Thermo-Mechanical Numerical Simulation in Manufacturing of Aluminum Components: A Comprehensive Review of Turning and Deep Drawing Processes
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With their outstanding strength-to-weight ratio, corrosion resistance, and workability, aluminum alloys play a pivotal role in modern lightweight manufacturing. The prediction of the thermo-mechanical response during machining and forming is crucial for optimizing the processes parameters, minimizing the tool wear, reducing the residual stresses and improving the dimensional accuracy. This review is systematic and examines comprehensively the state of the art of the numerical simulation of two of the main methods of producing aluminium products: turning (a subtractive machining process) and deep drawing (an incremental sheet forming process). Topics covered include finite element method (FEM) formulations, constitutive material models such as Johnson–Cook and Zerilli–Armstrong models, contact and friction models, thermal analysis (heat generation and dissipation), prediction of chip morphology, springback and earing defects. The 90 publications that have undergone peer review are critically reviewed and synthesized. Key findings and consolidated data tables are provided to compare various simulation approaches and highlight the greatest research gaps around high speed turning of Al 7xxx alloys, multi-scale modelling of microstructure evolution and machine-learning enhanced FEM. This review is intended as a reference for folks who are engaged in research and practice in the area at the intersection of computational mechanics and aluminum manufacturing.
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