Numerical Modelling and Simulation of Metal Processing

This book deals with metal processing and its numerical modelling and simulation. In total, 21 papers from different distinguished authors have been compiled in this area. Various processes are addressed, including solidification, TIG welding, additive manufacturing, hot and cold rolling, deep drawing, pipe deformation, and galvanizing. Material models are developed at different length scales from atomistic simulation to finite element analysis in order to describe the evolution and behavior of materials during thermal and thermomechanical treatment. Materials under consideration are carbon, Q&T, DP, and stainless steels; ductile iron; and aluminum, nickel-based, and titanium alloys. The developed models and simulations shall help to predict structure evolution, damage, and service behavior of advanced materials

Impulse-Based Manufacturing Technologies

In impulse-based manufacturing technologies, the energy required to form, join or cut components acts on the workpiece in a very short time and suddenly accelerates workpiece areas to very high velocities. The correspondingly high strain rates, together with inertia effects, affect the behavior of many materials, resulting in technological benefits such as improved formability, reduced localizing and springback, extended possibilities to produce high-quality multi material joints and burr-free cutting. This Special Issue of JMMP presents the current research findings, which focus on exploiting the full potential of these processes by providing a deeper understanding of the technology and the material behavior and detailed knowledge about the sophisticated process and equipment design. The range of processes that are considered covers electromagnetic forming, electrohydraulic forming, adiabatic cutting, forming by vaporizing foil actuators and other impulse-based manufacturing technologies. Papers show significant improvements in the aforementioned processes with regard to: Processes analysis; Measurement technique; Technology development; Materials and modelling; Tools and equipment; Industrial implementation

Active thermography for the investigation of corrosion in steel surfaces

The present work aims at developing an experimental methodology for the analysis of corrosion phenomena of steel surfaces by means of Active Thermography (AT), in reflexion configuration (RC). The peculiarity of this AT approach consists in exciting by means of a laser source the sound surface of the specimens and acquiring the thermal signal on the same surface, instead of the corroded one: the thermal signal is then composed by the reflection of the thermal wave reflected by the corroded surface. This procedure aims at investigating internal corroded surfaces like in vessels, piping, carters etc. Thermal tests were performed in Step Heating and Lock-In conditions, by varying excitation parameters (power, time, number of pulse, ….) to improve the experimental set up. Surface thermal profiles were acquired by an IR thermocamera and means of salt spray testing; at set time intervals the specimens were investigated by means of AT. Each duration corresponded to a surface damage entity and to a variation in the thermal response. Thermal responses of corroded specimens were related to the corresponding corrosion level, referring to a reference specimen without corrosion. The entity of corrosion was also verified by a metallographic optical microscope to measure the thickness variation of the specimens

Advances in Plastic Forming of Metals

The forming of metals through plastic deformation comprises a family of methods that produce components through the re-shaping of input stock, oftentimes with little waste. Therefore, forming is one of the most efficient and economical manufacturing process families available. A myriad of forming processes exist in this family. In conjunction with their countless existing successful applications and their relatively low energy requirements, these processes are an indispensable part of our future. However, despite the vast accumulated know-how, research challenges remain, be they related to the forming of new materials (e.g., for light-weight transportation applications), pushing the boundaries of what is doable, reducing the intermediate steps and/or scrap, or further enhancing the environmental friendliness. The purpose of this book is to collect expert views and contributions on the current state-of-the-art of plastic forming, thus highlighting contemporary challenges and offering ideas and solutions

Recent advances and applications of machine learning in metal forming processes

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Recent Advances and Applications of Machine Learning in Metal Forming Processes

Machine learning (ML) technologies are emerging in Mechanical Engineering, driven by the increasing availability of datasets, coupled with the exponential growth in computer performance. In fact, there has been a growing interest in evaluating the capabilities of ML algorithms to approach topics related to metal forming processes, such as: Classification, detection and prediction of forming defects; Material parameters identification; Material modelling; Process classification and selection; Process design and optimization. The purpose of this Special Issue is to disseminate state-of-the-art ML applications in metal forming processes, covering 10 papers about the abovementioned and related topics

Review on the prediction of residual stress in welded steel components

Residual stress after welding has negative effects on the service life of welded steel components or structures. This work reviews three most commonly used methods for predicting residual stress, namely, empirical, semi-empirical and process simulation methods. Basic principles adopted by these methods are introduced. The features and limitations of each method are discussed as well. The empirical method is the most practical but its accuracy relies heavily on experiments. Mechanical theories are employed in the semi-empirical method, while other aspects, such as temperature variation and phase transformation, are simply ignored. The process simulation method has been widely used due to its capability of handling with large and complex components. To improve its accuracy and efficiency, several improvements need to be done for each simulation aspect of this method

Engineering for a changing world: 60th Ilmenau Scientific Colloquium, Technische Universität Ilmenau, September 04-08, 2023 : programme

In 2023, the Ilmenau Scientific Colloquium is once more organised by the Department of Mechanical Engineering. The title of this year’s conference “Engineering for a Changing World” refers to limited natural resources of our planet, to massive changes in cooperation between continents, countries, institutions and people – enabled by the increased implementation of information technology as the probably most dominant driver in many fields. The Colloquium, supplemented by workshops, is characterised but not limited to the following topics: – Precision engineering and measurement technology Nanofabrication – Industry 4.0 and digitalisation in mechanical engineering – Mechatronics, biomechatronics and mechanism technology – Systems engineering – Productive teaming - Human-machine collaboration in the production environment The topics are oriented on key strategic aspects of research and teaching in Mechanical Engineering at our university