A Survey of Some Physical Defects Arising in Metal Working Processes

Johnson, W.; Mamalis, A.G.

doi:10.1007/978-1-349-81484-8_68

Cited by 38 publications

(11 citation statements)

References 23 publications

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“…The deformation and failure of the studied alloy were modeled using Johnson and Cook (JC) flow stress [4] and damage [19] models given sequentially as…”

Section: Materials Models and Testing Methodsmentioning

confidence: 99%

“…Nevertheless, the CWR has not found widespread applications among the metal forming industry, partly due to the lack of adequate technical knowledge on work piece failure mechanisms and partly due to the complexity of tool design [3]. There are basically three major defect groups in the CWR [4]. Excessive slip between work piece and tools results in improper deformation, misalignment and irregular cross-section of work piece.…”

Section: Introductionmentioning

confidence: 99%

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Cross wedge rolling of a Ti6Al4V (ELI) alloy: the experimental studies and the finite element simulation of the deformation and failure

Çakırcalı

Kılıçaslan

Güden

et al. 2012

Int J Adv Manuf Technol

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The cross wedge rolling (CWR) deformation and fracture of a Ti6Al4Al (ELI) alloy were investigated experimentally and numerically using a coupled thermomechanical finite element model analysis. The experimentally determined flow stress and damage model parameters were verified by tension split Hopkinson pressure bar testing of notched samples. The simulation and experimental CWR forces showed well agreements except near the end of the stretching zone. The model analysis showed that the temperature distribution in the work piece was nonuniform during the CWR. When the initial temperature of the work piece was relatively low, the work piece temperature increased, a heating effect of the plastic deformation, while relatively high initial work piece temperatures resulted in cooling the work piece, caused by the work piece contact with the tools. The cracks were shown numerically to initiate in the midsections of the work piece during the guiding action and elongated in a direction normal to the maximum tensile stress triaxiality, resulting in cruciformshaped crack formation, which was well agreed with the previously observed crack shape.

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“…The deformation and failure of the studied alloy were modeled using Johnson and Cook (JC) flow stress [4] and damage [19] models given sequentially as…”

Section: Materials Models and Testing Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Cross wedge rolling of a Ti6Al4V (ELI) alloy: the experimental studies and the finite element simulation of the deformation and failure

Çakırcalı

Kılıçaslan

Güden

et al. 2012

Int J Adv Manuf Technol

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“…MAT_SIMPLIFIED_JOHNSON_COOK material model, material type 98, was used to model 1050 H14 aluminum alloy. Johnson and Cook (JC) flow stress model is given as [14] r ¼ ½A þ Be…”

Section: Numerical Modelsmentioning

confidence: 99%

The impact responses and the finite element modeling of layered trapezoidal corrugated aluminum core and aluminum sheet interlayer sandwich structures

Kılıçaslan

Güden

Odacı

et al. 2013

Materials & Design (1980-2015)

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a b s t r a c tThe impact responses of brazed and adhesively bonded layered 1050 H14 trapezoidal corrugated aluminum core and aluminum sheet interlayer sandwich panels with 3003 and 1050 H14 aluminum alloy face sheets were investigated in a drop weight tower using spherical, flat and conical end striker tips. The full geometrical models of the tests were implemented using the LS-DYNA. The panels tested with spherical and flat striker tips were not penetrated and experienced slightly higher deformation forces and energy absorptions in 0°/90°corrugated layer orientation than in 0°/0°orientation. However, the panels impacted using a conical striker tip were penetrated/perforated and showed comparably smaller deformation forces and energy absorptions, especially in 0°/90°layer orientation. The simulation and experimental force values were shown to reasonably agree with each other at the large extent of deformation and revealed the progressive fin folding of corrugated core layers and bending of interlayer sheets as the main deformation mechanisms. The experimentally and numerically determined impact velocity sensitivity of the tested panels was attributed to the micro inertial effects which increased the critical buckling loads of fin layers at increasingly high loading rates.

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“…One of the primary concerns is the failure mechanisms encountered in the CWR process make it very difficult to design the tooling. The three major failure mechanisms encountered during the CWR include [2]: (1) an improperly formed workpiece cross section (2) external defects on the surface of the workpiece (i.e., spiral grooves) and (3) internal defects within the workpiece (voids and cracks). The formation of internal defects in the CWR process, which is the focus of this work, can be attributed to several possible mechanisms.…”

Section: Workpiece Deformation Processmentioning

confidence: 99%

The establishment of a failure criterion in cross wedge rolling

Lovell

2004

Int J Adv Manuf Technol

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Internal defects in the cross wedge rolling (CWR) process can lead to the catastrophic failure of products. Using specialised experiments and the explicit dynamic finite element model (FEM), this work investigates the mechanisms of void generation and growth in the cross wedge rolling process. Based on a combined numerical and experimental approach, the morphology of void generation is determined as a function of the workpiece material and three primary parameters in the cross wedge rolling process: the forming angle, a, the stretching angle, b and the area reduction, D A . Through the definition of a non-dimensional deformation coefficient, _ , a method for predicting the likelihood of void formation is subsequently ascertained and discussed with respect to CWR tooling design and operating conditions.

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A Survey of Some Physical Defects Arising in Metal Working Processes

Cited by 38 publications

References 23 publications

Cross wedge rolling of a Ti6Al4V (ELI) alloy: the experimental studies and the finite element simulation of the deformation and failure

Cross wedge rolling of a Ti6Al4V (ELI) alloy: the experimental studies and the finite element simulation of the deformation and failure

The impact responses and the finite element modeling of layered trapezoidal corrugated aluminum core and aluminum sheet interlayer sandwich structures

The establishment of a failure criterion in cross wedge rolling

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