MINI-SYMPOSIA

Coordinator: Prof. Philippe Boisse

Co-Organizers: Prof. Remko Akkerman, Prof. Emmanuelle Abisset-Chavanne, Prof. Stepan Lomov, Prof. James A. Sherwood, Dr. Pierpaolo Carlone

Description: The use of composite materials is expanding rapidly in various fields, in particular in civil aeronautics. These high level applications of composite materials created a significant demand for scientific knowledge and computational tools for composite material manufacturing. The mechanical behavior of the composite materials in service is dominated by the fiber orientation and density. The forming process, in turn, determines the fiber distribution. Hence, not only the in-service performance (stiffness, damage, fatigue…) has to be predicted, but certainly also the complex manufacturing processes, of which there are many. Their knowledge and their modelling are essential for the analysis of the composite structures in service. Since2001 and the Liege ESAFORM conference, an annual “Composite forming processes” mini symposium gathers researchers from Europe, and also from USA, Asia and Australia, who can present their works and exchange their points of view concerning research in the field of composite forming. The ESAFORM conference thus became a privileged and single place for this subject. Experimental and numerical “benchmarks” were set up on in-plane shear properties, double dome forming and friction. They are discussed within the composites forming mini-symposia. The topics of the developed sessions concern in particular: Material characterization; Constitutive laws during forming; Forming simulations; Mesoscopic analyses; Resin injection; Permeability, Fiber suspensions, Thermoforming; Contact and friction; Benchmark efforts, Natural fibres as reinforcement, Additive manufacturing of composites.

Coordinator: Prof. Henry Valberg

Co-Organizers: Dr. Soeren Müller, Prof. Wociech Z. Misiolek, Prof. André L. Costa

Description: Contributions that cover all aspects of the technology of drawing and extrusion of metals are welcomed to this mini-symposium; literature reviews, experimental and theoretical work on the mechanics and the metallurgical aspects of extrusion and drawing of various metals, FE-analysis of such processes to calculate forming parameters as well as the resulting microstructure and the mechanical properties of the products fabricated by means of drawing or extrusion. Technological testing and the mechanics of such test where the purpose is to collect material or processing data for describing of such processes are also included.

Coordinator: Prof. Bernd-Arno Behrens

Co-Organizer: Prof. Wolfram Volk, Prof. Alexander Brosius, Prof. Hinnerk Hagenah

Description: Topics covered by this minisymposium include but are not limited to: Development of new and optimization of existing forming and rolling processes; Mathematical description and parameterisation of flow, damage and fracture behaviour of new workpiece and tool materials; Mathematical description and parameterisation of friction, heat transfer and wear in forging and rolling; Development of numerical methods, formulations and algorithms for simulation of forging and rolling processes; Validation of simulation models on industrial examples; Computer-aided process control. Furthermore, the results of the Collaborative Research Center 1153 on Tailored Forming are presented.

Coordinator: Prof. Livan Fratini

Co-Organizers: Prof. Marion Merklein, Prof. Gianluca Buffa, Prof. Peter Groche, Prof. Wolfram Volk, Prof. Christof Sommitsch

Description: The main topics of the minisymposium are: mechanical fastening operations (clinching, riveting and so on); friction welding; friction stir welding and friction stir spot welding; hybrid joining processes; innovative joining processes (also using adhesives) including forming or pre-forming of the materials to be joined; computational methods for joining simulation of processes; applications of inverse analysis to material characterization in joining conditions; part integrity (prediction of residual stresses, distortions ecc); innovative measurement methods and devices to detect relevant variables in joining by forming (temperatures, pressures, vibrations, wear ….);

Coordinator: Prof. Robertt Angelo Fontes Valente

Co-Organizers: Prof. Pierpaolo Carlone, Prof. Sandrine Thuillier, Prof. Joost Duflou

Description: Nowadays, manufacturing processes are seeing a strong push towards the constant increase of their competitiveness and efficiency, together with more and more customization possibilities. Such improvements must also consider a higher level of sustainability and life cycle assessment, following the essence of a truly circular economy paradigm. Chain process involving forming and assembly technologies, as well as reliability assessment and control of the parts, must be considered for true and efficient optimization purposes. A unified or integrated analysis of the several aspects of manufacturing technologies can lead to a better understanding of the complex phenomena in forming, increasing its overall efficiency. Moreover, proper manufacturing process planning, as well as scrap minimization through near net shape manufacturing strategies, can lead to substantial energy and resource savings. Taking these broad aspects into consideration, the main goal of this Mini-Symposium is to provide a forum for discussion and presentation of research works, from both academia and industry stakeholders, focusing on integrated numerical and experimental methodologies that can provide viable paths to the sustainable forming processes and products of the future.

Coordinator: Prof. Chiara Mandolfino

Co-Organizers: Prof. Enrico Lertora

Description: This MS will focus on laser forming, expecially describing the mechanism related to the thermal process for the deformation of material and the response in terms of material characteristics. Particularly appreciated will be also the investigation about the modelling of the process.

Coordinators: Prof. Domenico Umbrello, Prof. Takashi Matsumura

Co-Organizers: Prof. Pedro J. Arrazola, Dr. Guenael Germain, Dr. Cédric Courbon

Description: The main topics of the minisymposium on Machining and Cutting are: Experimental and numerical analysis of machining operations; Material characterization and formulation of effective constitutive laws when severe plastic deformation are induced; Analysis of the tool wear, friction and material fracture in machining and cutting; Application of traditional and advanced coolant methodologies (near to dry, MQL, cryogenic, etc.) for enhancing the machinability and the product’s performance; Surface integrity (prediction of residual stresses, roughness, microstructural changes).

For the first time, this Mini-Symposium features workshops on cooperative research projects and initiatives that are of high relevance for the ESAFORM community but not explicitly covered by existing Mini-Symposia. Depending on the participation in the workshops, these can be turned into Mini-Symposia in future ESAFORM conferences.

The Workshops will be organized by a coordinator team in the same way as Mini-Symposia. The synopsis can be found below

Workshop A: Tribology in Sheet Metal Forming Processes

Coordinator: Dr. Javad Hazrati

Co-Organizers: Dr. Lander Galdos, Dr. Dirk Drees

Description: Sheet metal forming (SMF) is one of the most important technologies in manufacturing industry in particular; automotive, aerospace and packaging. In sheet metal forming, relative motion of the tool and workpiece during production makes tribology (friction, wear and lubrication) of the utmost importance. The tribological performance in SMF is influenced by several parameters at the micro- and macro levels (local contact conditions: surface texture, contact pressure, temperature and lubrication). For optimum process design, improving formability of sheet metal and finally control of tribology, a better understanding of tribology and an accurate prediction of friction in sheet metal forming is necessary. In the current workshop, different aspects of tribology in cold/hot stamping processes are included such as tribological effects on process modeling and applied plasticity, modeling friction and wear, tribological characterization methods, surface engineering and control of tribology in SMF.

The current workshop will be also organized as the final event of the ASPECT project, financed from the INTERREG North-West Europe programme – and will showcase the developed technology during the project. The aim of ASPECT was to develop advanced simulations technology to account for temperature increase and adaptive control systems to adjust the machine settings during the start-up of the production line.

Workshop B: Artificial Intelligence in Manufacturing

Coordinator: Dr. Omar Fergani

Co-Organizers: Prof. Markus Bambach, Prof. Satish Bukkapatnam

Description: Artificial intelligence (AI) is commonly defined as the mimicking of cognitive capabilities of humans by machines. In manufacturing, algorithms that perform machine learning and pattern recognition tasks have been explored over decades, but the developments in computing power and algorithms in recent years now boost AI applications that radically transform manufacturing. This workshop invites contributions on current topics in AI related to manufacturing processes featured by ESAFORM, i.e. metal and composite forming, additive manufacturing and machining. Suitable topics are generative design, predictive maintenance, smart process planning, quality and monitoring. The workshop explicitly invites contributions from computer science and industry to achieve a knowledge exchange between the ESAFORM community and AI experts.

Workshop C: Damage-controlled forming (DFG TRR 188)

Coordinator: Prof. Erman Tekkaya

Co-Organizers: Prof. Sebastian Münstermann, Dr. Till Clausmeyer

Description: Most metals and alloys undergo a forming operation during processing from the as-cast state to the final product. All forming operations may induce damage into the material. One prominent mechanism is the formation of voids by decohesion of the metallic matrix from second-phase particles or by fracture of those particles. Under the guiding principle that damage is not failure, a fundamental understanding of the damaging mechanisms involved in forming processes and their effects on product properties will be investigated in the TRR188 project funded by the German Research Foundation. The interdisciplinary scientific consortium consisting of forming technology, materials science, and material testing technology as well as mechanics aims at two paradigm shifts: In forming technology, the transformation from “formability” to “usability” of the products is aimed at. When designing the products, the use of the actual product properties after forming should be taken into account instead of the nominal properties. In the long term, the TRR 188 wants to be able to quantify the degree of damage of a component, to control it, and to specifically adjust it along the process chain. This creates a fundamental prerequisite for the development of a new generation of tailor-made, high-performance lightweight products that are reliable during the utilization phase. This workshop presents work from the TRR188 and invites contributions from other groups working in the field of damage-controlled metal forming.

Coordinators: Prof. Francisco Chinesta and Prof. Elias Cueto

Co-Organizers: –

Description: This MS covers all aspects related to non-conventional modeling and simulation of forming processes. By that we consider all those developments in the field of numerical simulation that can eventually and potentially be applied to the simulation of any forming process. Among these, the following non-exclusive list of topics is considered: – Advances in Finite Element Technology – Meshless and mesh free methods – Particle methods – Advanced shell methodologies, solid/shell formulations – Numerical techniques for challenging processes (FSW, LFW, …) – Speeding up simulations (parallel computing, model order reduction, …) – Data-driven simulation and control of forming processes, – This year we encourage particularly submissions in the following challenging fields: 1 – Fine versus coarse modeling (incremental forming is a nice candidate, but also processes like FSW, …) 2 – Simulation-based real time control, 3 – Real time simulations 4 – Supercomputing (GPUs, …) and deployed  systems  5 – From virtual to augmented reality  6 – Alleviating mesh constraints (anisotropic meshes, advanced remeshing, meshless, …) 7 – Data-driven simulation for factories of the future…

Coordinator: Dr. Margareta Coteata

Co-Organizers: Dr. Hans-Peter Schulze, Prof. Massimo Durante, Prof. Loredana Santo, Prof. Laurentiu Slatineau.

Description: The main topics of MS are: EDM, ECM, EME, EHE, cold spray, Friction Stir Welding and Single Point Forming for polymers, creep age forming. Historically starting from some innovative processes initially included in this MS, new symposia were created.
Therefore, in order to maintain this characteristic of individuating new processes of scientific interest, the papers regarding innovative processes or forming processes of non-conventional materials (innovative materials or hybrid structures) will be considered in this MS.

Coordinator: Prof. Matteo Strano

Co-Organizers: Prof. A. Gil Andrade-Campos, Prof. Sam Coppieters

Description: Contributions on the following subjects are welcomed: METHODS FOR METAMODELING, CONTROL AND OPTIMIZATION OF FORMING PROCESSES: shape and topological optimization; optimization of manufacturing processes and machines; process control; new metamodeling techniques. INVERSE ANALYSIS: identification of constitutive, friction, heat transfer or damage parameters; identification of boundary conditions or unknown process conditions; design of experimental procedures and measurement techniques for inverse analysis; numerical methods and algorithms for inverse analysis. Stochastic approaches: reliability assessment; robust design; optimisation under uncertainty.

Coordinator: Prof. Fabrice Schmidt

Co-Organizers: Dr. Nadine Allanic, Prof. Olivier De Almeida, Dr. Gary Menary, Dr. Roberto Spina, Dr. Vincent Sobotka

Description: The aim of this symposium is to bring together specialists from academia and industry dealing with modelling and experimental analysis of polymer processing and induced properties. This MS extends from thermo-chemo-mechanical characterization of polymers to coupled transfers in processes, in particular heat transfer in molded parts, tools and interfaces. The main topics of the mini symposium are: Thermomechanical modelling and optimization of polymers processes. New challenges for characterization and modelling of thermo-chemo-physical properties in homogeneous and heterogeneous media; Heat transfer phenomena in molds/tools associated with polymers processes; Specific thermal metrology applied to polymers processing.

Coordinator: Dr. Jokin Lozares

Co-Organizers: Dr. Zigor Azpilgain, Dr. Iñaki Hurtado

Description: Semi-solid metal processing (SSM) is a near net shape variant of metal forming. The process is used with all metallic alloys and widely applied to non-ferrous metals, such as aluminium and magnesium, steel application remain at laboratry scale. The process combines the advantages of casting and forging. The process is also named thixoforming, due to the fluid property thixotropy, which is the phenomenon that allows this process to work. Simply, thixotropic fluids shear when the material flows, but thicken when standing. The potential for this type of process was first discovered in 1970s. There are four different SSM processes: thixoforging, thixocasting, rheocasting, thixomolding…The industrial development of thixoforming must be accompanied by knowledge and control of the various parameters driving the process: the identification of the suitable materials for thixoforming; the homogeneous temperature heating of the slug before deformation; design or re-design of the part to adapt it to the process; the forming parameters including ram speed and load profiles, hold time and pressure at the end of the stroke, die temperature, die material. The handling system is also important; it allows the slug to be transferred, in the semi-solid state, between the heating zone and the tooling and to eject the thixoformed part so as to ensure the quality heat treatment of the part. In parallel to experimental investigations, modelling and simulation of die fill and rheological property measurement remain one of the challenging investigations to predict most of these parameters. Bringing semi-solid forming community together with experts in numerical simulation and material forming will allow sharing great experiences in the field of advanced metal processing.

Coordinator: Prof. Dermot Brabazon

Co-Organizer: Prof. Antonello Astarita, Prof. Jean Yves Hascoet, Dr. Anne Mertens

Description: The aim if this min-symposium is to discuss the optimisation, capabilities and development within Additive Manufacturing. The pre-process, in-situ process, and post process aspects of additive manufacturing are important to characterise and understand well how these impact on the final produced part properties. Experimental, fundamental modelling and data analytic developments in relation to additive manufacturing are considered within this mini-symposium. Charactreisation of aspects of additive manufacturing production quality will be discussed within this mini-symposium.

Coordinator: Dr. Gabriela Vincze

Co-Organizers: Prof. Frederic Barlat, Prof. Toshihiko Kuwabara, Prof. Dorel Banabic, Dr. Holger Aretz, Dr. Sam Coppieters, Prof. Sandrine Thuillier

Description: The aim of this mini-symposium is to discuss the formability of metallic materials. Namely, their ability to undergo plastic deformation and result in products with minimum damage and defects. Limiting mechanisms are not restricted to plastic flow localization, fracture and spring back, which are only a few examples under consideration. Contributions based on experimental, theoretical and numerical approaches and leading to a better understanding of the relationship between material properties, mechanical and thermal loading, and other environmental constraints on the formability of metallic materials are encouraged.

Coordinator: Prof. Markus Bambach

Co-Organizers: Prof. Guisy Ambrogio

Description: This mini-symposium focuses on contributions that detail new developments and enhance the understanding of incremental and sheet metal forming processes. The topics of interest include (but are not limited to) novel process designs, in-process measurement techniques, innovative tooling, methods for the analysis and modeling of friction phenomena and methods for the optimization, robust design and control of incremental and sheet forming processes.

Coordinator: Prof. Anne Habraken

Co-Organizers: Prof. Semih Perdahcioglu, Dr. Lionel Leotoing

Description: Description: Issued from an academic, a research institution or an industry, any contribution focused on material behaviour modelling from phenomenological macroscopic laws to plasticity, DDD, MD approaches is welcome. CONSTITUTIVE MODELLING FOR ANY MATERIAL: metals like Al, steel, Ti, Mg… but also glass, wood, food, textile, composite… generic or dedicated models covering complex loading paths, high strain rates, high temperatures, cyclic loading…APPROACHES BRIDGING THE SCALES: from atomistic to macroscopic scale, mechanism explanations of formability, hardening, rate sensitivity, anisotropy, toughness, phase transformation…FRACTURE PREDICTION: by continuum damage mechanics, fracture criteria…EXPERIMENTS AND MODELS: experimental procedure of identification of model parameters, or physical mechanisms experimental method applied for model validation (both model and experiments should be described).