This research provides an insight on the performances of machine learning (ML)-based algorithms for the estimation of the energy consumption in metal forming processes and is applied to the radial-axial ring rolling process. To define the mutual influence between ring geometry, process settings, and ring rolling mill geometries with the resulting energy consumption, measured in terms of the force integral over the processing time (FIOT), FEM simulations have been implemented in the commercial SW Simufact Forming 15. A total of 380 finite element simulations with rings ranging from 650 mm < DF < 2000 mm have been implemented and constitute the bulk of the training and validation datasets. Both finite element simulation settings (input), as well as the FI (output), have been utilized for the training of eight machine learning models, implemented with Python scripts. The results allow defining that the Gradient Boosting (GB) method is the most reliable for the FIOT prediction in forming processes, being its maximum and average errors equal to 9.03% and 3.18%, respectively. The trained ML models have been also applied to own and literature experimental cases, showing a maximum and average error equal to 8.00% and 5.70%, respectively, thus proving once again its reliability.

Sheets’ buckling instability, also known as oil canning, is an issue that characterizes the resistance to denting in thin metal panels. The oil canning phenomenon is characterized by a depression in the metal sheet, caused by a local buckling, which is a critical design issue for aesthetic parts, such as automotive outer panels. Predicting the buckling instability during the design stage is not straightforward since the shape of the component might change several times before the part is sent to production and can actually be tested. To overcome this issue, this research presents a robust prediction model based on the convolutional neural network (CNN) to estimate the buckling instability of automotive sheet metal panels, based on the major, minor, and Gaussian surface curvatures. The training dataset for the CNN model was generated by implementing finite element analysis (FEA) of the outer panels of various commercial vehicles, for a total of twenty panels, and by considering different indentation locations on each panel. From the implemented simulation models the load-stroke curves were exported and utilized to determine the presence, or absence, of buckling instability and to determine its magnitude. Moreover, from the computer aided design (CAD) files of the relevant panels, the three considered curvatures on the tested indentation points were acquired as well. All the positions considered in the FEA analyses were backed up by industrial experiments on the relevant panels in their assembled position, allowing to validate their reliability. The combined correlation of curvatures and load-displacement curves allowed correlating the geometrical features that create the conditions for buckling instability to arise and was utilized to train the CNN algorithm, defined considering 13 convolution layers and 5 pooling layers. The trained CNN model was applied to another automotive frame, not used in the training process, and the prediction results were compared with experimental indentation tests. The overall accuracy of the CNN model was calculated to be 90.1%, representing the reliability of the proposed algorithm of predicting the severity of the buckling instability for automotive sheet metal panels.

The interest in research and development for additive manufacturing (AM) processes has grown significantly over the last years and attracts both industry and academia alike. Among the available AM technologies, stereolithography (SLA) is one of the most discussed, researched, and employed. On the other hand, being based on thermoset resins, all the limitations of this typology of materials still apply, limiting the range of applications of this highly versatile process. To overcome these limitations, especially brittleness, this research analyzes the effects of Tungsten (W) micro-size (average size 1 μm) particles reinforcement on a methacrylate base material. First, the manufacturing process for creating the W-reinforced methacrylate material is presented and investigated to define the effect of pre- and post-processing operations on the quality of the pre-cured solution considering 4% and 10% wt. W particles concentrations. Afterward, tensile, compressive, and impact specimens were manufactured with both concentrations and compared with the experimental results from clear (unfilled) resin-based specimens used as the benchmark. The addition of tungsten particles showed a strong improvement in the impact strength of the methacrylate base material, quantified in 28% for the 4% and 55% for the 10% wt., respectively, although at the expense of a slight reduction in elastic and yield properties on average −12%. Furthermore, using Scanning Electron Microscope (SEM) analyses, the particle–matrix interaction was investigated, showing the interaction between the polymer matrix and the reinforcement and the mechanism by which the impact resistance is enhanced.

Fiber reinforcement orientation in thermoplastic injection-molded components is both a strength as well as a weak point of this largely employed manufacturing process. Optimizing the fiber orientation distribution (FOD) considering the shape of the part and the applied loading conditions allows for enhancing the mechanical performances of the produced parts. Henceforth, this research proposes an algorithm to identify the best injection gate (IG) location/s starting from a 3D model and a user-defined load case. The procedure is composed of a first Visual Basic Architecture (VBA) code that automatically sets and runs Finite Volume Method (FVM) simulations to find the correlation between the fiber orientation tensor (FOT) and the IG locations considering single and multiple gates combinations up to three points. A second VBA code elaborates the results and builds a dataset considering the user-defined loading and constraint conditions, allowing the assignment of a score to each IG solution. Three geometrical components of increasing complexity were considered for a total of 1080 FVM simulations and a total computational time of ~390 h. The search for the best IG location has been further expanded by training a Machine Learning (ML) model based on the Gradient Boosting (GB) algorithm. The training database (DB) is based on FVM simulations and was expanded until a satisfactory prediction accuracy higher than 90% was achieved. The enhancement of the local FOD on the critical regions of three components was verified and showed an average improvement of 26.9% in the stiffness granted by a high directionality of the fibers along the load path. Finite element method (FEM) simulations and laboratory experiments on an industrial pump housing, injection-molded with a polyamide-66 reinforced with 30% of short glass fibers (PA66-30GF) material were also carried out to validate the FVM-FEM simulation frame and showed a 16.4% local stiffness improvement in comparison to the currently employed IG solution.