Manipulating martensitic transformation and residual stress development in stress superposed incremental forming of SS304
Stress superposition is one of the strategies used in metal deformation processes to increase the material formability, decrease the required forming forces, and create highly customized components. To investigate the effects of tensile and compressive stresses superposed to the single point increme...
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Elsevier
2025-05-01
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| Series: | Advances in Industrial and Manufacturing Engineering |
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| author | Elizabeth M. Mamros Fabian Maaß Thomas H. Gnäupel-Herold A. Erman Tekkaya Brad L. Kinsey Jinjin Ha |
| author_facet | Elizabeth M. Mamros Fabian Maaß Thomas H. Gnäupel-Herold A. Erman Tekkaya Brad L. Kinsey Jinjin Ha |
| author_sort | Elizabeth M. Mamros |
| collection | DOAJ |
| description | Stress superposition is one of the strategies used in metal deformation processes to increase the material formability, decrease the required forming forces, and create highly customized components. To investigate the effects of tensile and compressive stresses superposed to the single point incremental forming (SPIF) process, experiments and numerical simulations were conducted for a stainless steel 304 (SS304) truncated square pyramid geometry. Tensile stresses were superposed in-plane on the specimen blank by a custom hydraulic frame, and compressive stresses were incorporated via a polyurethane die. Identified parameters for a martensitic transformation kinetics model for SS304 were used in a two-step finite element approach to predict the α’-martensite volume fraction. These results were compared to experimental results measured by a Feritscope at four locations along each pyramid wall and validated by electron backscatter diffraction. The residual stresses were measured using x-ray diffraction. The parts from each incremental forming process revealed differences in the residual stresses, which impacted the final geometries, and the α’-martensite volume fraction at the four measurement locations. The evolution of the stress state, defined by the stress triaxiality and Lode angle parameter, for each process contributed to the phase transformation variance. It was found that superposing both tensile and compressive stresses to SPIF resulted in the greatest phase transformation and lowest magnitude of residual stresses near the base and the greatest overall geometrical accuracy. Stress-superposed incremental forming can be implemented to manipulate final part properties, which is ideal for applications requiring highly customized parts, e.g., biomedical trauma fixation hardware. |
| format | Article |
| id | doaj-art-66cebc3d49f243aa8d6d6f3ddc463789 |
| institution | DOAJ |
| issn | 2666-9129 |
| language | English |
| publishDate | 2025-05-01 |
| publisher | Elsevier |
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| series | Advances in Industrial and Manufacturing Engineering |
| spelling | doaj-art-66cebc3d49f243aa8d6d6f3ddc4637892025-08-20T03:07:50ZengElsevierAdvances in Industrial and Manufacturing Engineering2666-91292025-05-011010016110.1016/j.aime.2025.100161Manipulating martensitic transformation and residual stress development in stress superposed incremental forming of SS304Elizabeth M. Mamros0Fabian Maaß1Thomas H. Gnäupel-Herold2A. Erman Tekkaya3Brad L. Kinsey4Jinjin Ha5Department of Mechanical Engineering, Bucknell University, Lewisburg, PA, 17837, USAInstitute of Forming Technology and Lightweight Components, TU Dortmund University, 44227, Dortmund, GermanyNeutron-Condensed Matter Science Group, National Institute of Standards and Technology, Gaithersburg, MD, 20899, USAInstitute of Forming Technology and Lightweight Components, TU Dortmund University, 44227, Dortmund, Germany; Corresponding author.Department of Mechanical Engineering, University of New Hampshire, Durham, NH, 03824, USADepartment of Mechanical Engineering, University of New Hampshire, Durham, NH, 03824, USAStress superposition is one of the strategies used in metal deformation processes to increase the material formability, decrease the required forming forces, and create highly customized components. To investigate the effects of tensile and compressive stresses superposed to the single point incremental forming (SPIF) process, experiments and numerical simulations were conducted for a stainless steel 304 (SS304) truncated square pyramid geometry. Tensile stresses were superposed in-plane on the specimen blank by a custom hydraulic frame, and compressive stresses were incorporated via a polyurethane die. Identified parameters for a martensitic transformation kinetics model for SS304 were used in a two-step finite element approach to predict the α’-martensite volume fraction. These results were compared to experimental results measured by a Feritscope at four locations along each pyramid wall and validated by electron backscatter diffraction. The residual stresses were measured using x-ray diffraction. The parts from each incremental forming process revealed differences in the residual stresses, which impacted the final geometries, and the α’-martensite volume fraction at the four measurement locations. The evolution of the stress state, defined by the stress triaxiality and Lode angle parameter, for each process contributed to the phase transformation variance. It was found that superposing both tensile and compressive stresses to SPIF resulted in the greatest phase transformation and lowest magnitude of residual stresses near the base and the greatest overall geometrical accuracy. Stress-superposed incremental forming can be implemented to manipulate final part properties, which is ideal for applications requiring highly customized parts, e.g., biomedical trauma fixation hardware.http://www.sciencedirect.com/science/article/pii/S2666912925000054Stainless steelStress superpositionIncremental formingMartensite transformationResidual stresses |
| spellingShingle | Elizabeth M. Mamros Fabian Maaß Thomas H. Gnäupel-Herold A. Erman Tekkaya Brad L. Kinsey Jinjin Ha Manipulating martensitic transformation and residual stress development in stress superposed incremental forming of SS304 Advances in Industrial and Manufacturing Engineering Stainless steel Stress superposition Incremental forming Martensite transformation Residual stresses |
| title | Manipulating martensitic transformation and residual stress development in stress superposed incremental forming of SS304 |
| title_full | Manipulating martensitic transformation and residual stress development in stress superposed incremental forming of SS304 |
| title_fullStr | Manipulating martensitic transformation and residual stress development in stress superposed incremental forming of SS304 |
| title_full_unstemmed | Manipulating martensitic transformation and residual stress development in stress superposed incremental forming of SS304 |
| title_short | Manipulating martensitic transformation and residual stress development in stress superposed incremental forming of SS304 |
| title_sort | manipulating martensitic transformation and residual stress development in stress superposed incremental forming of ss304 |
| topic | Stainless steel Stress superposition Incremental forming Martensite transformation Residual stresses |
| url | http://www.sciencedirect.com/science/article/pii/S2666912925000054 |
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