13th International Conference on the Technology of Plasticity (ICTP 2021): Technologies to Speed Innovation
Program Organizers: Glenn Daehn, Ohio State University; Libby Culley, The Ohio State University; Anupam Vivek, Ohio State University; Jian Cao, Northwestern University; Brad Kinsey, University of New Hampshire; Erman Tekkaya, TU Dortmund; Yoshinori Yoshida, Gifu University

Monday 10:20 AM
July 26, 2021
Room: Virtual: Room D
Location: Virtual

Session Chair: Gracious Ngaile, North Carolina State University


Experimental Investigation of Different WAAM (Wire-Arc Additive Manufacturing) Processes and Their Influence on the Component Properties and Formability: Pascal Colditz1; Marcel Graf1; André Hälsig2; Sebastian Härtel1; Keval Prajadhiana3; Yupiter Manurung3; Birgit Awiszus1; 1Technische Universität Chemnitz, Professur Virtuelle Fertigungstechnik; 2Technische Universität Chemnitz, Professur Schweißtechnik; 3Universiti Teknologi MARA, Faculty of Mechanical Engineering
    With the wire-arc additive manufacturing (WAAM) complex components can be built up layer by layer from metallic construction materials. In this investigation two different WAAM processes with high built-up rates (CMT and pulsed GMAW) were compared in terms of geometry formation and component properties. The reference is a rectangular thin-walled geometry made of the austenitic stainless steel 316LSi (1.4430). During the welding process, the temperature development in the base plate as well as in the weld layer were measured. The experimental comparison of CMT (Rm=630MPa) and pulsed GMAW (Rm=605MPa) is completed by the determination of the mechanical properties using micro tensile tests. Furthermore, the additive manufactured walls were cold rolled with a subsequent heat treatment or hot rolled to provide proof of formability and forming induced property improvement.

Validation of Automatically Generated Forging Sequences Using FE Simulations: Yorck Hedicke-Claus1; Mareile Kriwall1; Jan Langner1; Malte Stonis1; Bernd-Arno Behrens1; 1IPH-Institut für Integrierte Produktion Hannover gGmbH
     In this study an analytical method is developed to automatically design a multi-staged forging sequence based on the CAD file of the forged part. The method uses artificial neural networks to analyse the geometry of the forging and to classify it into a shape class. A slicer algorithm divides the forging into cutting planes and calculates the mass distribution around its centre of gravity line. An algorithm shifts the points of the polygon courses of the cross-sectional contours and approximates the mass distribution step by step from the forging to the semi-finished product. Each preform is exported as CAD file. The generated sequences are simulated and evaluated by form filling, folds and cracks. The conducted FE simulations showed, that the automatically generated forging sequences allow the production of different forgings. By help of the FE results, the algorithm is now refined, and the method subsequently validated by experimental forgings.

Pre-forging Shape Design Using Conformal Mapping Method: Chengshang Liu1; Wujiao Xu1; Minyao Liu1; 1Chongqing University
    In this paper, a novel method of using conformal mapping to design the pre-forging shape is proposed to achieve a reasonable three-dimensional (3D) shape of the pre-forging. Firstly, the 3D final forging was two-dimensional (2D) sliced to simplify the design problem. The new profile of each slice was calculated based on the conformal mapping method. Then, the discrete points on all new profiles were combined into a 3D point cloud for surface reconstruction to obtain 3D model of the pre-forging. Next, four parameters (conformal factor and triaxle scaling factors) were applied to describe the pre-forging shape. Finite element analysis was used to simulate the forging process of the designed pre-forging. Finally, this method was applied to design the pre-forging shapes of different forgings. Through reasonable parameter values, satisfactory pre-forging shapes can be obtained. This method is effective, easy to implement, and has universal adaptation.

Multi-objective Optimization of Elbow-bar Transmission Mechanism Based on Virtual Prototyping: Xinyu Dong1; 1Xuanwu District
    The kinematics and dynamics characteristics of transmission mechanism will directly affect the processing quality and efficiency of multi-link die forging press. Based on the structural parameters of a certain type of die forging press, the dynamic optimal model of elbow-bar transmission mechanism is established. Several performance indexes in the respect of kinematics and dynamics were put forward which were took as the objective functions and constraint functions. Based on virtual prototyping, this paper proposed an improved genetic algorithm method for an elbow-bar transmission mechanism, which can also be applied to optimal synthesis of multi-link mechanisms where there it is possible to obtain the analytically solution of the kinematic position. And with this, we find an optimized dimensions of elbow-bar transmission mechanism. Theoretical and simulation results examine the performance of the optimized mechanism, and demonstrate that its performance parameters are improved obviously.