Interactive effect of grain size and crystal structure on deformation behavior in progressive micro-scaled deformation of metallic materials

Tang, Xuefeng; Shi, San-Qiang; Fu, Ming

doi:10.1016/j.ijmachtools.2019.103473

Cited by 41 publications

(7 citation statements)

References 59 publications

(79 reference statements)

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“…On a micro scale, material deformation mechanisms and fracture modes are significantly different from those in macro scale [303,304]. The influence of crystal structure and grain size on material behavior during progressive micro-scaled deformation of metallic materials was investigated by Tang et al [305]. It was found that rollover and burr in microparts made Recently, the micro ISF (µISF) method for producing microstructures has been developed by Saotome and Okamoto [298].…”

Section: Emerging Incremental Forming Methodsmentioning

confidence: 99%

Emerging Trends in Single Point Incremental Sheet Forming of Lightweight Metals

Trzepieciński

Oleksik

Pepelnjak

et al. 2021

Metals

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Lightweight materials, such as titanium alloys, magnesium alloys, and aluminium alloys, are characterised by unusual combinations of high strength, corrosion resistance, and low weight. However, some of the grades of these alloys exhibit poor formability at room temperature, which limits their application in sheet metal-forming processes. Lightweight materials are used extensively in the automobile and aerospace industries, leading to increasing demands for advanced forming technologies. This article presents a brief overview of state-of-the-art methods of incremental sheet forming (ISF) for lightweight materials with a special emphasis on the research published in 2015–2021. First, a review of the incremental forming method is provided. Next, the effect of the process conditions (i.e., forming tool, forming path, forming parameters) on the surface finish of drawpieces, geometric accuracy, and process formability of the sheet metals in conventional ISF and thermally-assisted ISF variants are considered. Special attention is given to a review of the effects of contact conditions between the tool and sheet metal on material deformation. The previous publications related to emerging incremental forming technologies, i.e., laser-assisted ISF, water jet ISF, electrically-assisted ISF and ultrasonic-assisted ISF, are also reviewed. The paper seeks to guide and inspire researchers by identifying the current development trends of the valuable contributions made in the field of SPIF of lightweight metallic materials.

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Section: Emerging Incremental Forming Methodsmentioning

confidence: 99%

Emerging Trends in Single Point Incremental Sheet Forming of Lightweight Metals

Trzepieciński

Oleksik

Pepelnjak

et al. 2021

Metals

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Section: The Effect Of β Grains On the Extrusion Forcementioning

confidence: 99%

“…In conclusion, with the increase in the β grain size, the extrusion force increased. However, research literature [18,33] revealed that the flow stress has an apparent decreasing tendency with the coarsening of initial grains at ambient temperature because the decreasing grain boundaries facilitate the slip transfer among grains and further weakens the strength of the material and the resistance to deformation. In the present study, the β grain size increased while the grain boundary decreased according to the increase in the holding time.…”

Section: The Effect Of β Grains On the Extrusion Forcementioning

confidence: 99%

Effect of Holding Time on the Extrusion Force and Microstructure Evolution during the Plastic Forming of Ti-6Al-4V Micro-Gears

Yan

Zhang²,

Huang

et al. 2022

Materials

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The application of titanium alloy micro-gears in microelectromechanical systems has been severely restricted, as the graphite mold is prone to abrasion or even to crack at high temperatures, mainly due to the forming load. We aimed to manufacture Ti-6Al-4V alloy micro-gears through hot extrusion under an electric field and to clarify the influence of holding time on the extrusion force. The results suggest that the formed gears had a complete filling and clear tooth profile. Moreover, the contact resistance and current density caused a gradient temperature distribution inside the billet, resulting in a carburized layer and inhomogeneous β grains. The extrusion force increased with an increased holding time, which can be ascribed to the increase in the thickness of the carburized layer and the β grain size. Among these two factors, β grain size played a leading role in the extrusion force. Continuous dynamic recrystallization dominated the deformation in a single β phase, and the misorientation of the transformed α laths from β grains followed the Burgers orientation relationship. This study may pave the way for the extrusion forming of other titanium alloy micro-components.

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“…Recent flexibility improvements in metal forming through combinations of different processes have played a vital role in the manufacturing industry [4,5] . Tang et al [6] demonstrated that progressive sheet microforming for the creation of bulk microparts is a promising process due to its advantages of low production cost and high efficiency, as well as the ability to obtain net shapes or near net shapes. Notably, the positioning, forming, and blanking of dies take the same position alignment in the microscaled progressive sheet forming process, which ensures the dimensional accuracy and precision of the formed parts [7] .…”

Section: Introductionmentioning

confidence: 99%

Ductile fracture behavior in micro-scaled progressive forming of Magnesium-Lithium alloy sheet

Wang

Xiao²,

Wang³

et al. 2022

Preprint

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Micro-scaled progressive sheet metal forming is a promising process for producing bulk microparts, given itsadvantages of high efficiency and low cost. To enhance forming quality andefficiency, it is important to have an in-depth understanding of the forming mechanism andmodel the forming process and fracture behavior accurately. However, prediction of fracture formation in sheet materials at the micro scale has not yet been well explored, and thus current knowledgeis not sufficient to support the continued development and application of microforming technology. This study investigated progressive sheet forming of magnesium–lithium alloy sheets of different grain sizes to produce bulk microparts directly from sheet metal via shearing, extruding, piercing, and blanking. Using the Gurson–Tvergaard–Needleman (GTN) damage model, the effects of the size factor on the formation and evolution of voids were considered, and the shear-modified GTN model was established by combining Thomason’s and Lemaitre's damage mechanics models. The modified model could predict not only the ductile fracture behavior dominated by tension under high stress triaxiality at the micro scale, but also the damage behavior controlled by shear deformation under low stress triaxiality. The progressive forming process was simulated using the modified model, which was verified by experimentation and simulation. Comparisons of the experiments and simulations revealed the size effects on the forming defects and fracture behaviors of microparts during progressive sheet forming. The results show that the stress during deformation is mainly concentrated at the edge of mircoparts, and irregular geometric defects include burr, rollover, incline, and bulge become deteriorated with the increase of the initial grain size. This study enhances the understanding and prediction of ductile fracture in the micro-scaled progressive forming of sheet metals.

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Interactive effect of grain size and crystal structure on deformation behavior in progressive micro-scaled deformation of metallic materials

Cited by 41 publications

References 59 publications

Emerging Trends in Single Point Incremental Sheet Forming of Lightweight Metals

Emerging Trends in Single Point Incremental Sheet Forming of Lightweight Metals

Effect of Holding Time on the Extrusion Force and Microstructure Evolution during the Plastic Forming of Ti-6Al-4V Micro-Gears

Ductile fracture behavior in micro-scaled progressive forming of Magnesium-Lithium alloy sheet

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