Bending is a crucial operation in the sheet forming of Mg alloys for automotive and aerospace applications. In this work, three kinds of sheets from an AZ31 rolled plate, sheared at 0° (S0), 45° (S45), and 90° (S90) to the rolling direction, were subjected to three-point bending tests. In-situ digital image correlation (DIC) system was employed to capture the strain fields. Electron backscatter diffraction (EBSD) was used to examine the through-thickness microstructures. A crystal plasticity finite element method (CPFEM) incorporating twinning and slip mechanisms was developed to simulate the bending deformation. The texture effect on the neutral layer shift and twinning behaviors was systematically investigated in terms of both experiments and simulations. The results show that CPFEM effectively simulated the texture-dependent shifting behaviors of neutral layer and the associated twinning behaviors. Particularly, the spatial distributions of neutral layer across the entire bent plates were captured by both DIC and CPFEM. Additionally, some unusual twinning behaviors were analyzed in depth, such as the {10-12}-{10-12} secondary twins in S90, localized twin bands in S0, and the twin traces difference in S45. These findings reveal a close relationship between the neutral layer shift and twinning activity induced by the initial texture and strain levels. This work provides valuable insights into the bending deformation mechanisms of Mg alloys and has important implications for improving their formability and controlling springback.

This study introduces an innovative theoretical model critical for predicting stress and strain distributions in Ti/Al bi-metal sheet production and its subsequent deep drawing process. Grounded in extensive mechanical and geometric analysis, the model facilitates manufacturing process optimization and the production of high-quality components. Finite Element Method (FEM) simulations are integrated to examine the significant effects of die geometric parameters on metal flow dynamics and susceptibility to material stress. The model’s precision is enhanced by incorporating anisotropic material properties and cohesive zone models. A rigorous experimental framework validates the model, highlighting the practical utility of optimized parameters in Ti/Al bi-metal component fabrication. Additionally, uniaxial tensile tests using the Video Image Correlation-3D (VIC-3D) system provide detailed insights into material deformation, elucidating stress distribution and metal flow in composite layers. Thus, the research presents a refined methodology for the efficient production of Ti/Al bi-metal components, offering valuable knowledge transferable to various materials and processing scenarios. The findings of this work are expected to make a significant impact on material engineering and mechanical manufacturing.

Based on twin-roll casting technology and multi-roll groove rolling technology, a Multi-Roll Solid-Liquid Cast-Rolling Bonding (MRSLCRB) process was proposed to fabricate Cu/steel cladding bars, which processes the advantages of short flow and high-efficiency. However, it is a typical 3-D thermal-fluid-mechanics coupled problem, and determining cast-rolling force is difficult during the equipment design. Therefore, the geometrical evolution of the cast-rolling area was studied, laying the foundation to establish contact boundary equations and analyze mechanical schematics and metal flow. Then, a 3-D steady-state thermal-fluid coupled simulation model, including casting roll, substrate bar, and cladding metal, was established. The Kissing Point (KP) height, average outlet temperature, and process window were predicted, and simulation results of the three-roll layout indicate that the KP distribution along the circumferential direction can be considered uniform. Hence, the engineering cast-rolling force model was derived based on the differential element method and plane deformation hypothesis. The accuracy was verified by the 3-D finite element model, and the influences of process layouts and technological parameters on the cast-rolling force were analyzed. Through the indirect multi-field coupled analysis method, the temperature–pressure evolution and reasonable process window can be predicted, which provides a significant basis for guiding equipment design and improving product quality.