https://popups.uliege.be/esaform21/index.php?id=2425 Index terms fr 0 https://popups.uliege.be/esaform21/index.php?id=954 Multi-material solutions represent a promising approach for the production of load-optimised parts. The combination of material-specific advantages of different materials in a single component allows the fulfilment of conflicting requirements e.g. high performance and low weight. Fabrication of hybrid components is challenging due to the dissimilar properties of the individual materials and requires the development of suitable manufacturing technologies. The present paper deals with the simulation-based design of a forming process for the production of a suspension control arm consisting of steel and aluminium. With the focus on material flow, two forming concepts, open-die and closed-die forging, were investigated, in order to ensure the required material distribution similar to the final part. In addition, a tool analysis was carried out to avoid thermo-mechanical overload of the tool system. It was found that the required material distribution can be achieved with both forming concepts. However, a closed-die forging concept is not suitable because of the high stresses in the forging dies exceed the tool steel’s strength. Mon, 22 Mar 2021 10:30:37 +0100 Mon, 05 Apr 2021 18:22:43 +0200 https://popups.uliege.be/esaform21/index.php?id=954 https://popups.uliege.be/esaform21/index.php?id=4095 Wire arc additive manufacturing process (WAAM) is an innovative technology that offers freedom in terms of designing functional parts, due to its ability to manufacture large and complex workpieces with a high rate of deposition. This technology is a metal AM process using an electric arc heat source. The parts manufactured are affected by thermal residual stresses due to high-energy input between wire and workpiece despite numerous advantages with this technology. It could cause severe deformation and change the global mechanical response. A 3D transient thermal model was created to evaluate the thermal gradients and fields during metal deposition. The material used in this study is a steel alloy (S355JR-AR). This numerical model takes into account the heat dissipation through the external environment and the heat loss through the cooling system under the base plate. Birth-element activation strategy was used to generate warm solid part following the movement of the heat source. The metal deposition is defined with constant welding speed. Goldak model was used to simulate the heat source in order to have a realistic heat flow distribution. Results were in concordance for thermal cycles at different points comparing with experimental results issued from bibliography in terms of: (1) Temperature maximum, (2) Thermal cycles and (3) Cooling gradient phase. This study enabled to check the numerical model and used as a predictive tool Tue, 30 Mar 2021 15:17:25 +0200 Tue, 30 Mar 2021 15:17:32 +0200 https://popups.uliege.be/esaform21/index.php?id=4095 https://popups.uliege.be/esaform21/index.php?id=2168 Automotive stamping is a multi-stage process where a sheet material is drawn in first stage and then redrawn, flanged and pierced in subsequent stages. In the first draw stage, continuous strain path change is induced in the material while a discontinuous strain path change occurs when the material is processed in the subsequent stages of a multi-stage stamping operation. The strain path transition can potentially alter the forming limit of the material. Previous research has investigated the effect of the discontinuous mode of strain path change by loading the sample in one strain path, unloading it, then reloading it in a second path. Thus, discontinuous strain path change was obtained. In this work, the effect of continuous strain path change was investigated with a novel experimental design that allowed cruciform samples to change strain path continuously without unloading. The work was carried out in two stages. In the first stage, the design of the cruciform sample was verified with finite element modelling to ensure the occurrence of continuous strain path change and this was validated experimentally using DX54 material by capturing full-field strain measurements data using digital image correlation technique. The size of the experimental apparatus permitted it to be placed inside a scanning electron microscope chamber. In the second stage, the validated test method was used to evaluate microstructural changes during the deformation including full-field strain and texture evolution. The micro-strain evolution showed rotation of strain bands while the texture evolution conveyed grain rotation during continuous strain path change. Tue, 23 Mar 2021 14:01:05 +0100 Mon, 29 Mar 2021 18:40:20 +0200 https://popups.uliege.be/esaform21/index.php?id=2168 https://popups.uliege.be/esaform21/index.php?id=2424 The highly used Ti6Al4V alloy is a well know hard-to-machine material. The modelling of orthogonal cutting process of Ti6Al4V attract the interest of many researchers as it often generates serrated chips. The purpose of this paper is to show the significant influence of cutting speed on chip formation during orthogonal cutting of Ti6Al4V along with different material constitutive models. Finite element analyses for chip formation are conducted for different cutting speeds and are investigated with well-known Johnson-Cook constitutive model, a modified Johnson–Cook model known as Hyperbolic Tangent (TANH) model that emphasizes the strain softening behavior and modified Johnson-Cook constitutive model that consider temperature dependent strain hardening factor. A 2D Lagrangian finite element model is adopted for the simulation of the orthogonal cutting process and the results from the simulations such as calculated forces, chip morphologies are analyzed and are compared with the experimental results to highlight the differences. The results analysis shows that, the temperature in the secondary deformation zone is directly proportional to the cutting speed. Tue, 23 Mar 2021 18:41:10 +0100 Mon, 29 Mar 2021 09:19:29 +0200 https://popups.uliege.be/esaform21/index.php?id=2424