L. Cannizzaro

Prediction of Ductile Fractures in Metal-Forming Processes: an Approach Based on the Damage Mechanics

The Authors propose a new approach for the prediction of ductile fractures in bulk metal forming processes: the approach is based on a numerical analysis able to take into account damage occurrence and evolution in constitutive equations. The model supplies the distribution of the void volume fraction in the workpiece during the deformation path: consequently, the comparison to a critical value, determined by means of a simple tension test, allows to predict the growth of defects. The proposed approach has been applied to the drawing process: the numerical results have been compared with a set of experimental tests showing a good predictive capability of the model.

Validation of Frictional Studies by Double-Cup Extrusion Tests in Cold-Forming

Abstract Studies on frictional conditions in cold-forming have shown that, for a given lubricant, friction factor values are strongly affected by the test method. In the present paper, different cold-forging processes of an aluminium alloy, are modelled by a FEM numerical code using the m values obtained by both the double cup extrusion and ring compression tests. It appears that the m values given by the ring tests can be effectively used in the simulation of upsetting processes, while the m values derived by the double cup extrusion tests are more appropriate for predictions in extrusion and closed-die forging operations.

Knowledge-Based Systems and F.E. Simulations in Metal-Forming Processes Design An integrated Approach

Summary The automatic computer aided planning and design of cold forming processes includes several phases, among which the most important are the optimal choice of the forming operations sequence and, for each operation, the determination of the more suitable operating parameters. With this aim the Authors propose an integrated approach based on the preliminary choice of some feasible forming sequences, carried out by means of a knowledge-based system, and on the subsequent determination of the optimal one employing a finite element simulation of the process.

A New Numerical Method for Axisymmetrical Forming Processes

Summary In this paper a numerical method for the analysis of axisymmetrical forming processes is proposed. This method represents the last development of a previous one which allows to solve forming problems in plane strain condition. The proposed model is baaed on the finite element discretization and on the linearization of the yield surface which leads to solve a LP problem. Two different examples of application, concerning the upsetting of a cylinder and of a hollow disk are reported.

A Numerical Method for the Analysis of Plane-Strain Forming Processes with Unilateral Constraints

The Authors propose a numerical model for the solution of plane-strain forming processes, based on the linearization of the yield surface. This allows to employ the linear programming technique for the solution of the variational problem derived from the application of the upper-bound theorem. Such a model permits to take into account the unilateral constraints in a very simple way. Therefore it is well suited to solve a large class of problems, such as sheet forming, in which the unilateral constraints are often present.

Coupled Thermal-Mechanical Analysis of Hot Metal Forming Processes

Summary A numerical model able to perform the coupled thermal mechanical analysis of metal forming processes is proposed. The model allows to obtain the simultaneous solution of the mechanical and thermal problems avoiding staggered procedures. The proposed approach is a further development of the LP finite element code based on the linearization of the yield surface which allows a non iterative solution procedure; this feature has been saved since the thermal balance is taken into account through a further set of linear constraints of the LP problem.

Computer-Aided Simulation of Die Filling Processes

Summary A numerical method for analysing the filling of axisymmetrical dies of complex shape is proposed. The method, which is a further development of a LP finite element model, is able to take into account the contact conditions directly in the mathematical formulation of the problem. In such a way the solution of the die filling process is obtained by solving a LP problem, avoiding problems of numerical convergence and the heavier calculations requested by other iterative methods.

H and P Mesh Refinement in the Metal-Forming F.E.M. Analysis

In this paper a comparison between H and P refinement techniques in the metal-forming F.E.M. analysis is carried out in order to evaluate their computational efficiency. The results are compared using a particular error estimator which locally allows determining the workpiece zones where the refinement is necessary.

The Continuous Extrusion Process CONFORM: a full 3D Thermal and Mechanical Analysis

The principle of the Conform extrusion process is based on the action of a rotating wheel that drags and push the feed material by means of the frictional force existing between them. The Conform process has several advantages over the traditional extrusion processes. The preheating phase may be neglected, so that furnaces for heating are not necessary; furthermore, the product is continuous and welding phase of the billets is not required. The influence of three operative parameters, die geometry, velocity and die cooling rate, has been analysed in this paper by means of an “outranking approach” able to give precious indications for the assessment of the process.

Limits of the Open-Die Forward Extrusion: Numerical Analysis and Experimental Tests

In the paper the open-die forward extrusion process is analysed in order to determine the influence of the most important geometrical and frictional parameters on the practical suitability of the operation. Experimental tests have been carried out and their results have been compared with the numerical ones derived by FEA.