Size effects play a significant role in metal processing when the specimen dimensions are reduced. In this study, influence of size effects were investigated on two problem specific processes. First, numerical simulations of a small-scale forward extrusion with varying grain size were performed for both 2D and 3D cases. Here, grains were assigned to non-homogeneous properties in a random fashion. The computational geometry was obtained from Voronoi tessellation in MATLAB, and python-scripting in ABAQUS. Then the effects of size and property non-homogeneity were investigated. Second, a numerical model was simulated to predict final form shapes, punch load requirement, and thickness distribution of hemispherical bowl-shaped forming. The die, punch and cover plate were fabricated using stereolithographic apparatus (SLA). Numerically obtained punch load requirement, thickness distribution, von-Mises contours, and equivalent plastic strain contours were compared for different thickness specimens. Finally, the models were validated by experimental results.

Este trabalho visa modelar e estabelecer procedimentos experimentais para permitir a construção de mapas de conformabilidade plástica dos metais fundamentados na mecânica da fratura não-linear elasto-plástica. Um critério de conformabilidade plástica foi desenvolvido pela utilização de uma integral invariante generalizada baseada no teorema de Noether das integrais invariantes. Discute-se também as limitações da teoria da plasticidade que impossibilitam a obtenção de critérios de conformabilidade por seu intermédio. É um importante objetivo proporcionar o surgimento de uma metodologia de ensaio contendo alto rigor técnico mas sendo de baixo custo e de fácil implementação em simples instalações industriais. O procedimento foi aplicado no estudo do caso do forjamento a frio em matriz aberta, simulado por ensaio de compressão em prensa hidráulica. / The present study is aimed to the development of a low cost, to be implemented with ease, and technicality satisfactory industrial type testing for metal forming workability analysis. It is concerned with the development of an experimental procedures to permit the building up the metal forming workability maps, based on the nonlinear elastic-plastic fracture mechanics. A generalized nonlinear fracture mechanics invariant integral was applied to the case problem of the cold forging in flat open die of a ductile metallic material. At end a fracture criterion was developed in order to be possible the construction of the fracture deformation maps of the case study.

<p>Metal forming is widely used in the industry to produce cans, tubes, car chassis, rods, wires etc. Forming certain materials such as stainless steel, aluminium and titanium, is often difficult, and problems associated with transfer of work material to the tool material are frequent. Transferred material may scratch and deform the following manufactured pieces, a phenomenon named galling. Lubricants can, to some degree, solve these problems. However, many forming oils are hazardous to the environment, and therefore it is highly desirable to replace them or get rid of them.</p><p>This thesis investigates the nature of the galling phenomenon and tries to explain under which conditions such problems arise. Dry sliding tests have been performed in a dedicated load-scanner equipment. Difficult work materials have been tested against tool materials under various conditions and the samples have then been studied by advanced analytical techniques, such as ESCA and TEM, to study the detailed tribological mechanisms occurring in the contact between work and tool material.</p><p>The general assumption is that material transfer only occurs when there is metal to metal contact. In this work it has been found that, for stainless steel, the oxide plays a very important role for the sticky behaviour of stainless steel, and that metal to metal contact is not a necessary condition for galling.</p><p>Several PVD-coated tool materials have been tested and it was found that vanadium nitride coatings can be tuned regarding their chemical composition, to be more galling resistant than conventional coatings.</p><p>The surface roughness of the tool material is very strongly coupled to the tools ability to resist galling. The smoother the tool surface, the less risk of material transfer and galling.</p><p>Some work materials, like aluminium and titanium, transfer to even the smoothest tool materials. A proposed explanation for this is that their oxides are much harder than the bulk material and the tool material matrix. When deforming the work material, the oxide will fracture into small hard scales, which can indent the tool material. Indented hard scales will then contribute to material transfer of more work material to the tool.</p>

Metal forming is widely used in the industry to produce cans, tubes, car chassis, rods, wires etc. Forming certain materials such as stainless steel, aluminium and titanium, is often difficult, and problems associated with transfer of work material to the tool material are frequent. Transferred material may scratch and deform the following manufactured pieces, a phenomenon named galling. Lubricants can, to some degree, solve these problems. However, many forming oils are hazardous to the environment, and therefore it is highly desirable to replace them or get rid of them. This thesis investigates the nature of the galling phenomenon and tries to explain under which conditions such problems arise. Dry sliding tests have been performed in a dedicated load-scanner equipment. Difficult work materials have been tested against tool materials under various conditions and the samples have then been studied by advanced analytical techniques, such as ESCA and TEM, to study the detailed tribological mechanisms occurring in the contact between work and tool material. The general assumption is that material transfer only occurs when there is metal to metal contact. In this work it has been found that, for stainless steel, the oxide plays a very important role for the sticky behaviour of stainless steel, and that metal to metal contact is not a necessary condition for galling. Several PVD-coated tool materials have been tested and it was found that vanadium nitride coatings can be tuned regarding their chemical composition, to be more galling resistant than conventional coatings. The surface roughness of the tool material is very strongly coupled to the tools ability to resist galling. The smoother the tool surface, the less risk of material transfer and galling. Some work materials, like aluminium and titanium, transfer to even the smoothest tool materials. A proposed explanation for this is that their oxides are much harder than the bulk material and the tool material matrix. When deforming the work material, the oxide will fracture into small hard scales, which can indent the tool material. Indented hard scales will then contribute to material transfer of more work material to the tool.

Sheet metal forming is one of the most common forming processes used in the industry, especially in the automotive industry. It becomes a common sense, that by increasing the accurate simulation of sheet metal forming, the industry can save dramatic cost in trial-and-error process when designing the sheet metal forming tools. In past decades, considerable studies have been done in the field of numerical analysis of metal forming processes, particularly in springback prediction. Significant progresses have been made, but the accuracy of simulation results still needs to improve. One reason is that, in the typical sheet metal forming analysis the tools are considered as absolute un-deformable rigid bodies. The deformation of the tools, which happens in the real production, is not taken into account. Another reason may be that the classic simulation considers the friction coefficient between the tools and blank as constant. However, the actual friction condition depends on a number of parameters. The objective of this thesis work is trying to investigate how it will affect the springback prediction results when either the tool deformation or more complex friction conditions are considered. The purpose is nothing related with the precise simulation about the true problem or how accuracy the simulation results show compared to the experiment results. The work is only to give an emphasis hint that how the FE-model and friction mode chosen affects the springback results when doing a numerical analysis. A simple model called flex rail is used for sheet metal forming simulations with three different friction models. A comparison between the results clearly shows a difference when advanced friction models are applied. A 3D elastic solid model is created to compare the result with rigid model. The results show the difference when deformation of the tools is taken into account. Finally, an actual case with tools from the industry is investigated. The tools are from SAAB Cars Body Components. This case is to investigate the possibility and necessity of applying the advanced friction model and elastic tools when a complex real industry problem is faced. Further study is needed to do with comparison experimental data to verify the accuracy when these models are used.

Sheet metal forming has an important place among metal forming processes. As the usage of sheet metal increases, the fatigue simulation and optimization of these parts become more important. This thesis study examines the change of the fatigue life of a sheet metal part after forming. A sphere-like shape is deep drawn and change in thickness and residual stresses are analyzed. To understand the effect of residual stresses, deep drawn parts with and without residual stress tested against the fatigue failure. In parallel, the forming process is simulated with an implicit finite element method (FEM). The success of forming simulation is discussed in the study. Thickness changes and residual stresses calculated with FEM are included in computer aided fatigue analysis. The effect of thickness changes is examined with the results of FEM analysis. The effectiveness of the whole simulation process is discussed by comparing the outputs of experiments and computational analysis.

Aluminum based alloys have wide area of usage in automotive and defense industry and bending processes are frequently applied during production. One of the most important design criteria of bending processes is springback, which can be basically defined as elastic recovery of the part during unloading. To overcome this problem, heat treatment is generally applied to the workpiece material to refine tensile properties. In this study, the effect of heat treatment on springback characteristics of aluminum studied both numerically by using finite element analysis and experimentally. For this purpose, two different materials are selected and various heat treatment procedures are considered. The aluminum sheets having thickness of 1.6 mm, 2 mm and 2.5 mm are bent to 60&amp / #730 / , 90&amp / #730 / and 120&amp / #730 / . The von Mises stress distributions, plastic strain values and punch load values and comparison of the numerical and experimental results are also given.

The aim of this thesis is to investigate the effects of bulging and deep drawing processes on St4 cold rolled steel by simulation and experimental characterization. In the simulations, commercial software programs MSC Marc and Simufact.forming were used. The experimental studies cover metallographic investigations, hardness measurements, and residual stress measurements. Residual stress measurements were carried out by different non- destructive characterization methods / X-ray diffraction and Magnetic Barkhausen Noise. The experimental and simulation results were correlated with each other.

Abstract Today sheet metal forming is used to make a variety of mass production because it has a high production rate. One of the biggest concerns in sheet metal forming is wear of the tool in form of galling. Galling in sheet metal forming is characterised by an increased tool surface roughness, unstable friction in the forming process and undesirable scratches on the final products. Several ways of ranking materials resistance to galling exist today but only ASM G98 is standardised. Nevertheless, some different methods developed for ranking tool materials’ tendency to galling have also been developed. The aim of this thesis is to develop and improve the Uddeholm Tooling Tribo Test rig located at Uddeholm Tooling AB. The rig, which is a variation of cylinder-on-cylinder test equipment, was improved with a new tool holder, a utilization of the real sheet material counter face and a new data acquisition system and software. The galling was detected using scratches on the sheet, metallographic analysis of the material adhered on the tool specimen, monitoring of coefficient of friction and the standard deviation of the coefficient of friction. The obtained results show difficulties with ranking of tool materials in terms of galling resistance under non-lubricated conditions. The tool steels tested were SVERKER21 and UNIMAX. AISI304-10, DC04 and DOCOL1000DP sheets were used. Additionally a low friction coating of BalinitC on SVERKER21 was also included. All specimens of the tool steels showed signs of galling on every run, only the low friction coating showed a transition in behaviour of friction coefficient corresponding to galling initiation. The standard deviation of the coefficient of friction increased at low loads. A decrease of the test loads led to stability loss of the system detected by an increase in the standard deviation of the coefficient of friction. This might happen because the Kistler platform is originally designed for larger loads. Although, the test rig does not work properly in its present state, the concept looks promising.

Sheet metal forming has found increasing applications in modern industries. To eliminate use of expensive tools during product development, thermal forming, a rapid prototyping process that is flexible enough to decrease costs has been developed. Thermal forming processes use a heat source to perform the required deformation mainly by creating a thermal difference along the thickness of the sheet. Gas flames, lasers and plasma heat sources have been used for sheet metal bending by thermal forming. An alternative to laser and gas flames, plasma-jet forming has been developed that uses a non-transferred plasma arc as a heat source. The plasma-jet forming system uses a highly controllable non-transferred plasma torch as a heat source to create the necessary thermal gradient in the sheet metal that causes the required plastic deformation. Various experiments to produce simple linear bends and other complex shapes have been conducted by using different scanning options and coupling techniques. A computer simulated model using finite element method is being developed to study key parameters affecting this process and also to measure the thermal transient temperature distribution during the process. A predictive model to relate the deformation to the temperature gradient for various materials is being developed. Simulation results that are in accordance to experimental observations will further improve this material forming process to be highly controllable and more accurate