Plastic forming processes


The study of plastic forming processes is performed through the systemic approach consisting in analyzing the relationships between the input and output parameters of the process, in order to obtain defect-free parts with high mechanical properties. In this framework, experimental methodologies, numerical computational codes and artificial intelligence techniques have also been used.
In detail, the research mainly concerns the following topics:

  • development and implementation of constitutive models
  • development and implementation of friction models
  • massive plastic forming processes with focus on:
    • hot plastic workability
    • hot pressing of composite materials and optimization of process conditions using decision-making techniques
    • compression of molding cycle times
  • sheet metal forming processes with focus on:
    • elastic springback
    • plastic formability
    • molding of solid-state welded sheets
    • thin metal sheet processing
  • superplastic forming and diffusion welding processes

Influence of fibre orientation on the: (a) flow curves and (b) peak stress.

Effect of time between two subsequent deformation steps on the experimental flow curve and predicted envelope curves (T = 525 → 300 °C;   ; ɛp = 0.8 → 0.2): (a) tp = 20 s, and (b) tp = 300 s.

Comparison between BM and FSWed samples, characterised by different width to length ratios, subjected to the hemispherical punch test at 350 °C and 0.1 mm/s: (a) 100 mm × 100 mm; (b) 45 mm × 100 mm.

Billet before and after different forging steps (alloy: AA 6082-W; temperature: 200°C).

Air bending test for measuring elastic springback of metal sheet

Samples tested at different strain rate up to failure

  1. M. El Mehtedi, A. Forcellese, L. Greco, M. Pieralisi, M. Simoncini, Flow curve prediction of ZAM100 magnesium alloy sheets using artificial neural network-based models. Procedia CIRP, 79, 2019, 661-666
  2. M. El Mehtedi, A. D’Orazio, A. Forcellese, M. Pieralisi, M. Simoncini, Effect of the Rolling Temperature on Hot Formability of ZAM100 Magnesium Alloy. Procedia CIRP 67, 2018, 493-497
  3. M. Sasso, E. Mancini, G. Chiappini, M. Simoncini, A. Forcellese, Adapted Nakazima test to evaluate dynamic effect on strain distribution and dome height in balanced biaxial stretching condition. International Journal of Mechanical Sciences 148, 2018, 50-63
  4. M. Simoncini, A. Forcellese, Effect of the welding parameters and tool configuration on micro- and macro-mechanical properties of similar and dissimilar FSWed joints in AA5754 and AZ31 thin sheets. Materials & Design 41, 2012, 50-60
  5. A. Forcellese, M. Simoncini, Plastic flow behaviour and formability of friction stir welded joints in AZ31 thin sheets obtained using the “pinless” tool configuration. Materials & Design 36, 2012, 123-129
  6. A. Forcellese, F. Gabrielli, M. Simoncini, Prediction of flow curves and forming limit curves of Mg alloy thin sheets using ANN-based models. Computational Materials Science 50, Issue 11, 2011, 3184-3197
  7. C. Bruni, A. Forcellese, F. Gabrielli, M. Simoncini, Post-welding formability of AZ31 magnesium alloy. Materials & Design 32, Issue 5, 2011, 2988-2991
  8. C. Bruni, A. Forcellese, F. Gabrielli, M. Simoncini, Effect of temperature, strain rate and fibre orientation on the plastic flow behaviour and formability of AZ31 magnesium alloy. Journal of Materials Processing Technology 210, Issue 10, 2010, 1354-1363
  9. C. Bruni, A. Forcellese, F. Gabrielli, M. Simoncini, Modelling of the rheological behaviour of aluminium alloys in multistep hot deformation using the multiple regression analysis and artificial neural network techniques. Journal of Materials Processing Technology 177, Issues 1–3, 2006, 323-326
  10. C. Bruni, A. Forcellese, F. Gabrielli, Hot workability and models for flow stress of NIMONIC 115 Ni-base superalloy. Journal of Materials Processing Technology, 125–126, 2002, 242-247
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