Mohammad A. Nazzal

Finite element modeling and optimization of superplastic forming using variable strain rate approach

Detailed finite element simulations were carried out to model and optimize the superplastic blow forming process using a microstructure-based constitutive model and a multiscale deformation stability criterion that accounts for both geometrical instabilities and microstructural features. Optimum strain rate forming paths were derived from the multiscale stability analysis and used to develop a variable strain rate forming control scheme. It is shown that the proposed optimization approach captures the characteristics of deformation and failure during superplastic forming and is capable of significantly reducing the forming time without compromising the uniformity of deformation. In addition, the effects of grain evolution and cavitation on the superplastic forming process were investigated, and the results clearly highlight the importance of accounting for these features to prevent premature failure.

Combined Mechanics-Materials Based Optimization of Superplastic Forming of Magnesium AZ31 Alloy

A new optimization approach for superplastic forming of Mg AZ31 alloy is presented and experimentally validated. The proposed new optimization approach is based on a multiscale failure criterion that takes into account both geometrical necking and microstructural evolution, yielding a variable strain rate forming path instead of the commonly used constant strain rate approach. Uniaxial tensile tests and free bulge forming experiments, in conjunction with finite element analysis, are used to evaluate the proposed optimization approach. Significant reduction in forming time is achieved when following the proposed optimization approach, without compromising the uniformity of deformation.

Finite Element Modeling of Superplastic Forming in the Presence of Back Pressure

It is established that some superplastic materials undergo significant cavitation during deformation. Cavitation not only limits the superplastic ductility of the material, but also reduces the service properties and the fatigue performance of the formed parts. Experimental results have shown that an effective method to eliminate cavitation is the application of hydrostatic pressure during deformation. In this work, finite element simulations are carried out to study the effects of hydrostatic pressure on damage evolution during SPF. The analysis is conducted for the superplastic copper based alloy Coronze-638 at 550 °C. The results clearly demonstrate the effectiveness of the superimposition of hydrostatic pressure in reducing the amount of cavities generated during SPF and improving the integrity of the formed part.

Inclination Angle Effect on the Thickness Distribution in a Superplastic Formed Long Rectangular Pan

In the superplastic process, the non-uniformity of the produced part thickness and the possibility of severe thinning are among the major disadvantages. This paper presents a parametric study on the superplastic forming of a Pb-Sn sheet into the shape of a long rectangular pan. A two dimensional plain strain finite element model was used to predict the forming times and thinning profiles of the formed Pb-Sn pan. The effect of varying the sidewall inclination angle was investigated for different friction conditions at the die-sheet interface. Results showed that increasing the side wall inclination angle reduced the forming time and provided a better thickness distribution.

On The Stability of Superplastic Deformation Using Nonlinear Wavelength Analysis

Optimum variable strain rate forming paths based on two multiscale deformation-based stability criteria are developed. The first criterion is based on Hart’s linear stability analysis while in the second criterion; we introduce a modified one dimensional nonlinear long wavelength analysis introduced by Hutchinson and Neale [7] based on the well known 2-D Marciniak-Kuczynski criterion. The stability criteria are calibrated for the AZ31 Mg alloy at 400 °C yielding two different variable strain rate forming paths. These paths show that the nonlinear wavelength analysis is more sensitive to strain rate sensitivity and results in larger attainable uniform strains than Hart’s approach especially at low strain rates. This result is demonstrated through finite element simulations of a deep rectangular box using pressure profiles derived from the two variable strain rate forming paths. The FE results clearly illustrate that Hart’s approach underestimates the amount of uniform deformation and therefore prolongs the forming time to prevent failure compared to the nonlinear analysis.

Proposal of an alternative material for the Energy Storage And Return foot

With the ever growing demand of prosthetics due to increased amputations, there is a need for development of an economic prosthetic foot which has similar functional integrity to that of a higher end model. The main need of this arises in developing countries where people are not able to afford such prosthetics. The primary objective of this study is the development of an Energy Storage And Return foot that is economically viable. In this Work, finite element simulations were conducted for a new Acrylonitrile Butadiene Styrene (ABS) material. The proposed ABS foot showed identical results to that of a commercial Carbon Fiber foot. Moreover, the proposed foot is cheaper, has a less weight, and appropriately stiff.

An Experimental Study on the Stability of Superplastic Deformation of AZ31 Mg Alloy

Optimum variable strain rate forming paths based on two different multiscale deformation‐based stability criteria were developed. These criteria account for both geometrical necking (macroscopic feature) and microstructural evolution. In the first criterion, we defined the onset of instability using Hart’s stability analysis, where a linear perturbation in a small region along the tensile specimen is introduced. In the second criterion, we introduced a modified one dimensional nonlinear long wavelength analysis, based on the one introduced by Hutchinson and Neale. The two stability criteria are calibrated for the AZ31 magnesium alloy at 400 °C, yielding two different variable strain rate forming paths. Uniaxial tensile tests are carried out following the derived forming paths to examine the validity of both criteria. Results show that the linear approach underestimates the amount of uniform deformation, and therefore prolongs the forming time to prevent failure compared to the nonlinear analysis.