https://popups.uliege.be/esaform21/index.php?id=81 Coordinator: Prof. Robertt Angelo Fontes Valente Co-Organisers: Prof. Pierpaolo Carlone, Prof. Sandrine Thuillier, Prof. Joost Duflou Description: Nowadays, manufacturing processes are seeing a strong push towards the constant increase of their competitiveness and efficiency, together with more and more customization possibilities. Such improvements must also consider a higher level of sustainability and life cycle assessment, following the essence of a truly circular economy paradigm. Chain process involving forming and assembly technologies, as well as reliability assessment and control of the parts, must be considered for true and efficient optimization purposes. A unified or integrated analysis of the several aspects of manufacturing technologies can lead to a better understanding of the complex phenomena in forming, increasing its overall efficiency. Moreover, proper manufacturing process planning, as well as scrap minimization through near net shape manufacturing strategies, can lead to substantial energy and resource savings. Taking these broad aspects into consideration, the main goal of this Mini-Symposium is to provide a forum for discussion and presentation of research works, from both academia and industry stakeholders, focusing on integrated numerical and experimental methodologies that can provide viable paths to the sustainable forming processes and products of the future. Mini Symposia fr Wed, 03 Mar 2021 09:34:29 +0100 Wed, 14 Apr 2021 09:54:07 +0200 https://popups.uliege.be/esaform21/index.php?id=81 0 https://popups.uliege.be/esaform21/index.php?id=437 The current market requirements are increasingly pushing the industry towards the manufacturing of highly customized products. Tailored blanks are a class of sheet metals characterized by the local variation of properties, attributable to the presence of different materials, different thickness distribution, and thermal treatments. In the manufacturing of tailored welded blanks, welding and forming processes cover a central role. In this framework, friction stir welding demonstrated to be a suitable candidate technology for the production by joining of tailored blanks. Indeed, sheet metals welded by this solid-state welding process typically exhibit high formability when compared to the conventional welding methods. Due to the improved formability, a good deal of attention has been recently given toward the single point incremental forming (SPIF) process and its integration with FSW. Remarkable efforts have been dedicated to the numerical modeling of the SPIF of metallic alloy sheets jointed by FSW. The main criticisms in these models are related to the definition of the mechanical properties of the materials, which are affected by the structural alteration induced by the FSW. The present work aims to model the local alterations in the mechanical properties and to analyze how these local characteristics affect the formability of the blanks. With this purpose, a 20 mm wide sample collected from a FS welded blank of aluminum alloy AA6082 has been modeled using the mechanical properties variation achieved in a previous work. The influence of this local variation in properties has been assessed using a Finite Element Model Updating strategy. Fri, 19 Mar 2021 19:38:16 +0100 https://popups.uliege.be/esaform21/index.php?id=437 https://popups.uliege.be/esaform21/index.php?id=2382 Higher quality requirements by customers demand higher precision and accuracy from manufacturing processes. Application oriented preparation of semi-finished materials is key for subsequent forming operations, therefore, straightening machines are employed. Straightening strengthens the material by increasing plastic deformation by means of strain hardening, resulting in undesirable reduction in formability when processing high strength materials, in particular. Conventional roll-type straightening machines process either bars or strips. This is achieved upon passing material between rolls arranged in two staggered rows. However, conventional straightening processes do not adapt to the local varying distortion of coiled strips. Innovative, self-correcting process control techniques, which adapt to the initial geometric characteristics of the strip, present a promising approach to fix this issue through optimization of the leveling process. Here, an innovative strategy to improve straightening of high strength steel materials (1.4310) is presented. This implements optimized leveling, adding minimal plastic deformation and, thus, strain hardening. To operate an intelligent straightening machine, a reliable online measurement of the surface defects is fundamentally essential. The MagnaTest, which is developed for material testing, is made feasible for such purposes after calibrating for curvature measurement. Preliminary results are promising in regards to measuring the curvature online, so that the following straightening process can be close loop controlled. The bending measurement is linked to open/closed loop control, therefore providing an optimal straightening result in regards to formability, leveling, and reduced strain hardening. Tue, 23 Mar 2021 18:18:32 +0100 https://popups.uliege.be/esaform21/index.php?id=2382 https://popups.uliege.be/esaform21/index.php?id=2542 Advanced materials, especially carbon fiber reinforced composites (CFRP), have gained the attention of different industries whichproduce lightweight and high-performance components. The most used manufacturing processes to realize these kinds of products are Resin Transfer Molding (RTM) and vacuum bag molding with autoclave curing. RTM is based on dry fiber technology and it appears the most promising manufacturing process to realized high-quality carbon fiber parts reducing cost and manufacturing time, especially if high pressure variants are employed. On the other hand, vacuum bag molding with autoclave curing is a very consolidated process which is, however, associated with long manufacturing time and costs as well as to low repeatability of the process due to the high labor input. Out-of-autoclave methods, such as pressure bag molding (PBM) have been developed to overcome the issues of vacuum bag molding process. From the environmental point of view, the manufacturing of CFRP components is associated with high environmental loads due to the impacts related to both raw materials and manufacturing processes. For this reason, reducing the energy consumption of production phases can lead to the development of greener CFRP products. In this context, the main scope of the present research is to evaluate and compare the environmental loads of a component for the automotive industry realized exploiting the RTM, the PBM and the bag molding processes to determine which one is eco-friendlier. This analysis has been conducted following the standard Life Cycle Assessment methodology based on a “cradle to gate” approach. In this way, the use phase and the disposal of the CFRP component have not been included in the analysis. Results have been evaluated by comparing the equivalent CO2 related to each manufacturing process. Wed, 24 Mar 2021 14:42:19 +0100 https://popups.uliege.be/esaform21/index.php?id=2542 https://popups.uliege.be/esaform21/index.php?id=2651 The use of composite hybridization using both synthetic and natural fibers, is one of the most established way to combine the advantages of each material that forms the composite system in order to obtain a composite with good in-plane and out-of-plane properties. For example, as pointed out in authors previous research works, considering carbon/hemp hybrid composites, it is possible to combine the ductile behavior and the capacity to absorb energy of hemp fibers with the higher strength and stiffness of carbon allowing the development of a hybrid system with enhanced energy absorption capability, reduced production cost and lower environmental impact respect to traditional carbon fibers composites. The aim of this work is to investigate both experimentally and numerically the mechanical behavior at impact of pure carbon, pure hemp and carbon/hemp hybrid composite laminate. Low velocity impact tests at 10 J and 20 J were carried and non-destructive analyses were performed for each impact energy to evaluate the internal damage extent. The same tests were numerically simulated with LS-DYNA software using shell elements and different material cards (i.e. MAT 54/55, MAT 24 depending on typology of fibers) and contact conditions in order to find the best configuration that matches the experimental results. Wed, 24 Mar 2021 18:37:18 +0100 https://popups.uliege.be/esaform21/index.php?id=2651