Abstract
Low-cycle fatigue cropping (LCFC) is a new metal bar separation method which utilizes the material fracture under cyclic load. To achieve good and fast separation of metal bars, a control scheme based on characteristics of whole cropping process is necessary. Three kinds of materials, such as 16Mn, 1045 and Al 6061, have been operated in this study and found that the kurtosis is more suitable as a monitoring parameter in control method, because it has a better stability in the complicated industrial environment. In addition, crack instability stage formed the most uneven region on the section and the best time when change the frequency is before crack instability stage. According to the above results, an optimal control scheme which by reducing the loading frequency before the crack instability stage based on the acoustic emission kurtosis is proposed. Moreover, four control strategies’ results for three kinds of materials are compared, and find the section quality increases with the decrease of loading frequency, but the effect of this increase decreases with the decrease of loading frequency. To evaluate the advantages and disadvantages of the control strategy, a parameter combining efficiency and section quality is proposed, and according to this parameter, the most suitable control strategy for three materials is obtained.
Highlights
The cropping of metal is the first step of industrial production
Wang et al [3] used the analytical, numerical and experimental methods to investigate the kinetic properties of the new approach; the results showed this new type of cropping method is an advanced green manufacturing method, which overcomes the problem of high load in the traditional cropping methods
Kurtosis representing an outlier prone distribution which related to the fourth standardized moment about the mean of the data [19]; it can be used to characterize the sudden variation of material and describe the abrupt change between various stages
Summary
There are some common deficiencies in traditional cropping methods such as the high active load, low energy efficiency and a large number of sectional defects exits. Hua et al [1] proposed the low-cycle fatigue cropping (LCFC) method, which could solve the above problem. In this method, a metal bar is applied on the cyclic loading, and a V-shaped groove is prefabricated on the surface of the bar to produce the stress concentration effect. Wang et al [3] used the analytical, numerical and experimental methods to investigate the kinetic properties of the new approach; the results showed this new type of cropping method is an advanced green manufacturing method, which overcomes the problem of high load in the traditional cropping methods
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