School of Chemical Engineering

 

The Centre’s access to UQ’s advanced engineering groups supports HBIS’s strategic business objectives for developing innovative technologies in environmental engineering, metallurgical resources and high quality steel materials. More than a collaborative research centre, ICSS also enriches training in research and business management with internships and customised executive courses through UQ Business School.


 

Advanced Forming Mechanics Groups

Our primary research fields are Advanced Forming Mechanics Groups, providing fundamental and practical insight and control of highly nonlinear plastic deformation processes to produce many everyday products from sheet metal.

Our research interests include:

  1. Finite Element modelling techniques
  2. Sheet metal forming techniques includes roll forming, millipede forming, incremental sheet forming and Chain-die forming
  3. Elastic - plastic theory and experiments
  4. Digital image correlation (DIC)
  5. Non-linear dynamics, vibrations, controls, rolling contact, elastoplastic and wear phenomena, with applications to manufacturing, mining, railway, spacecraft and biomedical systems

Experimental facilities

  1. Incremental sheet forming machine

    Incremental sheet forming (ISF), as a promising technology, has demonstrated its high potential to shape complex three-dimensional parts without using specific tooling. AMINO® DLNC-PC incremental forming machine is used in many of our projects. The machine is a 3-axis CNC machine with a maximum workspace of 2100×1450×500 mm3 and can exert maximum forces of 3.0 kN in vertical axis and 1.5 kN in X and Y axis. The maximum feed rate in the X and Y axis is 6000 mm/min and 1000 mm/min in the Z axis.

    Incremental sheet forming machine

    Incremental sheet forming machine

  2. Millipede former

    Millipede forming is an alternative sheet forming method to roll forming. It was first invented to overcome product defects that are difficult to be solved by roll forming. The concept of Millipede Forming is to manipulate a strip pass through an optimal strip’s surface defined as a transitional surface. The transitional surface is defined as the mid-surface of the strip form entry to exit positions of a forming stand. In Millipede Forming, a flat strip is bent into a final profiled product through the specifically designed transitional passes by continuous forming steps. The strip is gradually deformed by passing the optimized transitional surface leading to minimized longitudinal strains, which is the main cause of product defects in roll forming like the edge wave, end flare, sweep or camber.

    Millipede former

    Millipede former

  3. Chain-die former

    Chain-die forming is a new sheet metal forming technology which has been developed as a supplement to roll forming in fabricating Advanced High-Strength Steel (AHSS) products. It has an advantage by reducing redundant plastic deformation during the forming process. The implementation is achieved through increasing the deformation length, via increasing the virtual roll radii. The rolls with large radii are assemblies of shaped die-blocks through chains and therefore it is called “Chain-die Forming”.

    Chain-die former

    Chain-die former

  4. Bending test rigs

    To understand the formability of AHSS, a bend test apparatus was developed by the research team, as shown in below. The test rig applies a pure bend moment on the sample and obtains the bend moment-curvature diagram to analyse the AHSS formability including the springback at different bend radii. Also, the reverse bend may be processed to study and examine the Bauschinger effect of AHSS.

    Bending test rigs

    Bending test rigs

  5. VIVID 9i 3D Laser Scanner

    The VIVID 9i uses a new hardware design and an improved measurement algorithm to provide 4x the measurement accuracy than that of our previous models (to 50µm), enabling 3D measurement of automobile parts and other objects formed by casting, pressing, molding, etc. The VIVID 9i can be used for reverse engineering to reflect the shape and dimension data of mock-ups or prototypes in design drawings, or for checking part shape, checking molds, inspecting quality, etc. in prototype-production or mass-production processes.

    FactSage software

    VIVID 9i 3D Laser Scanner

  6. HANDYSCAN 3D 300 handheld scanner

    The HandySCAN 300 provides metrology-grade measurements and accuracy no matter the 3D scanning environment. This 3D scanner is handheld and portable. Indeed, the HandySCAN 300 weighs under 1kg. The Creaform HandySCAN 300 is suitable for a large amount of uses cases. These include reverse engineering, all steps of design and manufacturing processes, museology heritage preservation, restoration, digital archiving and entertainment. Also, this 3D scanner is user-friendly and only requires 2 minutes of setup, with a short learning curve.

    HANDYSCAN 3D 300 handheld scanner

    HANDYSCAN 3D 300 handheld scanner

  7. Talysurf i-Series

    The Talysurf i-Series is a simple to operate high accuracy instrument capable of roughness and waviness measurement. The systems low noise axes and high resolution gauge ensures measurement integrity. Decades of experience, ultra-precision machining expertise and FEA optimized design combine to provide low noise and near flawless mechanical execution of the measuring axes. Further enhancement via the use of traceable standards and exclusive algorithms effectively eliminates instrument influence from the measurement results.

    Talysurf i-Series

    Talysurf i-Series