Metal Forming 2004

STEEL-GRIPS 2 (2004) Suppl. Metal Forming 2004

PROCEEDINGS OF THE 10TH INTERNATIONAL CONFERENCE

ON METAL FORMING

METAL FORMING 2004

AKADEMIA GORNICZO-HUTNICZA KRAKOW, POLAND
September 19-22, 2004

Edited by
Jan Kusiak, Peter Hartley,
Janusz Majta, Ian Pillinger
and Maciej Pietrzyk

Akademia Gorniczo-Hutnicza
Krakow, Poland

2 (2004) Suppl. Metal Forming 2004

University of Birmingham
United Kingdom

Contents

Table of Contents
Preface

11

Keynote Papers
Reiner Kopp, Oliver Hofmann,. Vincent Honnet, Christian Plociennik
Real metal forming and virtual reality
Virtual reality, metal forming, CSP facility, hierarchy, visualization, simulation, portal virtual CSP plant,
ring rolling
Erkki Laitinen, Jali Pieska, Ismo Rentola, Valtteri Toivonen
Quality optimization of steel products in continuous casting process using
numerical optimization and soft reduction
Continuous casting, soft reduction, quality optimization, modelling, real time simulation
Wan Chastel, Roland Loge
Coupling microstructure models with large scale forming simulations
Metallurgical models, recrystallisation, phase change, texture
Jerzy Rojek, Michal Kleiber, Antoni Piela, Rafal Stocki, Jaroslaw Knabel
Deterministic and stochastic analysis of failure in sheet metal forming
operations
Sheet stamping simulation, reliability analysis, response surfaces, adaptive Monte Carlo technique
Andrzej Rosochowski, Lech Olejnik, Maria Richert
Metal forming technology for producing bulk nanostructured metals
Nanostructured materials, nanocrystalline metals, severe plastic deformation, equal channel angular
pressing
P. D. Hodgson, H. Beladi
The formation of ultrafine grained steel microstructures through
thermomechanical processing
Ultrafine ferrite, thermomechanical processing, steels, transformation, dynamic recrystallization, grain
refinement

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35

45

Rolling
Junfeng Mei, Michael R. Lovell, Frederick S. Pettit
Mechanical and metallurgical properties of hot rolling Ti-6AI-4V sheets
Ti-6A1-4V, Hot rolling, mechanical and metallurgical properties, recrystallization, intermediate plate, final sheet, mill annealing
Zhengyi Jiang, Xiaoming Zhang, KietA. Tieu, Weihua Sun
Mechanics of slab edging with friction consideration
Friction consideration, slab edging, horizontal rolling, rigid visco-plastic fem, width variation, dog-bone
Zhengyi Jiang, Hongtao Zhu, Kiet A. Tieu
Effect of roll edge local perturbation of deformation on thin strip rolling
Roll edge local perturbation of deformation, cold strip rolling, strip width, transverse friction, edge
contact length, numerical simulation

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Contents
Ahmed Ismail, Taher El-Bitar, Abdel-Wahab El-Morsy, Mohamed Abdel-Aziz
Parameters affecting free spread of stainless steel grade 304
Austenitic stainless steel, free spread, experimental design technique, friction coefficient, deformation
parameters, rolling velocity, box pass design, oval-round pass design, geometry of roll gap
Mahmoud Salimi, Mahmoud Kadkhodaie
Asymmetrical cold sheet rolling in free horizontal entry conditions
Asymmetrical sheet rolling, slab method, plane strain condition, shear stress distribution,
pressure distribution
Annika Nilsson, Agne Bogdanoff, Suvi Niemi
A study on the ski end direction in plate mills
Ski-ends, plate rolling, asymmetric rolling, FEM, shape factor

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75

81

Sebastian Mroz, Andriy Milenin, Henryk Dyja

A determination of the total roll separating force during rolling of
bimetal rods in the grooves
roll separating force, bimetallic rods, elongating grooves, FEM
Kazimierz Kolodziej, Zbigniew Bigaj, Ryszard Korzekwa
Production of a new type of block-tram rail for European Union at
Krolewska Steelworks Ltd.
Tramway block rail, roll pass design, free cross-flowing of metal, chambers of rail
Sebastian Mroz, Andriy Milenin, Henryk Dyja
Numerical modeling of stock stability in the roll grooves during shape rolling
Stock stability, elongating grooves, numerical modeling, FEM
Jaroslaw Bartnicki, Zbigniew Pater
The influence of tool geometry on the CWR process of hollowed shafts
Cross-wedge rolling, FEM, hollowed shaft, wedge tool
Carlo Bruni, Mohamad El-Mehtedi, Archimede Forcellese, Filippo Gabrielli, Michela Simoncini
Simulation of multipass hot rolling of AA 6082 aluminium alloy
Aluminium alloy, flow behaviour, hot torsion test, multistage deformation, rolling schedule, simulative
technique

85

93

97

103

109

Forging
Friedrich-Wilhelm Bach, Bernd-Arno Behrens, Helge Dahndel, Michael Gummert, Aziz Huskic
Reducing the process chain for the production of gear wheels by precision
forging - integration of heat treatment and necessary changes of the
process management
Reducing the process chain, precision forging, gear wheels, integrated heat treatment, process management, cost reduction, automotive industry
Maria Leopoldina Alves, Jorge Rodrigues, Paulo Martins
Numerical and experimental analysis of the closed-die forging of
aluminium spiders
Closed-die forging of spiders, finite element method, experimentation
Hendrik Just, Arno Behrens
Investigations on the use of damage criteria under semi-hot forging
conditions with FE-methods
Semi-hot forging, FE Simulations, fracture, damage mechanics
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Contents
Aneta tukaszek-Sofek, Jan Sihczak Piotr Skubisz
Design of forging technology with using the cost - volume - profit model
Forging technology, stress, model CVP, design, FEM, drop forging
Pavel Petrov, Victor Perfilov, Michael Petrov
Development and research on near net shape forging technology of
round part with flange made of aluminium alloy A95456
isothermal forming, near-net shape forging, precision forging, friction factor, aluminium alloy, numerical
simulation, finite-element method
Grzegorz Samolyk, Zbigniew Pater
An influence of the selected flash variables on the closed-die forging processes
Flash gap, closed-die steel forging, plane-strain forging, thermo-mechanical FEM, poly-optimisation
R. Di Lorenzo, S. Beccari, M. Piacentini, F. Micari
Numerical and experimental investigation on hot impression die forging:
flash design optimisation
Impression die forging, flash design, forging load, wear, process design, FEM, experimental tests
Mahmoud Salimi, Mojtaba Kabirian
An upper bound stream function elemental technique for the forging of
spur gears
Upper bound, stream function, elemental technique, forging, spur gears, spline

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147

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159

Extrusion
Thomas Hatzenbichler, Bruno Buchmayr, Alfred Umgeher
Numerical sensitivity study to determine the effects on transverse welds in
direct extrusion of AlMgSi-alloys
Billet-to-billet-extrusion, finite element simulation, transverse welds, Deform, aluminium

165

Piotr Skubisz, Jan Sihczak, Aneta Sofek

Extrusion of magnesium alloy profiles
Magnesium wrought alloy, AZ61, AZ80, extruded profiles, direct extrusion

171

Jung Min Lee, Byung Min Kim, Hyung Ho Jo, Chung Gil Kang
Development of direct extrusion process for Al multi-cell tube using porthole die
Porthole die, multi-cell tube extrusion, stress analysis

177

Byung Min Kim, Jung Min Lee, Hyung Ho Jo, Chung Gil Kang
Development of extrusion process and die design for Al speaker body
Speaker body, finite element method, extrusion, die design, aluminium

185

Drawing
Tsutomu Yamashita, Kazunari Yoshida
Prevention of wire breaks and its analysis by FEA in superfine
gold wire drawing
Wire drawing, Wire breaking, Inclusion, Superfine gold wire, FEA
Kazunari Yoshida
Cold drawing of magnesium alloy wire and fabrication of microscrews
Magnesium alloy wire, cold wire drawing, microscrew, form rolling, warm forging
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Contents
Andriej Milenin, Henryk Dyja, Zbigniew Muskalski, Jan Pilarczyk
FEM analysis of a multi-pass hydrodynamic drawing process of
high carbon steel wires with different drawing directions
FEM simulation, hydrodynamic drawing, roller die drawing, direction of drawing, high carbon steel
wires

203

Hydroforming - Tube Forming

Rudolf Kawalla, Serguei Gouk
Peculiarity of the interaction between material properties and
deformation conditions during sheet hydroforming
Microstructure constituents, local material flow, deep drawing, phase deformation, macro heterogeneity,
deformation and orientation of hard structural components

209

M. Tajdari, H. Moslemi Naeini, M. Kiuchi, Ali Sanati, S. E. Hosseini Mehraban, D. Rezaee

Computer aided design of reshaping process of circular pipes into square pipes
Circular pipes, square pipes, shear deformation, reshaping process, numerical simulation

215

Carl Labergere, Arnaud Lejeune, Jean-Claude Gelin

Optimization and control of flange and tube hydroforming processes
Optimisation, process control, finite elements, sensitivity analysis, process parameters, damage

221

Sheet Forming
Mehdi Ben Tahar, Elisabeth Massoni
Use of the modified maximum force criterion for necking analysis
during sheet bulging
Strain rate sensitivity, necking, bulging, FLC, modified maximum force criterion, strain path
Tony Downes, Peter Hartley, Ian Pillinger
A storage and retrieval system for roll-forming design data using a
neural network
Artificial neural networks, ANN, cold roll-forming, tool design, data storage, data retrieval
Malgorzata Sitek, Feliks Stach
Estimation of hole flangeability for AW5754 aluminium alloy sheets
Sheet metal, hole flanging, flangeability, aluminium alloy, punch geometry, strain hardening exponent,
plastic anisotropy, limit strains
Yohei Abe, Ken-ichiro Mori, Takuji Murao, Fujio Okubo
Improvement of roughness of inner surface in multi-stage deep drawn
stainless steel cups by inner ironing
Sheet metal forming, ironing, surface roughness, deep drawing, stainless steel, inner surface, finite element simulation
Tae-Wan Ku, Beom-Soo Kang
Analysis and design of multi-stage deep drawing process for rectangular
case of extreme aspect ratio by FEM
Multi-stage deep drawing, rectangular case , extreme aspect ratio, process design, FEM
Vincent Nalewajk, Jean Paul Nauzin, Yvan Chastel
Importance of temperature control in warm deep drawing of aluminium
Warm deep drawing, aluminium alloy, heat transfer coefficient, forming limit diagram
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Contents
Takahiro Ohashi

Multi-point die support system controlling deep-drawing die deformation

261

Drawing, die, multi-point support, press, trial-less

Gerrit Klaseboer, Jan Post, Erwin Stinstra, Han Huetink

A study on the influence of waiting time between forming steps on the

form accuracy of a three stage formed deep drawn product made of
Sandvik Nanoflex

267

Nanoflex, metal forming, DACE, stress-assisted, strain-induced, transformation

Yasuo Marumo, Hiroyuki Saiki, Liqun Ruan

Prevention of wrinkling and fracturing in deep drawing of metal foil using

resin dies and auxiliary sheets

273

Deep drawing, nickel foil, copper foil, resin auxiliary sheets, resin dies, wrinkling, fracturing,
deep drawability
Andrzej Matuszak, Dawid Krecisz

Springback analysis in drawbead simulator tests

279

Springback, drawbead, simulator, material properties, friction, Al-alloy, steel

Kuang-Jau Fann, Jing-Chin Yang, Pou-Yuan Hsiao

Bending profile metals in application with artificial neural networks

289

Bending, profile metals, artificial neural networks, error back propagation, finite element simulation

A Bit of Art
Kerstin Garbracht:

Metal - fascinating material for artists

283

Special Processes
Sanjay Jadhav, Roland Goebel, Werner Homberg, Matthias Kleiner

Die-less forming strategies for non-rotational symmetrical shapes

295

Die-less forming, incremental forming, process optimization

Miroslav Plancak, Dragila Vilotid, Milentije Stefanovid, Mladomir Milutinovic, Vesna Mandic

Cold indenting - UBET analysis, FE simulation and experimental verification

301

Cold indenting, UBET, FE method, CADform 2D

Robert Cacko, Piotr Czyzewski, Andrzej Kocahda

Initial optimization of self-piercing riveting process by means of FEM

307

SPR, self-piercing riveting, numerical modelling, FEM, sheet joining, mechanical joining
Isamu Aoki, Masahiro Sasada

Electromagnetic microforming of metal foil

311

Electromagnetic forming, thin parts, electromagnetic force, direct forming, indirect forming,
kinetic energy
Michael R. Lovell, Pushkarraj Deshmukh, Nicholas Yavelak

Towards a fundamental understanding of the stretch levelling process

317

Stretch levelling, edge wave, centre buckle, finite element analysis

Friction and Contact Phenomena

Simon P. Jupp, Jesus Talamantes-Silva, John H. Beynon

Application of a fundamental friction model to the hot rolling of steel

325

Adhesion theory of friction, hot rolling, steel, finite element modelling, friction algorithm, oxide scale
2 (2004) Suppl. Metal Forming 2004

Contents
Cristian Fedorciuc-Onisa, Didier CJ. Farrugia
Through process characterization of frictional conditions for
long product hot rolling
Friction, lubrication, wear, oxide scale, rolling, FEA
Jari Larkiola, Jari Nylander, Martti Verho
Monitoring of process variables and friction during cold rolling
Cold rolling, modelling, friction, monitoring, setup calculation
Matteo Strano, Luca Sorrentino, Luigi Carrino
Some issues about tools and friction in the negative dieless
incremental forming process
Sheet metal, dieless incremental forming, formability, robotic cell
Marek Burdek
A roll surface topography change during temper rolling
Temper rolling, surface topography, 3D measurement, work roll
Wolfgang Rasp, Christian Matthew Wichern
Effects of idealized surface geometry on lubricant entrapment during
plane-strain upsetting - an FEM study
Lubricant pockets, plane-strain upsetting, surface topography
Bernd-Arno Behrens, Lutz Barnert, Aziz Huskid
Use of ceramic inserts for reduction of wear in forging tools
Hot forging, wear, ceramic inserts, silicon nitride, sialon, active brazing, precision forging
Petr Kotrbacek, Jaroslav Horsky, Miroslav Raudensky, Michal Pohanka
Influence of parameters of hydraulic descaling on temperature losses and
surface quality of rolled material
Hydraulic descaling, experiment, heat transfer, surface quality, cooling

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345

351

355

361

367

Equipment and Measurements

Chikara Murata, Takeo Machida, Shoji Futamura, Junichi Endou
Development of direct drive digital servo press
Digital servo press ,4-point loading, eccentric load, slide parallelism, AC servomotor, ball screw
Uwe Dirksen, Sami Chatti, Matthias Kleiner
Measuring of the curvature distribution of bent profiles
Profile bending, three-roll-bending, closed-loop process control, curvature sensor, laser triangulation
sensor, measurement of radii distribution, linear guidance system

371

375

Annika Nilsson, Juha Jokisaari, Ake Stenstrom

Measuring and calculating flatness during hot-coiling
Hot coiling, experimental design, flatness, hot strip, strip tension

381

Luis E. Hernandez-Castillo, John H. Beynon, Christophe Pinna, Sybrand van der Zwaag
Determination of microscale deformation in hot worked steel
Microgrid technique, hot deformation, local strain, phase transformation

387

Modelling
Ghassane Ayad, Arnaud Lejeune, Thierry Barriere, Jean-Claude Gelin
Finite element modeling and optimization of powder segregation during
metal injection molding

393

Metal injection molding, segregation, optimization, response surface modelling, design ofexperiments, genetic algorithm
6

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Contents
John Alexis, Xavier Satheesh
An analysis on the parameter optimization in ring rolling process
Radial and axial forces, feed rate, thickness reduction, diametral growth, strain rate
Nicolas Pernin, Jerome Chambert, Philippe Picart
Implementation of a nonlocal damage model - mesh dependence in
sheet metal forming
Nonlocal damage, micromechanical model, finite element analysis, modelling, length scale parameter
Celine Pelissou, Elisabeth Massoni, Jean-Loup Chenot
A mixed temperature/heat flux formulation for solving unsteady thermal
problem during forming process simulation
Unsteady thermal problem, finite element, mixed formulation, linear interpolation, implicit time integration, discontinuous galerkin, thermal shock, hot forging process
Vincent Lemiale, Philippe Picart
Modelling and simulation of precision blanking for very thin components
Blanking, damage, fracture, finite element analysis
Andriy Milenin, Henryk Dyja
3D FEM analysis and optimization of metal forming and temperature
development during multi-pass rolling of the round shape
Multi-pass rolling, finite element method, inter-pass pause
Eckart Doege, Bernd-Arno Behrens, Falko Schaefer
Prediction of surface layer hardness in hot forging dies by means of
finite-element-analysis
FEM-simulation, precision forging, die temperature, surface layer, microstructure

399

403

407

413

417

423

Properties of Materials
Odd-Geir Lademo, Torodd Berstad, Odd Sture Hopperstad, Ketill Olav Pedersen
A numerical tool for formability analysis of aluminium alloys. Part I:
Theory
Instability, aluminium, texture, anisotropy, FLD, inhomogeneity
Odd-Geir Lademo, Ketill Olav Pedersen, Torodd Berstad, Odd Sture Hopperstad
A numerical tool for formability analysis of aluminium alloys. Part II:
Experimental validation.
Instability, aluminium, texture, anisotropy, FLD, inhomogeneity
Hirohiko Takuda, Tomofumi Kanie, Eiji Isogai, Tohru Yoshida
Application of ductile fracture criteria to prediction of forming limit of
high-strength steel sheets
Forming limit, high-strength steel sheet, ductile fracture criterion, biaxial stretching test, deep drawing,
finite element simulation
Matthias Weiss, Bernard F. Rolfe, Matthew E. Dingle, Peter D. Hodgson
The influence of interlayer thickness and properties on springback of SPS(steel/polymer/steel) laminates
SPS-laminates, draw-bending, springback, sheet, FEA simulation
Timo Manninen, Antti S. Korhonen, Pasi Aspegren, Tero Taulavuori
Identifying the material parameters of a combined isotropic and non-linear
kinematic hardening model for AISI 304 stainless steel sheet
Sheet metal, anisotropy, hardening, bauschinger effect, identification, tensile test, AISI 304

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433

439

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451

Contents
Frederic Pascon, Guilhem Bles, Chantal Bouffioux, Silvia Casotto, Stefania Bruschi, Anne Marie
Habraken
Prediction of distortion during cooling of steel rolled rings using
thermal-mechanical-metallurgical finite element model
Cooling, distortion, phase transformation, rolled ring, 42CrMo4, finite element method
Maciej Pietrzyk, Roman Kuziak
Development of the constitutive law for microalloyed steels deformed in the
two-phase range of temperatures
Flow stress, inverse analysis, two-phase material, rule of mixture, microalloyed steel
Zoubeir Tourki, Kacem SaY, Olfa Amdouni
A new coupled approach between a micromechanical and a phenomenological
modelling of the strain induced martensite transformation kinetics in a 304
austenitic stainless steel (TRIP Steels)
Kinetic of amartensitic transformation, y-martensite phase, austenite phase, stainless steel, AISI 304,
crystallographic approach, X-ray dispersing, 2M2C model
Tomasz Sleboda, Jason Kane, Roger N. Wright, Norman S. Stoloff, David J. Duquette
Thermomechanical processing and properties of P/M FeAl alloy
FeAl, thermomechanical processing, grain refinement, powder metallurgy, ultra-fine microstructure
Koh-ichi Sugimoto, Tomohiko Hojo, Akihiko Nagasaka, Shun-ichi Hashimoto, Shushi Ikeda
The effects of Nb and Mo additions on the microstructure and formability
of C-Mn-Si-Al TRIP-aided ferrous sheet steels with an annealed
martensite matrix
TRIP-aided steel, formability, ductility, high strength steel, retained austenite, annealed martensite, niobium, aluminum, molybdenum, automotive parts
Stefan Szczepanik, Katarzyna Piqtkowska
Selected properties of Ni-Al materials after hot forging of PM preforms
PM aluminium and nickel, PM alloy, forging, hot extrusion, intermetallics, mechanical properties, formability
Dmitry Svyetlichnyy
Application of the control theory methods to evaluation of
dislocation model parameters
Flow stress, dislocation theory, ordinary differential equations, optimal control methods, gradient methods
Carlo Bruni, Marcello Cabibbo, Alessio Cruciani, Archimede Forcellese, Filippo Gabrielli
Microstructural studies and flow stress modelling in a Ni-base superalloy
Constitutive equations, dynamic recrystallisation, hot workability, Ni-base superalloy, flow modelling,
microstructure, TEM
S.A.Risteska, J.K.Mickovski
Effects of Mg concentration, test temperature and strain rate on serration of
AIMg3 and AlMg5 alloys
Aluminum alloys, vacancy migration, aging, critical strain, activation energy, serratation, solute
Taher El-Bitar, Abdel-Wahab El-Morsy, Mohamed Abdel-Aziz, Ahmed Ismail
Grain size optimization of single hit-hot compressed nimonic 80A super-alloy
using experimental design technique
Super-alloy, nimonic, grain size, yield strength, hot compression tests, experimental design method
Khaled Mohamed Ibrahim, Ahmed Ismail Zaky
Fatigue behaviour of austempered steel
Steel, fatigue, TRIP, quasi - cleavage fracture, austempering, retained austenite
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489

495

499

505

511

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KEEL CTiP> 2 (2004) Suppl. Metal Forming 2004

Contents
Sebastien Huart, Mirentxu Dubar, Raphael Deltombe, Andre Dubois, Laurent Dubar
A methodology to identify bulk behaviour of galvanised coating:
An application to the skin-passed steel strip
Skin-pass, coating, bulk behaviour, inverse method

521

Pierre-Paul Jeunechamps, Pierre Duysinx, Jerome Walmag, Vincent Mathonet, Eric Delhez,
Patricia Tossings, Anne Marie Habraken, Jean-Philippe Ponthot
A trust-region algorithm for automatic identification of elasto-viscoplastic
parameters in metal forming problems
Optimization techniques, inverse problem, large strain, metal forming, automatic parameter identification, elasto-viscoplastic model

527

Jonathan G Mullins, Peter D Hodgson, Matthew E Dingle

Using inverse analysis to obtain material behaviour for crash simulations
Material characterization, material modelling, inverse analysis, sheet steel, strain rate, finite element
modelling

535

Andrzej tmudzki, Marcin Papaj, Roman Kuziak, Jan Kusiak, Maciej Pietrzyk
Validation of the forward-backward extrusion test, designed for evaluation of
friction coefficient and flow properties of metal alloys deformed in semi-solid
state
Extrusion, FEM, numerical modelling, plastometric tests, semi-solid state
Zbigniew Gronostajski, Norbert Misiolek
Minor cyclic deformation of AlMg0.45 aluminium alloy
Minor cyclic, deformation, aluminium alloy, stress, strain, recovery, recrystallization, temperature,
strain rate

541

547

Andrzej K. Lis, Natalia Piwek, Jadwiga Lis, Henryk Dyja, Marcin Knapihski,
Jarostaw Markowski
Hot ductility of low C-Mn-B steel under continuous casting simulation conditions
for metal forming applications
Hot ductility, strain, strain rate, temperature
Miroslaw Glowacki, Marcin Hojny
The mathematical modelling of strain and stress fields in samples with mushy
zone
Continuous casting, plastic metal flow, thermal-mechanical steel processing, mathematical modelling
Index of authors

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