP780 grade equivalent) was examined. These steels exhibited small variations in chemical composition (0.07 to 0.10 mass percent carbon) and martensite volume fraction (0.23 to 0.28), and they demonstrated similar hardening behavior. Uniaxial loading-unloading-loading tests were conducted at room temperature and quasi-static strain rates between engineering strains of 0.5 and 8%. Steel microstructures were examined using electron backscatter diffraction and nanoindentation techniques. The microplastic component of the unloading strain exhibited no dependence on the martensite volume fraction or the ferrite grain size within the small range encountered in this investigations. Instead, the magnitude of the microplastic component of the unloading strain increased as the strength ratio between the martensite and ferrite phases increased. Correspondingly, the apparent unloading modulus, or chord modulus, exhibited a greater reduction for equivalent increments of strain hardening as the strength ratio increased. These results suggest that springback can be reduced in structures containing two ductile phases if the strength ratio between the harder and softer phases is reduced.

Numerical Simulations on Warm Forming of Stainless Steel with TRIP‐Effect

In steels with TRIP‐effect, a phase transformation from the retained‐austenite to martensite occurs during forming, and it significantly affects hardening behaviours. Such an effect is sensitive to the amount of strain as well as the temperature variation. For materials with a strong TRIP‐effect, new forming techniques are needed to develop that can lead to lighter and stronger components in automotive industry. This paper presents a coupled thermo‐mechanical finite element modelling and simulation of a warm deep drawing of austenitic stainless steel (including a TRIP‐effect) using LS‐DYNA and temperature effect on forming process of such materials is investigated.

Experimental study into the correlation between the incremental forming and the nature of springback in automotive steels

Bending in a V-die has been well covered in the literature and the results have been used to indicate the out-come of bending in cold roll forming. However, recent work comparing springback between roll forming and single step bending has found lower springback in the roll forming process compared to single step bending. Roll forming is an incremental bending process and in this study a V-section was formed in a single operation and in multiple steps and the springback determined. The springback in V-die forming was significantly reduced by incremental forming. This suggests that the lower springback determined in roll forming compared to single step bending may be related to the incremental nature of the roll forming process.

Deformation and frictional heating in relation to wear in sheet metal stamping

Various analytical rules of mixture are commonly used to take into account heterogeneous features of a material and to derive global properties. But, with such models, one may not be able to fulfil the requirements for separating appropriately the different lengthscales. This might be the case for some issues such as strain localisation, surface effect, or topological distributions. At an intermediate lengthscale, which we refer to as the mesoscopic scale, one can still apply continuum mechanics. So why not perform calculations using the finite element method on volumes of material to obtain the response of Representative Elementary Volumes (R.E.V.). The construction of digital microstructures for such calculations is performed in two steps. First, a series of R.E.V.s with statistics of features of real materials should be defined. Then, finite element meshes should be produced for these R.E.V.s and updated when calculations involve large strains. Powerful automatic three-dimensional mesh generators and remeshing techniques prove necessary for this latter task. This strategy is applied to create digital R.E.V.s which match statistical features of forgings. Measurements provide micromechanical parameters of each subvolume. As an example of calculations, numerical simulations provide the anisotropic fatigue properties of forgings.

Localization with orientation using RSSI measurements: RF map based approach

Localization of RFIDs in the indoor environment will entail determining both the position and the orientation of the user. This paper develops estimator using RSSI measurements to predict the position and orientation of a transmitter in an indoor environment. The best estimator tried was an K-nearest neighbours model that gave an accuracy of approximately 83% for position prediction and 93% for orientation prediction. It was also found that the RSSI values change throughout the day, meaning that an adaptive estimator is necessary for localization.

Geometric shape errors in forging: developing a metric and an inverse model

Abstract The complexity of the forging process ensures that there is inherent variability in the geometric shape of a forged part. While knowledge of shape error, comparing the desired versus the measured shape, is significant in measuring part quality the question of more interest is what can this error suggest about the forging process set-up? The first contribution of this paper is to develop a shape error metric which identifies geometric shape differences that occur from a desired forged part. This metric is based on the point distribution deformable model developed in pattern recognition research. The second contribution of this paper is to propose an inverse model that identifies changes in process set-up parameter values by analysing the proposed shape error metric. The metric and inverse models are developed using two sets of simulated hot-forged parts created using two different die pairs (simple and ‘M’-shaped die pairs). A neural network is used to classify the shape data into three arbitrarily chosen levels for each parameter and it is accurate to at least 77 per cent in the worst case for the simple die pair data and has an average accuracy of approximately 80 per cent when classifying the more complex ‘M’-shaped die pair data.

An audio signal based model for condition monitoring of sheet metal stamping process

Tool condition monitoring is an important factor in ensuring manufacturing efficiency and product quality. Audio signal based methods are a promising technique for condition monitoring. However, the influence of interfering signals and background noise has hindered the use of this technique in production sites. Blind signal separation (BSS) has the potential to solve this problem by recovering the signal of interest out of the observed mixtures, given that the knowledge about the BSS model is available. In this paper, we discuss the development of the BSS model for sheet metal stamping with a mechanical press system, so that the BSS techniques based on this model can be developed in future. This involves conducting a set of specially designed machine operations and developing a novel signal extraction technique. Also, the link between stamping process conditions and the extracted audio signal associated with stamping was successfully demonstrated by conducting a series of trials with different lubrication conditions and levels of tool wear.

The numerical investigation of the material behavior of high strength sheet materials in incremental forming

Springback is an inevitable phenomenon in sheet metal forming and has been found to reduce with an increasing number of forming steps. In this study the effect of incremental forming on springback is analyzed for DP780 steel. The cyclic hardening characteristics of the DP780 steel are determined by fitting the experimental moment curvature data of a cyclic pure bending test using Abaqus Standard. The change in elastic modulus with pre-strain is also considered in the material model. Using the developed material model a V- die forming process is numerically analyzed for single and multiple-step forming, and the effect on springback determined. The numerical results show that there is a reduction in springback with an increasing number of forming steps, and that this may be due to the plastic strain accumulated in the blank during the sequential loading steps in the bending region. A very good agreement has been achieved between the simulation and the experimental results. The present study seems to offer an effective approach to increase the accuracy of the springback prediction and provide a greater insight into the nature of the springback in the incremental forming process.