Rotary forging with double symmetry rolls (DSRs) is a new metal plastic forming technology developed on the basis of conventional rotary forging with a single roll, which uses a pair of symmetrical cone rolls to realize continuous local pressure plastic deformation of the workpiece. Compared with the conventional rotary forging with a single roll, it has many outstanding advantages. Rotary forging with DSRs can form large diameter : thickness ratio discs.

This investigation is a further study on the consideration of the cutting edge radius of the cutter and the material of the workpiece based on the methods of finite element simulation and the micro end cutting experiment. The minimum undeformed chip thickness (MUCT) value increases with the increase of the cutting edge radius, no matter which process. In this study, the influence of important variables on MUCT is studied as much as possible to reflect a real application situation.

In this paper, a lined pipe was formed through a drawing process. In double-layered pipes, shear strength is the most important design factor. We verified the effect on shear strength by changing the pipe surface roughness. In order to apply the surface roughness in FEM analysis, the surface roughness was converted to the friction coefficient. Through FEM analysis, we obtained a critical value for the change in shear strength.

The paper highlights the importance of process parameters in the electromagnetic sheet metal forming process. Aluminium alloy I(Al6061T6) sheets with varying thicknesses were deformed by varying current, voltage and number of turns of the coil. A numerical model was also developed to predict the behaviour of the sheet under different processing conditions. The simulation and experimental results were in good agreement.

Cold Spray is a novel technology for the application of coatings, in which bonding is realized by the acceleration of powder particles through a carrier gas and their high speed impact over a substrate material. Different nozzle designs are shown experimentally to vary in deposition efficiency, which cannot be explained by standard computational simulations. In order to amend the modelling techniques, a stronger coupling of solid and gas phase is employed, which provided improved results.

The prime novelty of the present research is the numerical finite-difference solution of Navier-Stokes equations in the curl transfer form for the viscous workpiece flow through 2θ acute-angled angular dies of Segal geometry during Equal Channel Angular Pressing, taking into account the classical rectangular (2θ0=90º) and novel modified 2θ0-inclined or 2θ0-beveled punch shapes with 2θ0=2θ.