A Review of Characterization and Modelling Approaches for Sheet Metal Forming of Lightweight Metallic Materials

Abstract

Lightweight sheet metals are attractive for aerospace and automotive applications due to their exceptional properties, such as low density and high strength. Sheet metal forming (SMF) is a key technology to manufacturing lightweight thin-walled complex-shaped components. With the development of SMF, numerical simulation and theoretical modelling are promoted to enhance the performance of new SMF technologies. Thus, it is extraordinarily valuable to present a comprehensive review of historical development in SMF followed by state-of-the-art advanced characterization and modelling approaches for lightweight metallic materials. First, the importance of lightweight materials and their relationship with SMF followed by the historical development of SMF are reviewed. Then, the progress of advanced finite element technologies for simulating metal forming with lightweight alloys is covered. The constitutive modelling of lightweight alloys with an explanation of state-of-the-art advanced characterization to identify the constitutive parameters are presented. Then, the formability of sheet metals with major influencing factors, the techniques for measuring surface strains in SMF and the experimental and modelling approaches for determining the formability limits are clarified. Finally, the review is concluded by affording discussion of the present and future trends which may be used in SMF for lightweight metallic materials.

Rheological Behavior of TRIP600 Steel during Deformation

“…This complexity renders traditional stress-strain empirical formulas inadequate for springback analysis in TRIP steel. Numerous theoretical and numerical models have been developed to predict the formability of sheet metals [38][39][40][41]. Improving traditional constitutive models is a common approach to constructing a constitutive model for TRIP steel.…”

Springback Prediction Performance and Experimental Analysis in the V-bending Process of SCGADUB1180 Advanced High-Strength Steel

“…Springback varies according to the geometry and mechanical properties of the material used [20]. Hardness, formability, lightening, and energy absorption provide great advantages for high-strength sheets [11]. However, with these advantages, high strength values increase the springback potential.…”

“…All researchers also emphasized the importance of this issue. They used various finite element models in this regard [11], [29], [30]. Finite element analysis is a technique that studies the behaviour of a part under applied forces and pressure, giving information about the states of a real object under applied loads [31] [32].…”

Review of Multiscale Modeling and Simulation Techniques in Metal Forming, Bending, Welding, and Casting Processes for Enhanced Predictive Design and Analysis

“…As multiscale modeling and simulation techniques continue to advance, they drive innovation across materials science, manufacturing, and product development. By integrating computational approaches with experimental validation, researchers and engineers can explore new materials, novel process designs, and optimization strategies, ultimately fostering continuous improvement and technological breakthroughs [13].…”