PROCEEDINGS OF

THE 8th ESAFORM CONFERENCE ON MATERIAL FORMING

,,ESAFORM 2005"

Volume II

Editor:

Prof. Dorel BANABIC

TIB/UB Hannover 89126 679 487

ESAFORM 2005 Conference, Cluj-Napoca, Romania

FP007(Keynote paper)

FP185(Keynote paper)

FP001

FP044

FP080

FP124

FP155

FP208

FP008

FP230

FP277

VOLUME II

Extrusion and drawing technologies and modelling

Fast Material Forming 541

N.D. Cristescu

Measurement of Temperature and Pressure During Thin-Strip Extrusion 545

W. Wajda, P.T. Moe, S. Storen, M. Lefstad, R. Flatval

Effect of Strain-Hardening Exponent on the Occurrence of Central Burst in 549Aluminum Wire Drawing Process

S.M. Koohpayeh, A. Karimi Taheri

An Innovative Experimental Procedure To Investigate Seam Welding In 553Aluminum Extruded Profiles

A. Ghiotti, S. Bruschi, T. Dal Negro

Flash Formation In Conform Extrusion 557

T. Manninen, P. Ramsay, A. S. Korhonen

3D FEM Analysis of Seam Welds Formation in Aluminum Extrusion and Product 561Characterization

L. Donati, L. Tomesani

An Upper Bound Analysis of Forward Extrusion through Rotating Dies 565

X. Ma, M.R. Bamett

Development of a Laboratory Hot Extrusion Apparatus for Tribology and 569Rheology Parameters Identification

R.E. Loge, M. Minvielle, E. Cini, A. Le Floc'h, E. Felder

Finite-Element Modelling of Hydrostatic Extrusion of Magnesium 573

G. Barton, R. Kopp

An Experimental and Numerical Study of Induction Heating 577

P.T. Moe, W. Wajda, S. Stsren, M. Lefstad, R. Flatval

Radial Gear Extrusion Modeling: Analytical, Numerical and Experimental 581Approach

P. Skakun, M. Skunca, M. Plancak

XTT

Contents

Superplastic forming of aluminium and magnesium alloys

FP047 Optimum Variable Strain Rate Deformation Paths for Superplastic Forming of 587

(Keynote paper) AA5083 using Multiscale Stability Criterion

N. Thuramalla, M. K. Khraisheh

FP017 Finite Element Simulation of Warm Deep Drawing of Magnesium Alloy AZ31 591

Sheet

H. Takuda, T. Morishita

FP035 Superplastic Response in Coarse-Grained Al-Mg Alloys 595

A.R. Chezan, W.A. Soer, J.Th.M. De Hosson

FP059 Microstructural Evolution During Superplastic Forming of Coarse-Grained Al-Mg 599

Alloys

W.A. Socr, A.R. Chezan, J.Th.M. Dc Hosson

FP061 A Unified Interpretation of Hubble Flow, Plastic Flow and Super Plastic Flow 603

J. D. Mufloz-Andrade

FP068 Hot Deformation Characteristics of AZ31 Magnesium Alloys 607

S.M. Fatcmi-Varzanch, A. Zarci-Hanzaki, A. Araic

FP070 AA5083-SPF: From Bulge-Testing to Automotive Body Parts Forming 611

M. Vulcan

FP077 Tensile Ductility of Aluminium-Magnesium Alloys Sheets at Elevated 615

Temperatures

D. GliSic, M. Popovic, E. Romhanji

FP149 High Temperature Characterization of a 2024 Aluminium Alloy by Tensile Tests 619

and the Blow Forming Technique

D. Sorgentc, L. Tricarico

FP043 On the Failure of Superplastic PbSn60 Alloy in Biaxial Tension Tests 623

G.Giuliano, L. Carrino and S.Franchitti

FP046 Deformation Characteristics of AZ31 Magnesium Alloy under Various Forming 627

Temperatures and Strain Rates

F. K. Abu-Farha, M. K. Khraisheh

FP192 Aspects Concerning Superplastic Behaviour of Some Aluminum Alloys 631

A. - L. Rus, T. Canta, D. Frunza

FP050(Keynote paper)

Nanostructuring metals by severe plastic deformation

3D-ECAP of Square Aluminium Billets

A. Rosochowski, L. Olejnik, M. Richcrt

637

XIII

ESAFORM 2005 Conference, Cluj-Napoca, Romania

FP052

FP060

FP107

FP249

FP250

FP251

FP240

Effect Of The Strain Inhomogeneity On The Microstructure Evolution During 641Bidirectional Compression Of IF Steel Using MaxStrain Technology

R. Kuziak, V. Podvysockyy, M. Pietrzyk, D. Ferguson

Experimental and Numerical Investigation of Equal Channel Angular Pressing of 6451230 aluminium alloy

D.A. Gnevashev, P.A. Petrov, M.A. Petrov, S.A. Stebunov

Ultrafine Recrystallized Grains by Severe Shear Deformation During Hot Rolling 649of P-Titanium Alloy

T. Sakai, K. Nakamura, Y. Saito

The Influence of the ECAP Temperature on Superplasticity of Aluminium 653Allloys

R.K. Islamgaliev, N.F. Yunusova, R.Z. Valiev

Processing of Ultrafine-Grained Structure in the Ti-6A1-4V Alloy by Severe 657Plastic Deformation

I.P. Semenova, L.R. Saitova, G.I. Raab, R.Z. Valiev

Nanostructuring of Ti in Long-Sized Ti Rods be Severe Plastic Deformation 661

G.H. Salimgareeva, I.P. Semenova, V.V. Latysh, R.Z. Valiev

The Influence of the ECAP Temperature on Microstructure and Mechanical 665Properties of a Magnesium Alloy

O.B. Kulyasova, R.K.Islamgaliev

FP289(Keynote paper)

FP274(Keynote paper)

FP231(Keynote paper)

FP009

FP014

FP020

Rapid prototyping and rapid tooling

Initial Experimental and Numerical Investigations into a Class of new Strategies 671for Single Point Incremental Sheet Forming (SPIF)

M. Bambach, J. Ames, M. Azaouzi, L. Campagne, G. Hirt, J.L. Batoz

Achievable Accuracy in Single Point Incremental Forming: Case Studies 675

J. R. Duflou, B. Lauwers, J. Verbert, Y. Tunckol, H. De Baerdemaeker

The Application of Rapid Prototyping Technologies for Manufacturing the 679Custom Implants

P. Berce, H. Chezan, N. Bale

An Approach in Manufacturing of Medical Implants 683

P. Raos, A. Stoic

Microstructural and Hardness Investigation in Welding Based Rapid Prototyping 687Process

R.A. Mufti, M.P. Mughal, A.A. Khan, H.F. Junejo, M. Siddique, I. Khan

Optimization of Sheet Incremental Forming Process by Means of FE Simulations 691

E.Ceretti, A.Attanasio, C. Giardini

XIV

Contents

FP027

FP056

FP241

FP256

FP262

FP221

Finite Element Analysis of Laminated Tools for Sheet Metal Stamping 695

M. Oudjene, F. Mercier, L. Penazzi, J.L. Batoz

Application of the Neural Network Technique for Reducing Springback in 699Incremental Forming Processes

G. Ambrogio, L. Filice, F. Gagliardi, F. Micari, D. Umbrello

Experimental validation of the Finite Element Simulation of the First Stroke in 703Single Point Incremental Forming

K. Watzeels, Y. Tunckol, C. Henrard, J. Gu, H. Sol, J. Duflou, A.M. Habraken

Deep-Drawing Die Controlled by a Multi-Point Die-Support System 707T. OhashiEffect of FEM Choices in the Modeling of Incremental Forming of Aluminum 711Sheets

S. He, A. Van Bael, P. Van Houtte, Y. Tunckol, J. Duflou, C. Henrard, C. Bouffioux,A.M. Habraken

Active Elements Tools Made By Selective Laser Sintering

N. Bale, P. Berce, R. Pacurar

715

Machining and cutting technologies and modelling

FP023 Metal Forming Simulations using Recent Advances in the Natural Element 721

(Keynote paper) Method

J. Yvonnet, D. Ryckelynck, P. Lorong, F. Chinesta

FP026 Numerical Investigation of Effect of Hard Turning on Residual Stress 725

(Keynote paper) Distribution of Shot Peened Surface

X. Cheng, J. Hua, D. Umbrello, R. Shivpuri, F. Hashimoto

FP057 On the Finite Element Simulation of Thermal Phenomena in Machining 729(Keynote paper) Processes

L. Filice, D. Umbrello, F. Micari, L. Settineri

FP089 Simulation Analysis on Chip Breaking Process by Grooved Tool 733

T. Shirakashi, J. Shinozuka, T. Obikawa

FP120 High Speed Experimental Analysis of Orthogonal Cutting using Hopkinson Bars 737

and Optical Deformation Measurements

P. Guegan, Y. Guetari. A. Poitou

FP125 Simulation of The Blanking Process of Aluminium Sheet Using the Engineering 741

Software DEFORM

W. W. Wenzl, S. Treml

FP129 Study of the X-FEM Method Possibilities for the Simulation of Machining 745

Y. Guetari, S. Le Corre, N. Mofs

FP145 Comparison of Different Fracture Models for the Metal Blanking Process 749

V. Lemiale, J. Chambert, P. Picart

XV

ESAFORM 2005 Conference, Cluj-Napoca, Romania

FP147

FP166

FP217

FP288

FP123

FP229

A Finite Element Three Dimensional Approach to Metal Evaporative Laser 753Cutting: Temperature Field Non-Linear Model

P. Carlone, C. Cataldo, G.S. Palazzo

Simulation of Drilling Process Base on Energy Approach 757

T. Matsumura, 1. Hori, T. Shirakashi, E. Usui

Experimental and FEM Study of the Temperature Field During Superficial 761Grinding

A. Aguiar Vieira, A. Monteiro Baptista, R. Natal Jorge, M. Lages Parente

Dexel-based Milling Simulation 765

K. Tracht, B. Denkena, M. Clausen, J.-H. Yu

2D Orthogonal Cutting Simulation of Cl5 Steel 769

L. Donati, G. Tani, L. Tomesani

Numerical Modeling of the Chip Geometry in end Milling Operation 773

M. Ancau

FP030

FP034

FP193

FP267

Constitutive models for polymers

Deterministic Approach of Multi Bead-Spring Polymer Models 779

A. Ammar, F. Chinesta, D. Ryckelynck

Constitutive Model for Amorphous Polymers Based on the Quasi Point Defect 783Theory

R. Rinaldi, R. Gaertner, M. Brunei, E. Vidal-Salle, L. Chazeau

Hyper Elasticity and Strain-Rate Dependence of Behaviour in Amorphous 787Polymer in Stretch-Blow Moulding and Thermoforming

N. Billon

Constitutive Modeling of Polymers Solutions in Simple Shear and Oscillatory 791Tests

A. Marin, A. Calin, C. Balan

FP113(Keynote paper)

FP121(Keynote paper)

FP278(Keynote paper)

Structure development of polymers

Effect of Short Branches on the Crystallization of Potyamides 797

P. Van Puyvelde, S. Acierno

a-relaxation in polyethylene as a function of crystal thickness 801

T. Kazmierczak, A. Galeski

Heat Transfer and Crystallization During Fast Cooling of Thin Polymer Film 805

G. Lamberti, F. De Santis, V. Brucato, G. Titomanlio

Contents

FP028 External Calibration in PA 12 Tube Extrusion: Influence on Microstructure and 809

Mechanical Properties

A. Carin, J.-M. Haudin, M. Vincent, B. Monassc, G. Bcllct, N. Amouroux

FP039 Contribution to Numerical Modelling of Polymer Crystallization 813

J.-L. Chcnot, J. Smirnova, J.-M. Haudin and B. Monasse

FP130 Structural and Melting Studies on Photocrosslinked Polyethylene 817

V. Barboiu, M. Avadanci, C. V. Grigoras

FP 159 Rheological Study of the Early Crystallization Stages 821

S. Aciemo, S. Coppola, N. Grizzuti, D. Vlassopoulos

FP195 Flow Induced Crystallization of Polymers at Elevated Pressures 825

M.H.E. van dcr Beck, G.W.M. Peters, H.E.H. Mcijcr

FP198 Crystallization and Properties of Plasticized Poly(L-lactide) 829

R.Kulinski, E.Piorkowska

FP268 Determination of the Crystallization Kinetics of a PBT/PET Blend in Relation to 833

the Behaviour of the Constituents

V. La Carrubba, A. Stocco, S. Piccarolo, V. Brucato

FP021 Tabu Search Method Used In Macromolecular Designee 837

T. Rusu, V. Bulacovschi

FP 106 On the Effect of Chain Ends and Chain Stiffness on the Second Virial Coefficient 841

of Polysulfone - Theoretical Aspects

A. Filimon, S. loan, E. Avram

FP 108 Crosslinked Structures in Solution of poly(ether urethane)s 845

M. Lupu, S. loan, D. Macocinschi

FP 112 The Role Of Compatibilizers In The Structure Development Of Polymer Blends 849

E. Van Hcmelrijck, P. Van Puyveldc, P. Moldcnacrs

Link between process and final properties

FP036 Development of a Neural Network to Predict the Final Geometry of Forged 855

Rings after Cooling

S. Casotto, S. Bruschi, F. Pascon, A. M. Habraken

FP138 Numerical Implementation of a Fatigue Criterion Taking into Account the Grain 859Flow OrientationN. Caillct, P.-O. Bouchard, Y. Chastcl

FP173 Dimensional Stability and Mechanical Properties of Mouldings Featuring Novel 863Morphologies Produced with by Active Shear Rotation During InjectionMoulding

C.A. Silva, J. C. Viana, A. M. Cunha

XVII

ESAFORM 2005 Conference, Cluj-Napoca, Romania

FP207

FP172

Influence of Process Parameters on Friction Stir Welding Conditions - 867Application to 6061 T6 Al Alloy Thin Plates

F. Gratecap, G. Racineux, A. Poitou

Melt Manipulation Techniques in Non-Conventional Injection Moulding: 871Structure Development and the Mechanical Properties

A. D. Kouyumdzhiev, J. C. Viana, A. M. Cunha

FP051(Keynote paper)

FP148(Keynote paper)

FP287(Keynote paper)

FP045

FP167

FP180

FP189

FP190

FP254

FP255

FP269

Polymer Processing and Modelling

Numerical Simulation Of Plastic Sheath Coating Of Telephone Wires 877

E. Mitsoulis

Role of Process Simulation in Liquid Composite Moulding 881

V. Neacsu, A. Gokce, P. Simacek, J. M. Lawrence, S. G. Advani

Modeling of Anisothermal Dynamic Crystallization in Injection Molding 885

J. Smimova, L. Silva, B. Monasse, J.-M. Haudin, J.-L. Chenot

Influence of the PET Chain Structure on its Stretch Blow Moulding Ability 889

E. Deloye, J.-M. Haudin, N. Billon

PET under Uniaxial and Biaxial Tension Loading: Models Validation by 893Comparison Between Uniaxial and Biaxial Data's

L. Chevalier, Y. Marco

Determination of the Spatial Distribution of Molecular Orientation in Injection 897Molded iPP

R. Mendoza, G. Regnier, L. David, R. Fulchiron, C. Rochas

Multilayer Film Blowing Process. Numerical and Experimental Results 901

E. Gamache, J-F. Agassant, Y. Demay, P.G. Lafleur

3D Finite Element Modelling of the Stretch Blow Moulding Process 905

C. Champin, M. Bellet, F.M. Schmidt, J.-F. Agassant, Y. Le Maoult

Vectorial Algorithm for Bi-phasic Simulation of the Powder Segregation in 909Metal Injection Moulding

Z.Cheng, T.Barriere, B.Liu, J.C.Gelin

Experimental Study and Simulation of Heterogeneous Anisotropic Elastic 913Properties of Injection-molded Fiber-Reinforced Polymer

D. Liksonov, T. Barriere, N. Boudeau, J.C. Gelin, L. Maslov

Determination of the Volumetric Thermal Expansion Coefficient of Glass Fiber 917Reinforced (GFR) Thermoplastics through Pressure-Volume-Temperature (PVT)Measurements

V. La Carrubba, M. Butters, G. Struijk, W. Zoetelief

XVIII

Contents

FP282

FP191

FP194

Evolution of Morphology During Processing of Thermoplastic Polymers: the 921Injection Moulding Process

G. Titomanlio, I. Coccorullo, R. Pantani, V. Speranza

Optimisation of Infrared Heating System for the Thermoforming Process 925

M. Bordival, S. Andrieu, F.M. Schmidt, Y. Le Maoult, S. Monteix

Film Blowing and Characterization of PA6/LDPE Blends 929

F.P. La Mantia, N. Tzankova Dintcheva

Composite forming technologies and modelling

FP012 Strain Field in the Picture Frame Test: Large and Small Scale Optical 935

(Keynote paper) Measurements

S.V. Lomov, A. Willems, M.Barburski, T.Stoilova, I.Verpoest

FP076 Modelling the Effects of Blank-Holder Pressure and Material Variability on 939

(Keynote paper) Forming of Textile Preforms

A. C. Long, J Wiggers, P Harrison

FP094 Spring-Forward in Composite Plate Elements 943(Keynote paper) g w i j s k a m P j £ A D L a m e r s , R. AkkermanFP139 Consistent Preprocessor for the Unit Woven Cell for Meso-Macro Analyses of 947

(Keynote paper) Fabric Forming

G. Hivet, B. Laine, P. Boisse

FP025 Development of a Simplified Finite Element Model for Draping and Wrinkling of 951

Woven Material

A. A Skordos, C. Monroy Aceves, M. P F Sutcliffe

FP062 Mechanical Analysis of 3D Braided Fiber Reinforced Composites Based on 955

Homogenization and Elastic-Plastic Constitutive Laws

J.-H. Kim, M.-G. Lee, H. Ryou, M.-H. Lee, K. Chung, T. J. Kang, J. R. Youn

FPO79 Towards Real Time Manipulation of Virtual Fabric Reinforcement - Extending 959

and Enhancing Kinematic Drape Simulation Tools

S.G. Hancock, K.D. Potter

FP087 Finite Element Forming Simulation of NCF Considering Natural Variability of 963

Fiber Direction

W.R. Yu, P. Harrison, A.C. Long

FP100 Influence of Material and Process Parameters on Segregation Phenomena During 967

Compression Molding of GMT

P. Dumont, L. Orgeas, C. Servais, V. Michaud, D. Favier, J.-A. E. Manson

FP101 Development of a RTM Mould Filling System Integrating Simulation, 971Optimisation and Control TechniquesF. Sanchez, J.A. Garcia, F. Chinesta, G.Salvador, Ll.Gascon

XIX

ESAFORM 2005 Conference, Cluj-Napoca, Romania

FP102

FP104

FP115

FP131

FP137

FP202

FP206

FP085

FP118

FP133

FP157

FP162

FP279

Flow Of Non-Newtonian Viscous Fluids Through Fibrous Media: Experimental 975And Numerical Study

Z. Idris, C. Andre, C. Gcindreau, L. Orgcas, J.-F. Bloch, L. Dcbovc

Micro-Deformation Of Foam-Composite Sandwich Structures During Curing 979

S. S. Chcon, S. H. Chang

FE Modelling of Micro-Deformation of Carbon Fabric-Metallic Foam Sandwich 983Structures

S.S. Chang, S.S. Chcon

Kinematics of Intra-Ply Slip of Textile Composites During Bias Extension Tests 987

P. Harrison, M.-K. Tan, A. C. Long

Drape Simulation of Non-Crimp Fabrics 991

R.H.W. ten Thijc, R. Locndcrsloot, R. Akkcrman

Permeability Of The Woven Fabrics: A Parametric Study 995

B. Laine, G. Hivct, P. Boissc, F. Boust, S. V. Lomov

Experimental Study on Woven Composites with Different Temperature 999Trajectories

H. S. Cheng, J. Cao, N. Mahayotsanun

Simulation of Double Dome Stamping of Twill Woven Fabric Composites 1003

X. Li, J. A. Sherwood, L. Liu, J. Chen

Biaxial Tensile Tests on Glass/PP under Optical Strain Measurement 1007

A. Willems, D. Vandepitte, S. V.Lomov, I. Verpoest

Simulations and Experiments in Continuous Fibres Composites Forming 1011

J.L Daniel, D. Soulat, P. Boissc

Measurement of the Transverse and Longitudinal Viscosities of Continuous Fibre 1015Reinforced Composites

P. Harrison, T. Haylock, A.C. Long

Mechanical Analysis of 3D Braided Fiber Reinforced Composites Based on 1019Homogenization and Elastic-Plastic Constitutive Laws

J.-H. Kim, M.-G. Lee, H. Ryou, M.-H. Lee, K. Chung, T. J. Kang, J. R. Youn

Technological Parameters Optimisation for High Compression Strength of Parts 1023Made of Melamine and Clay Compounds

L. Hancu, D. Pauncscu, H, Iancau

FP266(Keynote paper)

FP048(Keynote paper)

General and special topics

Experimentation and FE Simulation of a Flow Forming Process

C.C. Wong, J. Lin, T.A. Dean

Three-Dimensional Finite Element Modelling for an Uterus Surgery

A. Paccini, Y. Tillier, J. Dclotte, M. Durand-Reville, J.-L. Chcnot

1029

1033

XX

Contents

FP058

FP150

FP186

FP187

FP291

FP300

FP013

FP071

FP074

FP093

FP299

Behaviour of Friction Stir Welded T-Components under Loading 1037

G. Buffa, L. Filice, L. Fratini, F. Gagliardi

Two Simple Models for Exploring a Novel Flexible Ring Rolling Process 1041

T. F. Stanistreet, J. M. Allwood

Simulation of Deformation in Mannesmann Piercing Process 1045

K. Komori

Power Evaluation in a Hot Rod Rolling Process 1049

F. Capece Minutolo, M. Durante, L. Giorleo, A. Langella

Requirements for the Design of Roll Materials for Wire Rod Rolling 1053

S.-E. Lundberg

High Magnetic Field Effect on Texture of Low GNO Silicon Steel 1057

C.M.B. Bacaltchuk, G.A. Castello-Branco, H. Garmestani, C. Iskandar, P. Koo, A.Kasseh, R. Abourialy, O.S. Es-Said

Clad Sheet Rolling Analysis by the Modified Slab Method 1061

F. Farhat-Nia, M. Salirai

An Investigation to the Alpha Phase Dynamic Globularization in Ti-6A1-4V 1065Alloys

A.R. Shahab, A. Zarei-Hanzaki, M. Mastoori, S.M.H. Hoseiny, H. Azizi-Alizamini

3-D Finite Element Modelling of Macular Translocation 1069

Y. Tillier, C. Falcot, A. Paccini, G. Caputo, J.-L. Chenot

A cost model for the Friction Stir Welding process 1073

R. Di Lorenzo, L. Fratini

The Components of Logarithmic Strain Tensor in Material Forming and 1077Comparison with the Components of Conventional Strain

V. Ungureanu

FP174(Keynote paper)

FP276(Keynote paper)

FP199

FP203

Semi-solid processing

Thixoforming of Steel: Experiments on Thermal Effects and Micromechanical 1083Modelling

P. Cezard, R. Bigot, V. Favier, M. Berveiller, M. Robelet

Study of liquid fraction evolution of semi-solid steels for thixoforming 1087

J. Lecomte-Beckers, A. Rassili, M. Carton, M. Robelet

Pseudo-Semi-Solid Thixofroming of Ceramics Matrix Composite 1091

Y.-S. Cheng, S.-J. Luo, Z.-M. Du

Semi-Solid Forming of Steels 1095

A. Rassili, C. Geuzaine, P. Dular, M. Robelet, J. Demeurger, D. Fischer

XXI

ESAFORM 2005 Conference, Cluj-Napoca, Romania

FP215

FP261

FP294

FP295

FP211

FP214

Twin roll casting of Al-16%Si hypereutectic aluminium alloy strip 1099

T. Haga, M. Ikawa, W. Hisaki

Semi-sold roll casting of AZ31B magnesium alloy by a horizontal roll caster 1103

H. Watari, T. Haga, K. Davcy, M. Sato, N. Takada

Flow Visualisation for Semi-Solid Alloys 1107

H.V. Atkinson, P.J. Ward

Rheological properties of semi-solid metallic alloys 1111

M. Modigell, L. Pape, M. Hufschmidt

SLC™ - Sub Liquidus Casting: An Economical Route to Rheocasting 1115

J. Jorstad, M. Thieman, R. Rogner

Semisolid roll casting of wire-inserted composite strip 1119

T. Haga, K. Takahashi, W. Hisaki