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The purpose of this paper is to present a shape optimization technique for powder forming processes based on the genetic algorithm approach. The genetic algorithm is employed to optimize the geometry of component based on a fixed‐length vector of design variables representing the changes in nodal coordinates. The technique is used to obtain the desired optimal compacted component by changing the boundaries of component and verifying the prescribed constraints.

The numerical modeling of powder compaction simulation is applied based on a large deformation formulation, powder plasticity behavior, and frictional contact algorithm. A Lagrangian finite element formulation is employed for large powder deformations. A cap plasticity model is used in numerical simulation of nonlinear powder behavior. The influence of powder‐tool friction is simulated by the use of penalty approach in which a plasticity theory of friction is incorporated to model sliding resistance at the powder‐tool interface.

Finally, numerical examples are analyzed to demonstrate the feasibility of the proposed optimization algorithm for designing powder components in the forming process of powder compaction.

A shape optimization technique is presented for powder forming processes based on the genetic algorithm approach.

The purpose of this paper is to determine if the nanoindentation technique is a reliable method and whether it can be used to measure the surface hardness (H) in friction stir welded aluminum alloys. In order to test the reliability of nanoindentation technique, nanohardness values for friction stir welded aluminum alloys were compared to microhardness values. Additionally, the onset of plasticity (yielding) is investigated.

Nanoindentation experiments were performed for the determination of onset on plasticity (yielding) and comparison of local mechanical properties of both welded alloys. In order to test the reliability of nanoindentation technique, nanohardness values for friction stir welded AA6082 were compared to microhardness values. The specimen was tested using two different instruments – a Vickers microhardness tester and a nanoindenter tester for fine scale evaluation of H.

The results of this study indicate that nanohardness values with a Berkovich indenter reliably correlate with Vickers microhardness values. Nanoindentation technique can provide reliable results for analyzing friction stir welded aluminum alloys. The welding process definitely affects the material mechanical properties.

Microhardness and nanohardness obtained values can be correlated carefully, regarding the similarities and the differences of the two above mentioned techniques.

This paper gives a review of the finite element techniques (FE) applied in the area of material processing. The latest trends in metal forming, non‐metal forming and powder metallurgy are briefly discussed. The range of applications of finite elements on the subjects is extremely wide and cannot be presented in a single paper; therefore the aim of the paper is to give FE users only an encyclopaedic view of the different possibilities that exist today in the various fields mentioned above. An appendix included at the end of the paper presents a bibliography on finite element applications in material processing for the last five years, and more than 1100 references are listed.

To study the nature of scuffing in boundary lubricated sliding contacts with subsurface plastic deformation, as it occurs in plastic deformation processing.

Low speed oblique plastic impact testing (LOSOPIT) has been conducted on copper specimen with a hard En31 ball in a test rig that has facility to measure the coefficient of friction. Based on the findings of friction coefficient in these experiments, friction power has been estimated and was found to be in the typical range. Scuffing studies were undertaken both by observation of the slid surface of En31 sphere in a ferrographic microscope with camera facility as well as by calculation of the friction power.

The boundary lubricant was found to have profound role in safeguarding the surface from severe deformation and micro‐cracks. Scanning electron microscope (SEM) examination of the craters produced by LOSOPIT has given evidence that using the boundary lubricant resulted in smooth transfer of shear stress from the sphere to the specimen surface through the boundary lubricant layer. Owing to this, the asperities have been found flattened in a smooth manner instead of metal at the surface being scuffed. A limited amount of reduction was found in the coefficient of friction due to the use of boundary lubricant from that in the dry testing.

The model used to estimate the friction power is predominantly governed by the friction coefficient itself rather than either the normal load or the sliding speed. Friction coefficient itself may be contributed by various mechanisms all of which may not equally contribute to scuffing. Study is underway to carefully glean out those components of friction that exactly result in scuffing, and to use more effective criteria for scuffing.

The knowledge and data developed in the paper give a clear explanation of conditions under which scuffing can take place in sliding contacts operating under boundary regime. The most important applications are metalforming and metal cutting. It is relevant to mechanical engineering machinery in which intense contact pressures are expected.

This paper fills the gap of lack of scuffing studies in plastic deformation processing. All earlier studies focused on elastic conditions prevailing at the contact. Since, industry has been witnessing a need to tackle the severe problems related to formed product quality and certain defects hitherto unexplained, this paper gives a new direction to explain the defects in products from scuffing point of view. In this paper, it has been shown that friction power can be a good criterion to represent scuffing intensity in boundary lubrication.

The purpose of this paper is to provide industrial, education and academic users of computer programs a basic overview of finite elements in metal forming that will enable them to recognize the pitfalls of the existing formulations, identify the possible sources of errors and understand the routes for validating their numerical results.

The methodology draws from the fundamentals of the finite elements, plasticity and material science to aspects of computer implementation, modelling, accuracy, reliability and validation. The approach is illustrated and enriched with selected examples obtained from research and industrial metal forming applications.

The presentation is a step towards diminishing the gap being formed between developers of the finite element computer programs and the users having the know‐how on the metal forming technology. It is shown that there are easy and efficient ways of refreshing and upgrading the knowledge and skills of the users without resorting to complicated theoretical and numerical topics that go beyond their knowledge and most often are lectured out of metal forming context.

The overall content of the paper is enhancement of previous work in the field of sheet and bulk metal forming, and from experience in lecturing these topics to students in graduate and post‐graduate courses and to specialists of metal forming from industry.

This paper is devoted to the analysis of metal forming with assumption of rigid‐plastic behaviour with strain hardening. As opposed to the classical rate problem formulation based on Markov's principle and the explicit scheme, a more satisfactory incremental approach is deduced from Moreau's catching up algorithm. This implicit scheme, although more complicated, gives better results concerning convergence and numerical stability. Using an internal variable representing the strain hardening, an incremental strain energy density is defined which leads to a principle of minimum of the total incremental strain energy. In the numerical approximation using finite elements, the non‐linear equilibrium equations are solved by classical Newton's method. An approximation of Coulomb's criterion is used in order to represent friction with a rigid foundation. The simple compression test is simulated and shows that the implicit scheme is faster than the explicit one.

Sheet metal forming is a process of shaping thin sheets of metal by applying pressure through male or female dies or both. In most of used sheet‐formating processes the metal is subjected to primarily tensile or compressive stresses or both. During the last three decades considerable advances have been made in the applications of numerical techniques, especially the finite element methods, to analyze physical phenomena in the field of structural, solid and fluid mechanics as well as to simulate various processes in engineering. These methods are useful because one can use them to find out facts or study the processes in a way that no other tool can accomplish. Finite element methods applied to sheet metal forming are the subjects of this paper. The reason for writing this bibliography is to save time for readers looking for information dealing with sheet metal forming, not having an access to large databases or willingness to spend own time with uncertain information retrieval. This paper is organized into two parts. In the first one, each topic is handled and current trends in the application of finite element techniques are briefly mentioned. The second part, an Appendix, lists papers published in the open literature. More than 900 references to papers, conference proceedings and theses/dissertations dealing with subjects that were published in 1995‐2003 are listed.

The paper considers a plane joint or interface element suitable for implementation into a standard non‐linear finite element code. Sliding of the joint is assumed to be governed by Coulomb friction, with a non‐associated flow rule and no cohesion. The constitutive equations are formulated in a manner appropriate for a backward difference discretization in time along the path of loading. It is shown that the backward difference assumption can lead to an explicit formulation in which no essential distinction need be drawn between opening and closing of the joint and sliding when the joint is closed. However, an inherent limitation of the dilatant Coulomb model becomes evident; the final formulation is internally consistent but does not describe reversed shear displacement in a physically reasonable way. Explicit equations for the consistent tangent stiffness and for the corrector step (or return algorithm) of the standard Newton—Raphson iterative algorithm are given. The equations have been implemented as a user element in the finite element code ABAQUS, and illustrative examples are given.

A numerical procedure is described for the elastic—plastic finite element analysis of crack propagation with branching. Constraint equations are used to model crack closing and sliding. Constraint conditions are imposed by using a penalty method for the self‐similar crack propagation and an elimination method for the off‐axis propagation. The contact condition is examined during plasticity iterations. The use of multiple constraints at the crack branching point to determine the mode of contact is discussed in detail. The method is then applied to (i) the self‐similar crack growth in a single‐edge notch specimen, (ii) the self‐similar propagation followed by interfacial splitting in a center‐cracked 0° composite plate, and (iii) the bifurcation of a crack in a compact tension specimen.

Granular materials possess multiscale structures, i.e. micro-scales involving atoms and molecules in a solid particle, meso-scales involving individual particles and their correlated structure, and macroscopic assembly. Strong and abundant dissipations are exhibited due to mesoscopic unsteady motion of individual grains, and evolution of underlying structures (e.g. force chains, vortex, etc.), which defines the key differences between granular materials and ordinary objects. The purpose of this paper is to introduce the major studies have been conducted in recent two decades.

The main properties at individual scale are introduced, including the coordination number, pair-correlation function, force and mean stress distribution functions, and the dynamic correlation function. The relationship between meso- and macro-scales is analyzed, such as between contact force and stress, the elastic modulus, and bulk friction in granular flows. At macroscales, conventional engineering models (i.e. elasto-plastic and hypo-plastic ones) are introduced. In particular, the so-called granular hydrodynamics theory, derived from thermodynamics principles, is explained.

On the basis of recent study the authors conducted, the multiscales (both spatial and temporal) in granular materials are first explained, and a multiscale framework is presented for the mechanics of granular materials.

It would provide a paramount view on the multiscale studies of granular materials.