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Fine-blanking is an effective and economical shearing process which offers a precise and clean cutting edge finish, eliminates unnecessary secondary operations and increases quality. Fine-blanking process utilizes triple-action tools: a punch, a stripper with an indented V-ring and a Counter punch (ejector) to generate a highly compressive stress state. The deformation is more violent and localized than that of any other metal forming operations. Therefore it is difficult to fully understand the mechanism of the process. This study investigates the effect of V-ring indenter, clearance of die, Force of holder and Counter punch, etc on state of stress, quality and accuracy of production. Some parameters have both positive and negative effect on quality of production and the life of the tool. Utilizing V-Ring indenter in Die will increase quality of production and life of the tool. Also Artificial Neural Networks was used to simulate Fine-Blanking process. It has been shown that booth of FEM and ANN is suitable for simulating and forecast of effect of the parameters on production.

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Incremental Sheet Metal Forming (ISMF) is based on localized plastic deformation. In this process, a hemispherical-head tool, controlled by a CNC milling machine, shapes a sheet metal according to a defined path. Study of the forming force is one of the most important topics in this process. Increasing of vertical step size, tool diameter, wall angle and sheet thickness together with using of high strength sheet metals and lightweight alloys, leads to an increase in the forming force. In this paper, the performance of a novel forming process, named Ultrasonic Vibration assisted Incremental Sheet Metal Forming (UVaISMF) has been investigated. The procedure of design, manufacture and test of vibratory forming tool, is presented. The occurrence of longitudinal mode and resonance phenomenon has been confirmed by the results of modal analysis and experimental test. Furthermore, the effect of ultrasonic vibration on the vertical component of forming force and spring-back has been studied. Aluminium sheet of grade Al 1050-O is used as a work material. Experimental results obtained from straight groove test, indicate that ultrasonic excitation of forming tool, will reduce the average of vertical component of forming force and spring-back in comparison to conventional process.

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In this paper, a new forward extrusion process is proposed for producing large-diameter tubular components. At the beginning of the process, a round billet is located in the container and then extruded into a preliminary die with three bean-shaped holes forcing a hole in the original billet. The material is then entered into another die with a diverging and converging surfaces designed to weld the material and decrease the tube thickness. Material flow behavior, applied strain and the required process load were predicted using finite element (FE) simulations. The results showed that the new extrusion process had three important advantageous namely a lower process load and a container with a smaller diameter while applying much higher plastic strain compared to the conventional methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .. . . . . . . . . .. . . .. . . . . . . .. . . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . .. . . . . .. . . . . . . . . . . . . . . . . .

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Spin-bonding is a method for fabrication of bilayer tubes based on flow-forming process. This new method is a process with high potential in production of seamless thin-walled tubes. Utilizing this process, aluminum tube (as the inner layer or clad layer) has been bonded into steel tube (as the outer layer) to fabricate tubular laminate composites. As important parameters for creating a suitable bond, effects of thickness reduction, initial aluminum thickness and strength on bonding strength were investigated. The bond strength was evaluated by peel test and the peeled surfaces were examined using scanning electron microscopy (SEM). The results indicated that thickness reduction has great influence on strength and quality of the bond. After a threshold reduction (about 35%) the bond strength increases rapidly with the amount of deformation, until it approaches the weaker metal strength, and samples fracture from the base metal in the peel test. Approaching the strength of the two metals and decreasing the initial thickness of the clad layer, with a high amount of deformation increased the bonding strength. Fracture surface images showed that the surface fraction of bonding area was increased when deformation increased. It was also increased with the reduction of the initial thickness of the clad layer and when the strength of the two layers approached each other. Additionally, distribution and shape of the fracture area changed from a disordered fibril structure to approximately straight area, with an increase in the deformation.

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In this paper, an upper bound analysis for novel backward extrusion has been presented. Initially deformation zone has been divided to four separated regions and an admissible velocity field for them has been suggested. Then total power in this process has been calculated for every region and extrusion force has been gained. Moreover investigation of relevance of extrusion force and process powers (friction, deformation, velocity discontinuity) with process parameters has been revealed better understanding in load estimation and process efficiency in this method. Finite element analysis by DEFORMTM3D has been done for validation of upper bound results. Upper bound analysis showed, increasing of initial billet diameter enhances extrusion force by nonlinear relation. In addition big billet size remodels novel backward extrusion to conventional backward extrusion and it proves lower requirement extrusion load in novel backward extrusion in comparison with conventional backward extrusion. Moreover Increasing of first region’s thickness in this process diminishes extrusion force by exponential relation and no considerable change in extrusion force can be seen in a particular thickness domain. Investigation of process parameters in power efficiency shows that bigger extruded part’s diameter creates critical condition in process efficiency because of high friction power. But increasing of thickness enhances power efficiency. Finally upper bound analysis results have a good agreement with FEM.

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Ironing is a conventional metal forming process for producing thin walled cans with uniform thickness components manufactured from deep drawn cups. The most important drawback of the conventional ironing is the lower thickness reduction ratio (TRR) causes needing annealing process and multi stage ironing. Recently, a new ironing process named constrained ironing was presented by the current authors to achieve an extra TRR to solve the conventional ironing problems. This process that is based on the compressive stresses makes it possible achieving high TRR without interruption for additional processing such as multi-stage ironing and annealing. In this paper, FEM simulation was performed to investigate the effective parameters. The simulation results showed that process the process load increases with increasing the friction coefficient. Also, the state of the stresses is fully compressive in constrained ironing process while it is tensile in the conventional ironing method. Thus, compressive stress components minimize formability problems, and higher thickness reduction ratio is achievable in the new ironing method. Also, experimental results showed that the tensile strength and hardness increased after constrained ironed of the deep drawn cup.