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Development of tool paths for multi-axis single stage incremental hole-flanging
(2020)Procedia Manufacturing ~ 23rd International Conference on Material FormingIn this paper, multi-axis single stage incremental hole-flanging is explored in place of three axis multi-stage tool paths in order to prevent flange conicity in hole-flanging by single point incremental forming (SPIF). The angle of inclination of the forming tool, the starting radius and step size of the tool paths are varied to investigate the feasibility of new tool paths. Using the proposed tool paths, an optimization is performed by ...Conference Paper -
On the numerical prediction of process-dependent properties of current high-performance materials with material model *MAT_254 in LS-DYNA
(2020)Procedia Manufacturing ~ 23rd International Conference on Material FormingOver the last years, the forecast quality in production and especially (cold) forming simulations has reached a high level at least for standard materials. It has become state-of-the-art to take the results of these process simulations into account e.g. for crashworthiness analyses. For most of the currently used high-performance materials, however, the manufacturing processes do not only result in plastic deformation and thinning of the ...Conference Paper -
Mathematical modeling and optimization for powder-based additive manufacturing
(2020)Procedia Manufacturing ~ 23rd International Conference on Material FormingIn powder-bed additive manufacturing, a laser beam melts a thin layer of metallic powder, which solidifies during cooling and bonds to the already processed solid material. After finishing one layer, the surface is covered with a new thin powder layer, and the melting process iterates, until an entire three-dimensional object emerges. Current scanning strategies are not optimized with respect to certain optimality criteria such as ...Conference Paper -
Rule-based path identification for direct energy deposition
(2020)Procedia Manufacturing ~ 23rd International Conference on Material FormingAdditive Manufacturing (AM) provides the possibility to produce complex part geometries on a layer-by-layer basis. In AM processes, a heat source moves over the part to either deposit powder or wire feedstock or to melt thin powder layers that are spread onto a powder bed. The moving heat source inevitably creates an inhomogeneous temperature distribution, which affects the residual stresses, part distortion, and local mechanical properties. ...Conference Paper -
Hot workability of a spark plasma sintered intermetallic iron aluminide alloy above and below the order-disorder transition temperature
(2020)Procedia Manufacturing ~ 23rd International Conference on Material FormingThe Fe-25Al-1.5Ta alloy has proved to be qualified for structural applications at and above 600°C due to a superior creep resistance to its binary counterpart. The creep resistance of the Fe-25Al-1.5Ta alloy at 650°C surpasses that of the P92 martensitic-ferritic steel, which is one of the most developed creep resistant alloys for steam turbine applications. From the viewpoint of cost-effectiveness in real-scale forgings, it is important ...Conference Paper -
Numerical analysis of different fixation strategies in direct energy deposition processes
(2020)Procedia Manufacturing ~ 23rd International Conference on Material FormingProduction of components through forming requires extensive machining, high tool costs and long manufacturing times. Wire Arc Additive Manufacturing (WAAM), a direct energy deposition process, uses conventional arc welding technology to generate complex near net shape 3D parts. In Wire-Arc Additive Manufacturing (WAAM), a moving heat source melts the electrode wire and deposits the metal on the substrate. The movement of the heat source ...Conference Paper -
Modeling the residual stresses induced in the metastable austenitic stainless steel disc springs manufactured by incremental sheet forming by a combined hardening model with phase transformation
(2020)Procedia Manufacturing ~ 23rd International Conference on Material FormingA numerical model for predicting the beneficial residual stress induced in metastable austenitic stainless steel (MASS) disc springs through incremental sheet forming (ISF) is developed. An important input for the numerical model is the phase-specific flow curves of the MASS constituents, i.e., austenite γ and martensite α phase. These curves are determined by using an available CP-FEM framework. The cyclic plasticity effects introduced ...Conference Paper -
A fast approach for optimization of hot stamping based on machine learning of phase transformation kinetics
(2020)Procedia Manufacturing ~ 23rd International Conference on Material FormingHot stamping is one of the key technologies to produce lightweight components for the automotive industry. Numerical simulations are an important tool to design hot stamping tools. However, the hot stamping simulations are highly complex due to the deformation as well as heat transfer and phase transformation mechanisms taking place simultaneously. An accurate prediction of these mechanisms leads to high computational cost. Conventionally, ...Conference Paper -
Multi-bead overlapping models for tool path generation in wire-arc additive manufacturing processes
(2020)Procedia Manufacturing ~ 23rd International Conference on Material FormingWire-arc additive manufacturing (WAAM) has received substantial attention in recent years due to the very high build rates. When bulky structures are generated using standard layer-by-layer tool paths, the build rate in the outer contour of the part may lag behind the build rate in the interior. In WAAM, the profile of a single weld bead resembles a parabola. In order to keep the build rate constant at each point of the layer, optimal ...Conference Paper -
A simple approach to stiffness enhancement of a printable shape by Hamilton-Jacobi skeletonization
(2020)Procedia Manufacturing ~ 23rd International Conference on Material FormingThe 3D-Printing technology is ready to produce parts with specific properties like individual stiffness. Based on a predefined outer shape, the inner structure of a printed part defines mainly the mechanical features. By Hamilton-Jacobi skeletonization, a stiffness enhancement of a printable shape can be achieved in a way, that a novel AM-corner includes linear axis function. Originating in the field of shape analysis in computer vision ...Conference Paper