Metal Forming 2004

STEEL-GRIPS 2 (2004) Suppl. Metal Forming 2004

PROCEEDINGS OF THE 10TH INTERNATIONAL CONFERENCE ON METAL FORMING

METAL FORMING 2004 AKADEMIA GORNICZO-HUTNICZA KRAKOW, POLAND September 19-22, 2004

Edited by Jan Kusiak, Peter Hartley, Janusz Majta, Ian Pillinger and Maciej Pietrzyk

Akademia Gorniczo-Hutnicza Krakow, Poland

2 (2004) Suppl. Metal Forming 2004

University of Birmingham United Kingdom

Contents

Table of Contents Preface

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Keynote Papers Reiner Kopp, Oliver Hofmann,. Vincent Honnet, Christian Plociennik Real metal forming and virtual reality Virtual reality, metal forming, CSP facility, hierarchy, visualization, simulation, portal virtual CSP plant, ring rolling Erkki Laitinen, Jali Pieska, Ismo Rentola, Valtteri Toivonen Quality optimization of steel products in continuous casting process using numerical optimization and soft reduction Continuous casting, soft reduction, quality optimization, modelling, real time simulation Wan Chastel, Roland Loge Coupling microstructure models with large scale forming simulations Metallurgical models, recrystallisation, phase change, texture Jerzy Rojek, Michal Kleiber, Antoni Piela, Rafal Stocki, Jaroslaw Knabel Deterministic and stochastic analysis of failure in sheet metal forming operations Sheet stamping simulation, reliability analysis, response surfaces, adaptive Monte Carlo technique Andrzej Rosochowski, Lech Olejnik, Maria Richert Metal forming technology for producing bulk nanostructured metals Nanostructured materials, nanocrystalline metals, severe plastic deformation, equal channel angular pressing P. D. Hodgson, H. Beladi The formation of ultrafine grained steel microstructures through thermomechanical processing Ultrafine ferrite, thermomechanical processing, steels, transformation, dynamic recrystallization, grain refinement

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Rolling Junfeng Mei, Michael R. Lovell, Frederick S. Pettit Mechanical and metallurgical properties of hot rolling Ti-6AI-4V sheets Ti-6A1-4V, Hot rolling, mechanical and metallurgical properties, recrystallization, intermediate plate, final sheet, mill annealing Zhengyi Jiang, Xiaoming Zhang, KietA. Tieu, Weihua Sun Mechanics of slab edging with friction consideration Friction consideration, slab edging, horizontal rolling, rigid visco-plastic fem, width variation, dog-bone Zhengyi Jiang, Hongtao Zhu, Kiet A. Tieu Effect of roll edge local perturbation of deformation on thin strip rolling Roll edge local perturbation of deformation, cold strip rolling, strip width, transverse friction, edge contact length, numerical simulation

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Contents Ahmed Ismail, Taher El-Bitar, Abdel-Wahab El-Morsy, Mohamed Abdel-Aziz Parameters affecting free spread of stainless steel grade 304 Austenitic stainless steel, free spread, experimental design technique, friction coefficient, deformation parameters, rolling velocity, box pass design, oval-round pass design, geometry of roll gap Mahmoud Salimi, Mahmoud Kadkhodaie Asymmetrical cold sheet rolling in free horizontal entry conditions Asymmetrical sheet rolling, slab method, plane strain condition, shear stress distribution, pressure distribution Annika Nilsson, Agne Bogdanoff, Suvi Niemi A study on the ski end direction in plate mills Ski-ends, plate rolling, asymmetric rolling, FEM, shape factor

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Sebastian Mroz, Andriy Milenin, Henryk Dyja A determination of the total roll separating force during rolling of bimetal rods in the grooves roll separating force, bimetallic rods, elongating grooves, FEM Kazimierz Kolodziej, Zbigniew Bigaj, Ryszard Korzekwa Production of a new type of block-tram rail for European Union at Krolewska Steelworks Ltd. Tramway block rail, roll pass design, free cross-flowing of metal, chambers of rail Sebastian Mroz, Andriy Milenin, Henryk Dyja Numerical modeling of stock stability in the roll grooves during shape rolling Stock stability, elongating grooves, numerical modeling, FEM Jaroslaw Bartnicki, Zbigniew Pater The influence of tool geometry on the CWR process of hollowed shafts Cross-wedge rolling, FEM, hollowed shaft, wedge tool Carlo Bruni, Mohamad El-Mehtedi, Archimede Forcellese, Filippo Gabrielli, Michela Simoncini Simulation of multipass hot rolling of AA 6082 aluminium alloy Aluminium alloy, flow behaviour, hot torsion test, multistage deformation, rolling schedule, simulative technique

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Forging Friedrich-Wilhelm Bach, Bernd-Arno Behrens, Helge Dahndel, Michael Gummert, Aziz Huskic Reducing the process chain for the production of gear wheels by precision forging - integration of heat treatment and necessary changes of the process management Reducing the process chain, precision forging, gear wheels, integrated heat treatment, process management, cost reduction, automotive industry Maria Leopoldina Alves, Jorge Rodrigues, Paulo Martins Numerical and experimental analysis of the closed-die forging of aluminium spiders Closed-die forging of spiders, finite element method, experimentation Hendrik Just, Arno Behrens Investigations on the use of damage criteria under semi-hot forging conditions with FE-methods Semi-hot forging, FE Simulations, fracture, damage mechanics 2

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Contents Aneta tukaszek-Sofek, Jan Sihczak Piotr Skubisz Design of forging technology with using the cost - volume - profit model Forging technology, stress, model CVP, design, FEM, drop forging Pavel Petrov, Victor Perfilov, Michael Petrov Development and research on near net shape forging technology of round part with flange made of aluminium alloy A95456 isothermal forming, near-net shape forging, precision forging, friction factor, aluminium alloy, numerical simulation, finite-element method Grzegorz Samolyk, Zbigniew Pater An influence of the selected flash variables on the closed-die forging processes Flash gap, closed-die steel forging, plane-strain forging, thermo-mechanical FEM, poly-optimisation R. Di Lorenzo, S. Beccari, M. Piacentini, F. Micari Numerical and experimental investigation on hot impression die forging: flash design optimisation Impression die forging, flash design, forging load, wear, process design, FEM, experimental tests Mahmoud Salimi, Mojtaba Kabirian An upper bound stream function elemental technique for the forging of spur gears Upper bound, stream function, elemental technique, forging, spur gears, spline

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Extrusion Thomas Hatzenbichler, Bruno Buchmayr, Alfred Umgeher Numerical sensitivity study to determine the effects on transverse welds in direct extrusion of AlMgSi-alloys Billet-to-billet-extrusion, finite element simulation, transverse welds, Deform™, aluminium

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Piotr Skubisz, Jan Sihczak, Aneta Sofek Extrusion of magnesium alloy profiles Magnesium wrought alloy, AZ61, AZ80, extruded profiles, direct extrusion

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Jung Min Lee, Byung Min Kim, Hyung Ho Jo, Chung Gil Kang Development of direct extrusion process for Al multi-cell tube using porthole die Porthole die, multi-cell tube extrusion, stress analysis

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Byung Min Kim, Jung Min Lee, Hyung Ho Jo, Chung Gil Kang Development of extrusion process and die design for Al speaker body Speaker body, finite element method, extrusion, die design, aluminium

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Drawing Tsutomu Yamashita, Kazunari Yoshida Prevention of wire breaks and its analysis by FEA in superfine gold wire drawing Wire drawing, Wire breaking, Inclusion, Superfine gold wire, FEA Kazunari Yoshida Cold drawing of magnesium alloy wire and fabrication of microscrews Magnesium alloy wire, cold wire drawing, microscrew, form rolling, warm forging iPi 2 (2004) Suppl. Metal Forming 2004

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Contents Andriej Milenin, Henryk Dyja, Zbigniew Muskalski, Jan Pilarczyk FEM analysis of a multi-pass hydrodynamic drawing process of high carbon steel wires with different drawing directions FEM simulation, hydrodynamic drawing, roller die drawing, direction of drawing, high carbon steel wires

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Hydroforming - Tube Forming Rudolf Kawalla, Serguei Gouk Peculiarity of the interaction between material properties and deformation conditions during sheet hydroforming Microstructure constituents, local material flow, deep drawing, phase deformation, macro heterogeneity, deformation and orientation of hard structural components

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M. Tajdari, H. Moslemi Naeini, M. Kiuchi, Ali Sanati, S. E. Hosseini Mehraban, D. Rezaee Computer aided design of reshaping process of circular pipes into square pipes Circular pipes, square pipes, shear deformation, reshaping process, numerical simulation

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Carl Labergere, Arnaud Lejeune, Jean-Claude Gelin Optimization and control of flange and tube hydroforming processes Optimisation, process control, finite elements, sensitivity analysis, process parameters, damage

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Sheet Forming Mehdi Ben Tahar, Elisabeth Massoni Use of the modified maximum force criterion for necking analysis during sheet bulging Strain rate sensitivity, necking, bulging, FLC, modified maximum force criterion, strain path Tony Downes, Peter Hartley, Ian Pillinger A storage and retrieval system for roll-forming design data using a neural network Artificial neural networks, ANN, cold roll-forming, tool design, data storage, data retrieval Malgorzata Sitek, Feliks Stach Estimation of hole flangeability for AW5754 aluminium alloy sheets Sheet metal, hole flanging, flangeability, aluminium alloy, punch geometry, strain hardening exponent, plastic anisotropy, limit strains Yohei Abe, Ken-ichiro Mori, Takuji Murao, Fujio Okubo Improvement of roughness of inner surface in multi-stage deep drawn stainless steel cups by inner ironing Sheet metal forming, ironing, surface roughness, deep drawing, stainless steel, inner surface, finite element simulation Tae-Wan Ku, Beom-Soo Kang Analysis and design of multi-stage deep drawing process for rectangular case of extreme aspect ratio by FEM Multi-stage deep drawing, rectangular case , extreme aspect ratio, process design, FEM Vincent Nalewajk, Jean Paul Nauzin, Yvan Chastel Importance of temperature control in warm deep drawing of aluminium Warm deep drawing, aluminium alloy, heat transfer coefficient, forming limit diagram 4

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Contents Takahiro Ohashi

Multi-point die support system controlling deep-drawing die deformation

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Drawing, die, multi-point support, press, trial-less Gerrit Klaseboer, Jan Post, Erwin Stinstra, Han Huetink

A study on the influence of waiting time between forming steps on the form accuracy of a three stage formed deep drawn product made of Sandvik Nanoflex™

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Nanoflex™, metal forming, DACE, stress-assisted, strain-induced, transformation Yasuo Marumo, Hiroyuki Saiki, Liqun Ruan

Prevention of wrinkling and fracturing in deep drawing of metal foil using resin dies and auxiliary sheets

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Deep drawing, nickel foil, copper foil, resin auxiliary sheets, resin dies, wrinkling, fracturing, deep drawability Andrzej Matuszak, Dawid Krecisz

Springback analysis in drawbead simulator tests

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Springback, drawbead, simulator, material properties, friction, Al-alloy, steel Kuang-Jau Fann, Jing-Chin Yang, Pou-Yuan Hsiao

Bending profile metals in application with artificial neural networks

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Bending, profile metals, artificial neural networks, error back propagation, finite element simulation

A Bit of Art Kerstin Garbracht:

Metal - fascinating material for artists

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Special Processes Sanjay Jadhav, Roland Goebel, Werner Homberg, Matthias Kleiner

Die-less forming strategies for non-rotational symmetrical shapes

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Die-less forming, incremental forming, process optimization Miroslav Plancak, Dragila Vilotid, Milentije Stefanovid, Mladomir Milutinovic, Vesna Mandic

Cold indenting - UBET analysis, FE simulation and experimental verification

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Cold indenting, UBET, FE method, CADform 2D Robert Cacko, Piotr Czyzewski, Andrzej Kocahda

Initial optimization of self-piercing riveting process by means of FEM

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SPR, self-piercing riveting, numerical modelling, FEM, sheet joining, mechanical joining Isamu Aoki, Masahiro Sasada

Electromagnetic microforming of metal foil

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Electromagnetic forming, thin parts, electromagnetic force, direct forming, indirect forming, kinetic energy Michael R. Lovell, Pushkarraj Deshmukh, Nicholas Yavelak

Towards a fundamental understanding of the stretch levelling process

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Stretch levelling, edge wave, centre buckle, finite element analysis

Friction and Contact Phenomena Simon P. Jupp, Jesus Talamantes-Silva, John H. Beynon

Application of a fundamental friction model to the hot rolling of steel

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Adhesion theory of friction, hot rolling, steel, finite element modelling, friction algorithm, oxide scale 2 (2004) Suppl. Metal Forming 2004

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Contents Cristian Fedorciuc-Onisa, Didier CJ. Farrugia Through process characterization of frictional conditions for long product hot rolling Friction, lubrication, wear, oxide scale, rolling, FEA Jari Larkiola, Jari Nylander, Martti Verho Monitoring of process variables and friction during cold rolling Cold rolling, modelling, friction, monitoring, setup calculation Matteo Strano, Luca Sorrentino, Luigi Carrino Some issues about tools and friction in the negative dieless incremental forming process Sheet metal, dieless incremental forming, formability, robotic cell Marek Burdek A roll surface topography change during temper rolling Temper rolling, surface topography, 3D measurement, work roll Wolfgang Rasp, Christian Matthew Wichern Effects of idealized surface geometry on lubricant entrapment during plane-strain upsetting - an FEM study Lubricant pockets, plane-strain upsetting, surface topography Bernd-Arno Behrens, Lutz Barnert, Aziz Huskid Use of ceramic inserts for reduction of wear in forging tools Hot forging, wear, ceramic inserts, silicon nitride, sialon, active brazing, precision forging Petr Kotrbacek, Jaroslav Horsky, Miroslav Raudensky, Michal Pohanka Influence of parameters of hydraulic descaling on temperature losses and surface quality of rolled material Hydraulic descaling, experiment, heat transfer, surface quality, cooling

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Equipment and Measurements Chikara Murata, Takeo Machida, Shoji Futamura, Junichi Endou Development of direct drive digital servo press Digital servo press ,4-point loading, eccentric load, slide parallelism, AC servomotor, ball screw Uwe Dirksen, Sami Chatti, Matthias Kleiner Measuring of the curvature distribution of bent profiles Profile bending, three-roll-bending, closed-loop process control, curvature sensor, laser triangulation sensor, measurement of radii distribution, linear guidance system

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Annika Nilsson, Juha Jokisaari, Ake Stenstrom Measuring and calculating flatness during hot-coiling Hot coiling, experimental design, flatness, hot strip, strip tension

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Luis E. Hernandez-Castillo, John H. Beynon, Christophe Pinna, Sybrand van der Zwaag Determination of microscale deformation in hot worked steel Microgrid technique, hot deformation, local strain, phase transformation

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Modelling Ghassane Ayad, Arnaud Lejeune, Thierry Barriere, Jean-Claude Gelin Finite element modeling and optimization of powder segregation during metal injection molding

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Metal injection molding, segregation, optimization, response surface modelling, design ofexperiments, genetic algorithm 6

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Contents John Alexis, Xavier Satheesh An analysis on the parameter optimization in ring rolling process Radial and axial forces, feed rate, thickness reduction, diametral growth, strain rate Nicolas Pernin, Jerome Chambert, Philippe Picart Implementation of a nonlocal damage model - mesh dependence in sheet metal forming Nonlocal damage, micromechanical model, finite element analysis, modelling, length scale parameter Celine Pelissou, Elisabeth Massoni, Jean-Loup Chenot A mixed temperature/heat flux formulation for solving unsteady thermal problem during forming process simulation Unsteady thermal problem, finite element, mixed formulation, linear interpolation, implicit time integration, discontinuous galerkin, thermal shock, hot forging process Vincent Lemiale, Philippe Picart Modelling and simulation of precision blanking for very thin components Blanking, damage, fracture, finite element analysis Andriy Milenin, Henryk Dyja 3D FEM analysis and optimization of metal forming and temperature development during multi-pass rolling of the round shape Multi-pass rolling, finite element method, inter-pass pause Eckart Doege, Bernd-Arno Behrens, Falko Schaefer Prediction of surface layer hardness in hot forging dies by means of finite-element-analysis FEM-simulation, precision forging, die temperature, surface layer, microstructure

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Properties of Materials Odd-Geir Lademo, Torodd Berstad, Odd Sture Hopperstad, Ketill Olav Pedersen A numerical tool for formability analysis of aluminium alloys. Part I: Theory Instability, aluminium, texture, anisotropy, FLD, inhomogeneity Odd-Geir Lademo, Ketill Olav Pedersen, Torodd Berstad, Odd Sture Hopperstad A numerical tool for formability analysis of aluminium alloys. Part II: Experimental validation. Instability, aluminium, texture, anisotropy, FLD, inhomogeneity Hirohiko Takuda, Tomofumi Kanie, Eiji Isogai, Tohru Yoshida Application of ductile fracture criteria to prediction of forming limit of high-strength steel sheets Forming limit, high-strength steel sheet, ductile fracture criterion, biaxial stretching test, deep drawing, finite element simulation Matthias Weiss, Bernard F. Rolfe, Matthew E. Dingle, Peter D. Hodgson The influence of interlayer thickness and properties on springback of SPS(steel/polymer/steel) laminates SPS-laminates, draw-bending, springback, sheet, FEA simulation Timo Manninen, Antti S. Korhonen, Pasi Aspegren, Tero Taulavuori Identifying the material parameters of a combined isotropic and non-linear kinematic hardening model for AISI 304 stainless steel sheet Sheet metal, anisotropy, hardening, bauschinger effect, identification, tensile test, AISI 304

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Contents Frederic Pascon, Guilhem Bles, Chantal Bouffioux, Silvia Casotto, Stefania Bruschi, Anne Marie Habraken Prediction of distortion during cooling of steel rolled rings using thermal-mechanical-metallurgical finite element model Cooling, distortion, phase transformation, rolled ring, 42CrMo4, finite element method Maciej Pietrzyk, Roman Kuziak Development of the constitutive law for microalloyed steels deformed in the two-phase range of temperatures Flow stress, inverse analysis, two-phase material, rule of mixture, microalloyed steel Zoubeir Tourki, Kacem SaY, Olfa Amdouni A new coupled approach between a micromechanical and a phenomenological modelling of the strain induced martensite transformation kinetics in a 304 austenitic stainless steel (TRIP Steels) Kinetic of a—martensitic transformation, y-martensite phase, austenite phase, stainless steel, AISI 304, crystallographic approach, X-ray dispersing, 2M2C model Tomasz Sleboda, Jason Kane, Roger N. Wright, Norman S. Stoloff, David J. Duquette Thermomechanical processing and properties of P/M FeAl alloy FeAl, thermomechanical processing, grain refinement, powder metallurgy, ultra-fine microstructure Koh-ichi Sugimoto, Tomohiko Hojo, Akihiko Nagasaka, Shun-ichi Hashimoto, Shushi Ikeda The effects of Nb and Mo additions on the microstructure and formability of C-Mn-Si-Al TRIP-aided ferrous sheet steels with an annealed martensite matrix TRIP-aided steel, formability, ductility, high strength steel, retained austenite, annealed martensite, niobium, aluminum, molybdenum, automotive parts Stefan Szczepanik, Katarzyna Piqtkowska Selected properties of Ni-Al materials after hot forging of PM preforms PM aluminium and nickel, PM alloy, forging, hot extrusion, intermetallics, mechanical properties, formability Dmitry Svyetlichnyy Application of the control theory methods to evaluation of dislocation model parameters Flow stress, dislocation theory, ordinary differential equations, optimal control methods, gradient methods Carlo Bruni, Marcello Cabibbo, Alessio Cruciani, Archimede Forcellese, Filippo Gabrielli Microstructural studies and flow stress modelling in a Ni-base superalloy Constitutive equations, dynamic recrystallisation, hot workability, Ni-base superalloy, flow modelling, microstructure, TEM S.A.Risteska, J.K.Mickovski Effects of Mg concentration, test temperature and strain rate on serration of AIMg3 and AlMg5 alloys Aluminum alloys, vacancy migration, aging, critical strain, activation energy, serratation, solute Taher El-Bitar, Abdel-Wahab El-Morsy, Mohamed Abdel-Aziz, Ahmed Ismail Grain size optimization of single hit-hot compressed nimonic 80A super-alloy using experimental design technique Super-alloy, nimonic, grain size, yield strength, hot compression tests, experimental design method Khaled Mohamed Ibrahim, Ahmed Ismail Zaky Fatigue behaviour of austempered steel Steel, fatigue, TRIP, quasi - cleavage fracture, austempering, retained austenite 8

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Contents Sebastien Huart, Mirentxu Dubar, Raphael Deltombe, Andre Dubois, Laurent Dubar A methodology to identify bulk behaviour of galvanised coating: An application to the skin-passed steel strip Skin-pass, coating, bulk behaviour, inverse method

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Pierre-Paul Jeunechamps, Pierre Duysinx, Jerome Walmag, Vincent Mathonet, Eric Delhez, Patricia Tossings, Anne Marie Habraken, Jean-Philippe Ponthot A trust-region algorithm for automatic identification of elasto-viscoplastic parameters in metal forming problems Optimization techniques, inverse problem, large strain, metal forming, automatic parameter identification, elasto-viscoplastic model •

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Jonathan G Mullins, Peter D Hodgson, Matthew E Dingle Using inverse analysis to obtain material behaviour for crash simulations Material characterization, material modelling, inverse analysis, sheet steel, strain rate, finite element modelling

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Andrzej tmudzki, Marcin Papaj, Roman Kuziak, Jan Kusiak, Maciej Pietrzyk Validation of the forward-backward extrusion test, designed for evaluation of friction coefficient and flow properties of metal alloys deformed in semi-solid state Extrusion, FEM, numerical modelling, plastometric tests, semi-solid state Zbigniew Gronostajski, Norbert Misiolek Minor cyclic deformation of AlMg0.45 aluminium alloy Minor cyclic, deformation, aluminium alloy, stress, strain, recovery, recrystallization, temperature, strain rate

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Andrzej K. Lis, Natalia Piwek, Jadwiga Lis, Henryk Dyja, Marcin Knapihski, Jarostaw Markowski Hot ductility of low C-Mn-B steel under continuous casting simulation conditions for metal forming applications Hot ductility, strain, strain rate, temperature Miroslaw Glowacki, Marcin Hojny The mathematical modelling of strain and stress fields in samples with mushy zone Continuous casting, plastic metal flow, thermal-mechanical steel processing, mathematical modelling Index of authors

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