Sustainability issues in sheet metal forming processes: an overview

Ingarao, Giuseppe; Lorenzo, Rosa Di; Micari, F.

doi:10.1016/j.jclepro.2010.10.005

Cited by 131 publications

(68 citation statements)

References 65 publications

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“…(2) In addition, the interaction between the different process parameters has a notable influence on these forces, especially the interaction between the feed rate and step size as discussed above. (3) The other parameter had a smaller effect compared with the rotation speed.…”

Section: Discussionmentioning

confidence: 99%

“…Based on the evident advantages of this process, ISF is a promising forming process, as it is highly impressive from both the academic and industrial perspectives [1][2][3]. In the beginning of the last century, high interest focused on improving and employing lightweight materials in various industrial applications, such as aerospace, marine and automobile sectors [4,5].…”

Section: Introductionmentioning

confidence: 99%

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Experimental Investigation of Forming Forces in Frictional Stir Incremental Forming of Aluminum Alloy AA6061-T6

Baharudin

Azpen

Sulaima

et al. 2017

Metals

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Abstract:The incremental sheet forming (ISF) process is an emerging flexible sheet-forming process, which is adequate for the manufacturing of unique or small-volume batches. Single-point incremental forming (SPIF) is the original technology of incremental sheet-forming processes. In this article, frictional stir-assisted SPIF was used to deform AA6061-T6 aluminum alloy. Experimental tests were conducted to measure the forming forces during this process for the concerned lightweight material. The influence of process parameters was investigated, which included tool rotation speed, feed rate, step size and tool diameter on the produced forming forces. A Taguchi technique for the design of experiment (DOE) and the varying wall angle conical frustum (VWACF) test was employed in this study. The results show that the rotation spindle speed was the most dominant parameter that affects the forming forces, followed by the step size, feed rate and tool diameter. In addition, the interaction between the feed rate and step size has a notable impact on the values of the forming forces.

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Section: Discussionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Experimental Investigation of Forming Forces in Frictional Stir Incremental Forming of Aluminum Alloy AA6061-T6

Baharudin

Azpen

Sulaima

et al. 2017

Metals

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“…The results of numerous studies have suggested that the emissions and the use of the energy in aluminum production were reduced in the secondary aluminum compared to the primary aluminum ( raw materials, energy and emissions related to the materials recycling process (Ferreira et al, 2014;Lacarrière et al, 2015). For example, aluminum scrap may be recycled straightly by hot extrusion that needed nearly 10% of energy demand for recycling by re-melt process (Ingarao et al, 2011). Extruded aluminum is widespread used for building sectors.…”

Section: Introductionmentioning

confidence: 99%

Life Cycle Assessment of Secondary Extruded Aluminum Production Process in Industrial City of Arak

Zare¹

2016

Appl Ecol Env Res

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Abstract. In this study, the life cycle assessment model for the secondary extruded aluminum represents a cradle-to-gate process that starts with recycling aluminum scrap and ends in the ultimate product of extruded aluminum transferred to final product manufacturer. In the following, data are mainly collected from the literature, and ecoinvent3's database. The quantitative analysis of the use of the energy and pollutants for production of the secondary extruded aluminum are estimated with eco-indicator-99 methodology and SimaPro8.0.4 package. The impact of the secondary extruded aluminum production on the environment is studied by evaluating three damage impacts: human health, ecosystem quality and resources. Results indicate that the resources make the highest contribution by 0.58pt (4284.35 MJ) and human health by 0.16pt (0.00136 DALY) is located in the next rank. The endpoint ecosystem quality (44.64 PDF * m 2 yr) is insignificant in this process. Also, the total required energy for manufacturing of 600 kg aluminum profile in the model was 8842 MJ. Based on the results, the impact of the secondary aluminum extrusion process on the ozone layer depletion is shown to be insignificant. Also, despite using aluminum scraps, the model incurs significant environmental load. The study is implemented in the industrial city of Arak.

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“…Due to very low capability of plastic strain at the ambient temperature and strong spring-back effect compared to conventional deep drawing steel sheets, obtaining of products made of titanium sheet metal (Gr 5) using conventional methods is limited and requires expert knowledge and non-standardized approach to solving this problem [5][6][7]. Obtaining deep drawn parts with complex geometry from hard-deformed sheet metal requires modification of conventional methods of forming or application of modern technologies such as electromagnetic forming, explosive forming, impulse forming, hydroforming or incremental sheet forming [1][2][3][4][7][8][9][10][11]. It should be remembered that forming titanium alloys at increased temperature necessitates solving the problems of its tendency for reacting with oxygen, nitrogen and hydrogen.…”

Section: Introductionmentioning

confidence: 99%

Forming Of Spherical Titanium Cups From Circular Blanks With Cutouts On The Perimeter

Lacki¹,

Adamus²,

Więckowski³

et al. 2015

Archives of Metallurgy and Materials

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TŁOCZENIE TYTANOWYCH CZASZ KULISTYCH Z WYKROJÓW OKRĄGŁYCH Z WYCIĘCIAMI NA OBRZEŻUDespite substantial demand for drawn parts made of high-strength sheet metal (including titanium alloys) observed in the modern industry, particularly automotive and aviation, their application remains insignificant. This results from the fact that such sheet metal shows poor plasticity and its cold-forming is almost impossible. Low drawability makes it impossible to obtain even such simple shapes as spherical cups. The authors of this study developed circular sheet-metal blanks with cutouts on their perimeter. The blanks allow for cold forming of spherical cups from Ti6Al4V titanium alloy sheet metal using conventional rigid tools. The cutouts proposed in the study affect plastic strain distribution, which in turn leads to an increase in forming depth by about 30%. The numerical analysis, performed using the PamStamp 2G System software based on finite element method, was verified experimentally.Keywords: sheet-metal forming, titanium sheet, FEM modelling Mimo, iż nowoczesny przemysł, głównie motoryzacyjny i lotniczy, zgłasza zapotrzebowanie na wytłoczki z wysokowytrzymałych blach metalowych, w tym stopów tytanu, ich zastosowanie jest znikome. Wynika to z faktu, że blachy te mają małą plastyczność i ich tłoczenie na zimno jest niemal niemożliwe. Niska tłoczność uniemożliwia kształtowanie nawet tak prostych geometrii jak czasze kuliste. W ramach niniejszej pracy opracowano kołowy wykrój z wycięciami na obwodzie, który umożliwia kształtowanie na zimno kulistych czasz z blachy ze stopu tytanu Ti6Al4V przy użyciu klasycznych, sztywnych narzędzi. Zaproponowane wycięcia wpływają na zmianę rozkładu odkształceń plastycznych, co w konsekwencji prowadzi do zwiększenia głębokości tłoczenia o około 30%. Analizy numeryczne, wykonane programem PamStamp 2G bazującym na metodzie elementów skończonych, zweryfikowano doświadczalnie.

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Sustainability issues in sheet metal forming processes: an overview

Cited by 131 publications

References 65 publications

Experimental Investigation of Forming Forces in Frictional Stir Incremental Forming of Aluminum Alloy AA6061-T6

Experimental Investigation of Forming Forces in Frictional Stir Incremental Forming of Aluminum Alloy AA6061-T6

Life Cycle Assessment of Secondary Extruded Aluminum Production Process in Industrial City of Arak

Forming Of Spherical Titanium Cups From Circular Blanks With Cutouts On The Perimeter

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