Journal Of Materials Processing Technology Research Articles

An overview of the effect of stirrer design on the mechanical properties of Aluminium Alloy Matrix Composites fabricated by stir casting

Aluminum Matrix Composites are widely utilized in a variety of applications, and their popularity is growing due to their excellent performance, low cost, and low environmental footprint. Metal Matrix Composites are made in a variety of ways, including liquid and solid states, but stir casting is the most common because of its flexibility, inexpensiveness, and offering a diverse range of materials and manufacturing conditions. The key challenge in the procedure is the homogeneous dispersion of reinforcing particles. The homogeneous dispersion of particles inside the metal matrix determines the microstructure and mechanical properties of the composites. Stirrer design has a vital role and it can be more effective through optimizing it. All available literature was reviewed from 1968 which stir casting method was initiated to produce Aluminium matrix composites. Mixer designs and mixing efficiency were also investigated in other related studies. The scope of this paper explores the experimental contributions of stirrer design in the production of composites. There are many variables in stir casting The large number and overlap of parameters appear to have an impact on the uniform distribution of reinforcing particles. Researchers on their path to the appropriate technique have had promising results with only their circumstances, without being able to generalize their findings. In this article, previous findings and contributions have been collected, organized, compared, and presented. Finally, several conclusions have been raised and scopes for the new research have been identified. References El -Kady, E. Y. et al. (2014) ‘" On the fabrication of A356 / Al2O3 metal matrix composites using rheocasting and squeeze casting techniques ",’ (March 2016). Adat, R. V, Kulkarni, S. G. and Kulkarni, S. S. 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RETRACTED ARTICLE: Machinability study on dry machining of white cast iron by polycrystalline cubic boron nitride inserts

We, the Editors and Publisher of Machining Science and Technology have retracted the following article: Xin Guo, Ling Chen, Wu Zhao, Hao Wan, Huiting Wen & Jinming Zhou (2022) Machinability study on dry machining of white cast iron by polycrystalline cubic boron nitride inserts, Machining Science and Technology, 26:2, 137–159. https://doi.org/10.1080/10910344.2022.2044851 Following publication, the authors requested the withdrawal of this article in 2022 due to conflicting findings with their recent research studies. However, upon further investigation by the Publisher, in collaboration with the Editors, it was found that this article has significant similarities with the following published article which has not been acknowledged appropriately: Ling Chen, Jan-Eric Stahl, Wu Zhao, Jinming Zhou. (2018). Assessment on abrasiveness of high chromium cast iron material on the wear performance of PCBN cutting tools in dry machining, Journal of Materials Processing Technology 255, 110–120. https://doi.org/10.1016/j.jmatprotec.2017.11.054. These unacknowledged similarities are in the form of: text overlaps in the sections “Material preparation”, “Nanoindentation test”, and “Tool wear”, and; reused images included in figures 5 and 6, which are not referenced. Upon query, the corresponding author has not been able to provide a satisfactory explanation for the significant level of overlap. As this is a serious breach of the journal’s editorial policies, we are retracting the article from the journal. The authors disagree with the Publisher’s and Editors’ reasons for retraction. We have been informed in our decision-making by our editorial policies and the COPE guidelines. The retracted article will remain online to maintain the scholarly record, but it will be digitally watermarked on each page as ‘Retracted’.

A bibliometric analysis and visualisation of research trends in Carbon Reinforced Plastics

Carbon Reinforced Plastics/polymers are metamaterials, widely used for diversified purposes for their unique features. The bibliometric analysis had been conducted to understand the active authors, organizations, journals, and countries involved in the research domain of “Carbon Reinforced Plastics”. All published articles related to “Carbon Reinforced Plastics” from “Scopus”, were analyzed using the VOS viewer to develop analysis tables and visualization maps. This article had set the objective to consolidate the scientific literature regarding the “Carbon Reinforced Plastics” and also to find out the trends related to the same. The most active journals in this research domain were Mechanics of Composite Materials, Journal of Materials Processing Technology, and Applied Mechanics Reviews. The most active countries were China, Japan, Portugal, and the United Kingdom. The leading organizations engaged in the research regarding Carbon Reinforced Plastics were the University of Tokyo of Japan, the Russian Academy of Sciences of Russia, and the Ministry of Education of China. The most active authors who had made valuable contributions related to Carbon Reinforced Plastics were Yates B. Davim J.P. Reis P. and Ishikawa T.

Development of an Electropolishing Process for Additively Manufactured 316L Parts Under Direct and Pulsed Potential Control

The initial purpose of additive manufacturing was mainly rapid prototyping, but all industrial sectors have adopted this technique that has increased in profitability and allows innovative shapes in almost all alloys. Advances in technology have led to AM components whose mechanical and structural properties are equivalent to machined parts. However, a major impediment to the extension of the process is due to the bad surface finish of the as built parts, characterized by a high roughness (Ra up to 40 µm) and the presence of un-melted particles and weld beads. These defects are incompatible with the planned applications (like inner channels for fluid flow), and also induce a degradation of the material functional properties such as an increased sensitivity to fatigue and corrosion. Electropolishing, an electrochemical method for planarization of metals based on their anodic dissolution in an appropriate electrolyte, is a solution to consider. During this work a specific electropolishing process dedicated to 316 L AM parts was developed with the originality of being under potentiostatic control [1,2]. First, a preliminary study done at laboratory scale in a three electrodes electrochemical cell, allowed us to determine the process parameters including the working potential range. Then, the same type of arrangement was subsequently up-scaled in a 3 L reactor in order to electrochemically polish bigger parts ( ≈40 cm2). The potential control is made possible thanks to the introduction of a reference electrode in the pilot and by the use of a high current/high voltage potentiostat able to monitor both direct and pulse potentials. When transposing the process at pilot scale, new difficulties are emerging, due to the large initial roughness of the parts. If a satisfactory roughness decrease is easily achievable in less than one hour, it goes with an inhomogeneous loss of dimension. This geometric deformation of the parts needs to be considered as least as much as roughness parameters. In this context, pulsed potential are emerging as an attractive way to performed electropolishing, by controlling the dissolution while getting interesting final surface properties and limited deformation [3]. Samples present a very bright finishing and low roughness values (Fig.1) In this study a special attention was paid to the quantification of the deformation on especially designed grooved test samples by 3D optical microscopy and laser scanning [4]. Acknowledgments : the authors would like to thank the IRT-M2P program AFTER ALM for its financial support. [1] Rotty C., Mandroyan A., Doche M.-L., Hihn J. Y., Surf. Coat. Technol., 307 Part A, 125–135 (2016) [2] Rotty C, Doche M.-L, Mandroyan A.,Hihn J-Y., Montavon G., Comparison of electropolishing behaviours of TSC, ALM and cast 316L stainless steel in H3PO4/H2SO4, Surfaces and Interfaces, 6, 170-176 (2017) [3] Taylor EJ., Sequential electromachining and electropolishing of metals and the like using modulated electric fields, US Patent 6,558,231 (2003) [4] C.M. Sulyma, P.C Goonetilleke, D.Roy, Journal of materials processing technology, 1189-1198 (2009) Figure 1

High Temperature Oxidation Resistance of Cr Coatings on 22MnB5 Steel Electroplated in Trivalent Cr Baths

22MnB5 steel is one kind of advanced high-strength steels commonly used for vehicles to enhance passengers’ safety and reduce carbon dioxide emission[1]. However, 22MnB5 steel is vulnerable to high-temperature oxidation and a protective coating is essential to inhibit oxidation during hot stamping process. For example, hot-dip Al-10 wt % Si coating has been extensively applied on press hardening steel although it does not provide sacrificial protection on the steel parts[2]. In contrast, hot-dip Zn coating, which confers sacrificial protection, tends to suffer oxidation and liquid metal embrittlement during hot stamping[3, 4]. This study investigated the structure and properties of Cr coatings on 22MnB5 steel electroplated in a trivalent Cr (Cr(III)) bath. The DC electroplating was conducted in a chloride-based Cr(III) electrolyte with and without the addition of sulfur-containing organic compounds. The morphology, microstructure, and composition of the Cr coating were characterized using scanning electron microscope (SEM), X-ray diffraction (XRD), and electron dispersive spectroscopy (EDS). The thickness of the deposit before and after high-temperature heat treatment (900℃ for 5 min in air) was measured using cross-sectional SEM. Experimental results show that the sulfur-containing organic compound in the electrolyte reduces the carbon content and increases the sulfur content of the Cr coating, which, in turn, reduces the residual stress of the coating. As a result, a crack-free Cr coating can be obtained in the electrolyte with the organic additive. In contrast, many cracks develop on the Cr coating plated in the electrolyte without the organic additive. After the heat treatment at 900℃ for 5 min, extensive oxidation was observed on the crack-free Cr coating, but not on the Cr coating with cracks. It is likely that the presence of sulfur in Cr coating deteriorates the oxidation resistance. Crack openings of the Cr coating free of sulfur are filled with compact oxides after 900℃heat treatment for 5 min. The steel substrate with a Cr overlay remains intact, indicating the Cr coating prevents the steel substrate from oxidation at 900℃.Finally, a 2-mm-thick Cr coating can be electroplated in the Cr(III) bath without the organic additive at a current density of 10 A/dm2and a plating time of 1 min and effectively protects the 22MnB5 steel from high-temperature oxidation. Reference [1] H. Karbasian, A.E. Tekkaya, Journal of Materials Processing Technology, 210 (2010) 2103-2118. [2] D.W. Fan, H.S. Kim, J.-K. Oh, K.-G. Chin, ISIJ international, 50 (2010) 561-568. [3] C.W. Lee, D.W. Fan, I.R. Sohn, S.-J. Lee, B.C. De Cooman, Metallurgical and Materials Transactions A, 43 (2012) 5122-5127. [4] M. Razmpoosh, A. Macwan, E. Biro, D. Chen, Y. Peng, F. Goodwin, Y. Zhou, Materials & Design, (2018).

Morphology of Surface Integrity as Effect of Cold Forging of Aluminum Alloy

ABSTRACT Aluminum and its alloys represent a common raw material for components released through a cold machining routine (i.e., forging, cold heading, and rolling processes). They offer easy manufacturing and high plastic strength, together with light weight, long life span, and easy recycling and are heavily used in the transport industry (P. M. G. P. Moreira, et al. (1), Theoretical and Applied Fracture Mechanics, 50, pp 81–91, 2008; H. Yoshimura and K. Tanaka (2), Journal of Materials Processing Technology, 98, pp 196–204, 2000). However, during processing, the sample–tool interfaces can generate sticking mechanisms that result in an increase in friction values and high wear rates, leading to irreversible damage to the workpiece surface. The surface morphology provides characteristics that allow detection of the damage amplitude. The hard contact between asperities causes nucleation and the formation of adhesive wear. The normal load and lubrication conditions may further affect the quantity of wear elements (A. Hase and H. Mishina (3), Tribology International, 42, pp 1684–1690, 2009). Optical nondestructive observations permit the detection of the quantity of wear elements as per material transfer from one side (specimen surface) to the other side (contactor surface). This article presents the mechanisms of the adhesive layer and material transfer that are directly proportional to the new roughness stature. A robust finite element method analysis was embedded to establish a relationship between time, plastic deformation, friction coefficients, and surface defects.

Silane-Based Coating on Hot-Dip Zn Steel Sheets for Hot Stamping

Advanced high strength steels have been widely used in the automobile structures to enhance passengers’ safety [1]. Hot stamping process is recently applied and the strength of press hardening steels is elevated via martensitic phase transformation [2; 3]. Nevertheless, the oxidation and decarburization generally occur during the heat treatment prior to stamping[4], which in turn deteriorate the properties of steels [5]. Hot-dip galvanizing has been applied in steel industries due to its effectiveness to produce a Zn coating with both barrier and cathodic protections again corrosion [6]. Recently, hot-dip galvanized coatings have been studied to evaluate the protection on steels during hot stamping and the corrosion resistance of the resultant coating after hot stamping. The critical issues of the galvanized steels for hot stamping are oxidation and liquid metal embrittlement [7; 8]. The former deteriorates the resistance spot weldability and paintability, whereas the later has a negative effect on formability [9]. Silane, a kind of Si-based coating on light metals, has been used in galvanized steels to offer barrier protection against corrosion [10]. In this study, silane coating was applied on galvanized (GI) and galvannealed (GA) steels to elevate the practicability for the hot stamping application. The GI and GA steel sheets were received from China Steel Co., Taiwan, with coating thickness of approximately 10µm. Silane coating film was formed by a laboratory rolling method. The treating solution was prepared by mixing tetraethyl orthosilicate (TEOS), acidified water (pH= 1.0, adjusted by HNO3), γ-glycidoxypropyltrimethoxysilane (GPTMS), followed by stirring for 2 h at room temperature. The GI and GA steel sheets with and without the silane coating were isothermally held at 900℃ under the atmosphere for 5 min to simulate austenitization prior to hot stamping. XRD, SEM, TEM, and XPS were employed to characterize the surface microstructure of the various steels. Corrosion behaviors were tested by electrochemical stripping and potentiodynamic polarization measurements. The GI steel displayed a gray color after austenitization. In contrast, the GI steel with the silane coating still exhibited a metallic color, suggesting the silane coating is effective in preventing the GI steel from oxidation at 900℃ (Fig(a)). This is consistent with the XRD pattern showing the absence of the peaks resulting from ZnO for the GI steel with the silane coating (Fig.(b)). However, the silane coating offered a less degree of protection on the GA steel. The cross section of the silane-coated GI and (b) GA steels was further characterized by the SEM. Zn oxides were readily observed on the GA steel; conversely, Zn oxide scale was hardly observed on the GI steel. After austenitization, the silane-coated GI coating transformed to a mixture of Γ phase and Zn saturated α-Fe, which retained the cathodic protection over the steel substrate. However, the alloy layer of the silane-coated GA steel was solely composed of Zn saturated α-Fe and the cathodic protection was largely reduced after austenitization. Reference [1] R. Kuziak, R. Kawalla, S. Waengler, Archives of civil and mechanical engineering 8 (2008) 103-117.[2] D.W. Fan, H.S. Kim, B.C. De Cooman, Steel Research International 80 (2009) 241-248.[3] H. Karbasian, A.E. Tekkaya, Journal of Materials Processing Technology 210 (2010) 2103-2118.[4] D.W. Fan, B.C. De Cooman, steel research international 83 (2012) 412-433.[5] L. Dosdat, J. Petitjean, T. Vietoris, O. Clauzeau, steel research international 82 (2011) 726-733.[6] A. Marder, Progress in materials science 45 (2000) 191-271.[7] C.W. Lee, D.W. Fan, I.R. Sohn, S.-J. Lee, B.C. De Cooman, Metallurgical and Materials Transactions A 43 (2012) 5122-5127.[8] R. Autengruber, G. Luckeneder, S. Kolnberger, J. Faderl, A.W. Hassel, steel research international 83 (2012) 1005-1011.[9] C.-W. Ji, I. Jo, H. Lee, I.-D. Choi, Y. Do Kim, Y.-D. Park, Journal of Mechanical Science and Technology 28 (2014) 4761-4769.[10] R. Figueira, C.J. Silva, E. Pereira, Journal of Coatings Technology and Research 12 (2015) 1-35. Figure 1

Finite Element and Experimental Investigation of the Multipoint Flexible Hydroforming

FINITE ELEMENT AND EXPERIMENTAL INVESTIGATIONS OF THE MULTI-POINT FLEXIBLE HYDOFORMING. N. Selmi*, H. BelHadjSalah* *Mechanical Engineering Laboratory (LGM), National Engineering School of Monastir (ENIM), University of Monastir, Avenue Ibn El Jazzar 5019, Monastir, Tunisia. naselmi2002@yahoo.fr, hedi.belhadjsalah@enim.rnu.tn. ABSTRACT Multi-point flexible forming (MPF) process is relatively recent flexible techniques [1], instead of the conventional fixed shape die sets, the basic idea in this process, consist to form the sheet metal between a pair of opposed matrices of punch elements, by adjusting the height of the punch elements [2]. Production of many parts with different geometry will be possible, just by using one same device and the need to design and manufacturing of various dies will be avoided that lead to great saving in time and manufacturing cost specially in the field of small batch or single production. The hydroforming process is attractive compared with conventional solid die forming processes, the basic idea consist to suppress one tool of two forming tools (punch or die), which is replaced by hydraulic pressure, only one tool is necessary to define the final shape of formed sheet. The multipoint flexible hydroforming, proposed in this paper, is an original process which combines the hydroforming and the multipoint flexible forming [3], to obtain a synergy of the advantages of both processes. The new process, subject of this work, is a combination of the last described processes that keep the whole flexibility of the basic multipoint flexible forming (with two dies), by using, only at one side, a single multipoint die to perform completely the final part shape, the fluid pressure is applied on the other side of the sheet metal part and substitutes advantageously the second die. Firstly, investigations were carried out by numerical simulation, to quantify, the effect of the most influent parameters on the process performances, and to highlight the ability of this new process, in the production of complex forms, as well as its contribution in quality, placed with regards existing flexible processes. Secondly, to prove the feasibility and to carry out a valuable experimental investigation of the multipoint flexible hydroforming, an experimental prototype was designed and realized, and successful doubly curved shell shape parts were obtained by the new process testing set up. The part profiles and the thickness distribution were in agreement with those obtained by numerical investigation furthermore, numerical investigation for efficient methods to suppress the dimpling phenomenon and edge buckling were confirmed by experimental investigation. From investigations it appears that the parameters attached to the discreet character of the multipoint tool, have an important effect on the quality of the final metal sheet product, such as, the punch elements density, the punch elements extremity curvature radius, the blank and the elastomeric interpolator thicknesses. From simulation results, it emerges essentially, that an adequate setting of parameters can upgrade the thickness distribution, reduce the residual stress and attenuate the dimples.

Inverse Identification of CDM Model Parameters for DP1000 Steel Sheets Using a Hybrid Experimental-Numerical Methodology Spanning Various Stress Triaxiality Ratios

A hybrid experimental-numerical methodology is presented for the identification of the model parameters regarding a mixed hardening anisotropic finite plasticity fully coupled with isotropic ductile damage in which the micro-crack closure effect is given account for, for steel sheets made of DP1000. The experimental tests involve tensile tests with smooth and pre-notched specimens and shear tests with specimen morphologies recently proposed by D.R. Shouler, J.M. Allwood (Design and use of a novel sample design for formability testing in pure shear, Journal of Materials Processing Technology, Volume 210, Issue 10, 1 July 2010, Pages 1304-1313). These tests cover stress triaxiality ratios lying between 0 (pure shear) and 1/√3 (plane strain). To neutralize machine stiffness effects displacements of the chosen material surface pixels are kept track of using the digital image correlation system ARAMIS, where recorded inputs are synchronized with force measurements. On the numerical part, developed constitutive model is implemented as user defined material subroutine, VUMAT, for ABAQUS/Explicit. FE models for the test cases are built using 3D brick elements (rather than thin shells) and devising developed VUMAT for the constitutive model, model parameters are identified using an inverse parameter identification procedure where the objective function relies on the difference of experimentally observed-numerically predicted forces for the selected pixel displacements. The validity of the material model and transferability of its parameters are tested using tests involving complex strain paths.

The authorship and internationality of Industrial Engineering journals

This paper surveys 32 renowned Industrial Engineering (IE) journals with regard to authorship for the period of 1996-2005. The findings show that the USA was the top contributing country, accounting for approximately one-third of the total number of articles. The 80/20 rule and the entropy measure consistently identify Issues in Science and Technology (IST), Industrial Engineer (IE), and R&D Magazine (RDM) as journals of high country concentration, or journals of low internationality. Conversely, Journal of Materials Processing Technology (JMPT), Production Planning & Control (PPC), and Technovation (TNV) have the highest degree of country diversity, or internationality. The quality of a journal, as expressed by impact factors, its internationality, and its number of articles published, are found to be independent of each other.

A genetic algorithm approach to determine the sample size for control charts with variables and attributes

Generally today’s production systems consist of multistage processes. Control of these processes is a very important to meet customer’s and engineering’s specifications. Generally control charts which are used to monitor the process and process capability analysis (PCA) which is a summary statistic to show the process performance are used to determine whether or not the process is in statistical control and meet specifications. Although control charts have been applied in very large area of process control, determining the sample size for control charts is generally a problem. In the literature many techniques to solve this problem have been executed. Kaya and Engin [Kaya, İ. & Engin, O. 2007. A new approach to define sample size at attributes control chart in multistage processes: An application in engine piston manufacturing process. Journal of Materials Processing Technology, 183, 38–48] also proposed a model based on minimum cost and maximum acceptance probability to determine the sample size in Attribute Control Charts (ACCs). In this paper, this model is solved by Genetic Algorithms (GAs) with linear real-valued representation and a new chromosome structure is suggested to increase the efficiency of GAs. The performance of GAs is affected by mutation and crossover operators and their ratios. To determine the most appropriate operators, five different mutation and crossover operators are used and they are compared with each other. For this purpose a computer program is coded by MS Visual Basic and it has been run to determine the suitable operators and ratios, respectively. One of the results of the model is sample size, n, and it is suggested to set up ACCs and Variable Control Charts (VCCs). Also the sample size, n, is used to PCA. To show the usage of the proposed model an application from a motor engine factory is illustrated. For quality characteristics cannot be easily represented in numerical form, “u-control charts” and for characteristics measurable on numerical scales, “ x ¯ - R control charts” are constructed for every stage by taking into account the sample size, n, determined by GAs from the proposed model. These control charts are used to determine whether or not the every stage is in statistical control. Then PCA has been executed for every stage and capability ratios are determined.

A genetic algorithm approach to determine the sample size for attribute control charts

Determining the sample size for control charts (CCs) is generally an important problem in the literature. In this paper, Kaya and Engin’s [İ. Kaya, O. Engin, A new approach to define sample size at attributes control chart in multistage processes: an application in engine piston manufacturing process, Journal of Materials Processing Technology 183 (2007) 38–48] model based on minimum cost and maximum acceptance probability to determine the sample size for attribute control charts (ACCs), and solved by genetic algorithms (GAs) with linear binary representation structure, is handled to solve it by a linear real-valued representation. A new chromosome structure is also suggested to increase the efficiency of GAs. The performance of GAs depends on mutation and crossover operators, and their ratios. To determine the most appropriate operators, five different mutation and crossover operators are used and they are compared with each other. An application in a motor engine factory is illustrated. u-Control charts are constructed with respect to the sample size determined by GA in the model. The piston production stages in this factory are monitorized using the obtained control charts.

Modélisation par éléments finis du chauffage infrarouge des membranes thermoplastiques semi-transparentes

This paper reports on a simplified approach for analysing the temperature evolution in a semi-transparent thin membrane of the amorphous polyethylene terephtalate type (PET) exposed to a radiative source. It is based on a 3D finite elements method. The thermophysical properties of the PET are assumed independent of temperature while the internal radiative intensity absorption is taken as one-dimensional and is governed by the Beer–Lambert law. To avoid the difficult problem of computing the shape factors, a semi-analytical approach is used. Finally, the numerical simulations have allowed to validate the analytical and experimental results. In the first place, we have written the energy conservation equation in absence of convection (based on the first law of thermodynamics) (1.a), the radiative source term (1.b) and the boundary conditions (2). As for the finite elements method, the Galerkin approach is used for the formulation of the 3D heat transfer equation (3) and the diagonalisation of the heat capacity matrix, “lumped matrix”, is adopted [M.A. Dokainish, K. Subbaraj, A survey of direct time-integration methods in computational structural dynamics, Comput. Struct. 32 (6) (1989) 1371–1386]. A single step implicit time integration scheme is used for the computation [M.A. Dokainish, K. Subbaraj, A survey of direct time-integration methods in computational structural dynamics, Comput. Struct. 32 (6) (1989) 1371–1386]. After recalling the classical expressions for the radiative flux divergence (5) and the flux itself (6), we have rewritten the radiative source term for an homogeneous medium as a function of spectral intensity (7) and given the integro-differential equation of radiative transfer [R. Siegel, J.R. Howel, Thermal Radiation Heat Transfer, Hemisphere Publishing Corporation, Washington, 1992], Eq. (8). The spectral relations linking coefficients of extinction, absorption, scattering and scattering albedo are given by Eqs. (9) and (10), while Eq. (11) expresses the boundary conditions. In the second place, on the basis of the non-scattering behaviour of amorphous PET [K. Esser, E. Haberstroh, U. Hüsgen, D. Weinand, Infrared radiation in the processing of plastics: Precise adjustment-the key to productivity, Adv. Polymer Technol. 7 (2) (1987) 89–128; M.D. Shelby, Effects of infrared lamp temperature and other variables on the reheat rate of PET, in: Proceedings of ANTEC'91 Conference, 1991, pp. 1420–1424; G. Venkateswaran, M.R. Cameron, S.A. Jabarin, Effect of temperature profiles trough preform thickness on the properties of reheat-blown PET containers, Adv. Polymer Technol. 17 (3) (1997) 237–249], we have assumed that extinction and absorption coefficients are equal, the corresponding albedo being zero. The radiative transfer equation can thus be rewritten in a reduced form (12). Moreover, for the temperature range prevailing in the processes of PET thermoforming and preforms blowing, temperatures of radiation sources are generally much higher than those used for the forming of these thermoplastic media. Under these conditions, the cold medium hypothesis is used [Y. Le Maoult, F.M. Schmidt, V. Laborde, M. El Hafi, P. Lebaudy, Measurement and calculation of perform infrared heating: a first approach, in: Proceeedings of the Fourth International Workshop on Advanced Infrared, 1997, pp. 321–331], which allows to express transmission of spectral intensity across the material as a function of position and direction (13), and to write the radiative flux divergence in a simplified form as well (14). For one-dimensional radiation, solution of the radiative transfer equation [R. Siegel, J.R. Howel, Thermal Radiation Heat Transfer, Hemisphere Publishing Corporation, Washington, 1992] is given by Eq. (15), which combines with Eq. (14) to yield the spectral flux generated inside the semi-transparent medium, Eq. (16). In case of radiation propagation in the same direction as the normal to the polymeric membrane surface, radiation intensity can then be expressed by the Beer–Lambert law (17). This permits to deduce the expression of spectral flux transmitted across the PET membrane thickness (18). Infrared radiation intercepted by the membrane For determining the infrared radiation intercepted by the membrane surface, the medium between the radiation source and the thermoplastic material is assumed to be completely transparent to radiation. It is also assumed that the surface of the source is diffuse. This allows to infer, from spectral expressions of the energy emitted by the source (Eqs. (19) and (20)) and of the energy received by the semi-transparent membrane (Eq. (21)), a relation for radiation intercepted by the surface at all wavelengths (Eqs. (22) and (23)). For an isotropically radiating source (Lambertian source) when considering an average emissivity of the heating source, Eq. (24), total radiation intercepted by the surface is given by Eq. (25). Infrared radiation absorbed by the membrane For the determination of infrared radiation absorbed by the polymeric membrane, first, based on the principle of energy conservation, spectral relation (27) which links reflectivity, absorptivity and transmissivity is recalled, as well as relation (28) associating spectral absorption and transmission coefficients following the Beer–Lambert law. Consequently, this allows to find the spectral energy absorbed by the semi-transparent medium (29) with the aid of Eq. (25). Concentrating on wavelength bands that constitute the transmission spectrum of the medium, Eq. (29) is then replaced by Eq. (30) where average values of reflectivity (31) and transmissivity (32) are considered. As a result, the volumetric total energy absorbed by the medium, the flux divergence, is then given by Eqs. (33) and (34). Furthermore, considering that reflectivity is low for polymeric materials (generally lower than 5%), the latter is neglected leading to Eq. (35) instead of Eq. (34). Fig. 1 illustrates a typical transmissivity curve for PET [G. Venkateswaran, M.R. Cameron, S.A. Jabarin, Effect of temperature profiles trough preform thickness on the properties of reheat-blown PET containers, Adv. Polymer Technol. 17 (3) (1997) 237–249]. Shape factor In order to take into account arbitrary shapes of sources and preforms, a semi-analytical approach is used for the computation of shape factors [G. Venkateswaran, M.R. Cameron, S.A. Jabarin, Effect of temperature profiles trough preform thickness on the properties of reheat-blown PET containers, Adv. Polymer Technol. 17 (3) (1997) 237–249]. The definition of shape factor is recalled in Eq. (36) and Fig. 2. An equivalent form based on the contour principle [R. Rammohan, Efficient evaluation of diffuse view factors for radiation, Int. J. Heat Mass Transfer. 39 (1996) 1281–1286] is given by Eq. (37), while the semi-analytical formula [F. Erchiqui, N.G. Dituba, Analyse comparative des méthodes de calcul des facteurs de formes pour des surfaces à contours rectilignes, Internat. J. Thermal Sci. 46 (2007) 284–293] is expressed by Eq. (39). Validation of this semi-analytical approach is obtained by comparison with the analytical solution [H.C. Hottel, Radiant heat transmission between surfaces separated by non-absorbing media, Trans. ASME 53 (1931) 265–273, FSP-53-196; A. Feingold, Radiant-interchange configuration factors between various selected plane surfaces, Proc. Roy. Soc. London Ser. A 292 (1996) 51–60; J.R. Ehlert, T.F. Smith, View factors for perpendicular and parallel rectangular plates, J. Thermophys. Heat Trans. 7 (1993) 173–174] as well as with results yielded by three different techniques, i.e. the area-integration method, the Gauss quadratic technique and the contour method. Table 1 summarizes the numerical results obtained in each case and gives the relative error. Analytical validation of the reheating Regarding the numerical validation, we have considered a PET semi infinite medium subjected to a uniform incident radiative flux density. The boundaries of the semi transparent medium are taken as adiabatic. Thermophysical properties and geometrics are given in Table 2. The one-dimensional Laplace equation which governs the radiation heat transfer is solved analytically with the aid of Laplace transforms. The temperature evolution within the depth of the semi transparent medium is obtained by analytical solution [A.B. De Vriendt, in: G. Morin, (Ed.), La transmission de la chaleur, vol. 1, Chicoutimi, Québec, 1984], Eq. (40). Fig. 3 shows a comparison between the numerical solution obtained by the 3D finite elements method and the analytical one. It is seen that, for the three cases, the relative error between numerical and analytical results stays lower than 0.1%. Numerical modeling of infrared heating An amorphous PET sheet is considered. The face of the membrane is a square of side 20 cm with a thickness of 1.5 mm. The lateral walls are assumed adiabatic. For modeling with the 3D finite elements method, the sheet is meshed with identical hexahedra comprising eight nodes. The thermophysical properties used for this study are given in [S. Monteix, F. Schmidt, Y. Le Maoult, R Ben Yedder, R.W. Diraddo, D. Laroche, Experimental study and numerical simulation of perform or sheet exposed to infrared radiative heating, Journal of Materials Processing Technology 119 (2001) 90–97] and the reheating time is 35 seconds. The heat transfer coefficient h on front and rear faces is 10 W m −2 K −1. Heat flux received by the polymer during heating To estimate the incident heat flux distribution on the surface of the polymer, we first calculate the shape factors between each pair of emitting/receiving surfaces. Then the flux distribution is obtained with Eq. (25). Fig. 4 illustrates this distribution. Validation against experimental results Figs. 5 and 6 compare the numerical results obtained by the simulation (via MEF 3D) with those obtained experimentally. Fig. 5 displays the temperature distribution on the front and rear surfaces. Results Figs. 7–10 illustrate the numerical results obtained for the temporal temperature evolution, during the first five seconds of heating, of the upper receiving face (surface directly exposed to the infrared source), the central plane and the lower face of the PET membrane, respectively. Figs. 11 and 12 give the temperature evolution at four positions on upper and lower faces of the membrane: 0 cm (edge), 2.5 cm, 5 cm and 10 cm (middle). It is observed that the trend is nearly linear during the period of infrared heating. On Figs. 13 and 14 is displayed the temperature evolution in the center of the membrane along its thickness during periods 0–4 and 5–35 seconds.

An analysis of localized necking in aluminium alloy tubes during hydroforming using a continuum damage model

In this work, localized necking in aluminium alloy tubes subjected to free hydroforming is analyzed. The main objective is to study the influence of loading conditions, such as prescribed fluid pressure or volume flow rate in conjunction with axial end feed, on the nature of the forming limit curve (FLC). To this end, the strain histories experienced at the tube mid-length, which were computed in an earlier investigation [14] [Varma NSP, Narasimhan R. A numerical study of the effect of loading conditions on tubular hydroforming, Journal of Materials Processing Technology 2005; [Submitted for publication]], are analyzed using the Marciniak–Kuczynski (M–K) method along with an anisotropic version of the Gurson model. The Gurson constitutive parameters are determined following an inverse approach using the sheet FLC for the chosen alloy. The predicted FLC for combined pressure and axial contraction corroborates well with the experimental data obtained in [12] [Kulkarni A, Biswas P, Narasimhan R, Luo A, Stoughton T, Mishra R, Sachdev AK. An experimental and numerical study of necking initiation in aluminium alloy tubes during hydroforming. International Journal of Mechanical Sciences 46:2004;1727–46] and is almost flat, whereas it is akin to the sheet FLC and increases with negative minor strain when fluid volume is specified. The forming limit strains for loading with specified fluid volume are in general higher when compared to those with prescribed fluid pressure. Finally, it is demonstrated that a transition from axial to circumferential necking occurs when high ratios of axial extension to volume flow rate are applied to the tube.

Wrinkling control in aluminum sheet hydroforming

In this paper, the wrinkling behavior of 6111-T4 aluminum alloys during sheet hydroforming process was numerically and experimentally investigated. In sheet hydroforming, one or both surfaces of the sheet metal are supported with a pressurized viscous fluid, while a punch forms the part. In sheet hydroforming the use of a matching female die is not needed. The use of the pressurized fluid delays the onset of material rupture (International Journal of Mechanical Science 2003;45:1815–48) and also acts as an active blank-holding force to control wrinkling in the flange area. To form a wrinkle-free deep-drawn hemispherical cup with sheet hydroforming, a theoretical analysis based on the work of Lo et al. (Journal of Materials Processing Technology 1993;37:225–39) was initially used to predict the optimum fluid pressure profile. Simplifying geometrical assumptions and Tresca material model used in the theoretical analysis provided a fluid pressure profile that resulted in premature rupture of the sheet metal. However, an optimum fluid pressure profile generated by the finite element method, using Barlat's anisotropic yield function (Journal of Mechanical Physics and Solids 1997;45(11/12):1727–63), was successfully applied in sheet hydroforming to make the deep-drawn hemispherical cup without tearing and with minimal wrinkling in the flange area. The finite element model was also capable of accurately predicting the location of the material rupture in pure stretch, and wrinkling characteristics of the aluminum alloy sheet in the draw-in process.

Review of Intelligent Grinding and Dressing Operations

With the increased use of advanced materials, grinding processes become a popular means in the processing of parts, particularly in fabricating products from brittle materials such as ceramics and composites. At present grinding appears to be the only practical and economical means of shaping the parts into the final products with fine surface finish, acceptable surface integrity, and high geometric accuracy (Kovach, J. (1987). Improved grinding of ceramic components. In: Proceedings of the Department of Defence, Machine Tool/Manufacturing Development Conference. AFWAL-TR-4137, Vol. 7, 72–100). In the machining of conventional materials, grinding is also usually used as a finishing operation when high accuracy and surface finish is required, and usually determines the major portion of the processing cost. Despite this importance and popularity, grinding still remains as one of the most difficult to control processes. Unlike machining processes where cutting is performed by a defined single/multiple cutting edge(s), grinding is performed by a number of abrasive grits, which are randomly oriented within a grinding wheel. Therefore, it is impossible to maintain or control the shape of these hard grits, which are active in the cutting process (Malkin, S. (1989). Grinding Technology, Theory and Applications of Machining with Abrasives, Chister, England: Ellis Horwood Limited; Okafor, A. C., Marcus, M., Tipirneni, R. (1990). Multiple sensor integration via neural networks for estimating surface roughness and bore tolerance in circular end milling. Transaction of NAMRI/SME 128–136). Grinding is a very complicated process, consisting of complex interactions between a large numbers of variables. These variables can be grouped into four major categories: (a) machine tool, (b) workpiece material, (c) grinding wheel, and (d) operating parameters (Allor, R. L. Whalen, T. J., Baer, J. R., Kumar, K. V. (1993). Machining of silicon nitride: experimental determination of process/property relationships. In: Proceedings of the International Conference on Machining of Advanced Materials. Washington, DC, 223–234; Lezanski, P., Rafalowicz, J., Jedrzejewski, J. (1993). An intelligent monitoring system for cylindrical grinding. Annals of the CIRP 42(1):393–396; Li, K., Liao, T. W. (1997). Modelling of ceramic grinding processes, number of cutting points and grinding forces per grit. Journal of Materials Processing Technology 65(1–3):1–10). The dressing and truing processes used to prepare the wheel have an important effect on the grinding wheel variables and consequently on the output of the grinding process. To achieve this understanding, many researchers focused on the modeling of grinding processes. Some of these models are completely theoretical, and others are practical with theoretical explanations and empirical equations. The aim of this research was to find the relationship between the process variables, the process parameters, and workpiece quality. This review presents the theoretical and experimental models used, process design algorithms, expert systems, artificial intelligent algorithms, fuzzy logic and neural network algorithms, process monitoring and control, and in particular artificial intelligence control systems.

COMPUTATIONAL MATERIAL TESTING OF PRE-DAMAGED METALS USING DAMAGE MECHANICS MODELS

International Journal of Computational Engineering ScienceVol. 05, No. 02, pp. 259-270 (2004) SPECIAL ISSUE ON RECENT ADVANCES IN COMPUTATIONAL SCIENCE AND ENGINEERING; EDITED BY H. P. LEE AND K. KUMARNo AccessCOMPUTATIONAL MATERIAL TESTING OF PRE-DAMAGED METALS USING DAMAGE MECHANICS MODELSYUTAKA TOI and SATOSHI HIROSEYUTAKA TOIInstitute of Industrial Science, University of Tokyo, 4-6-1 Komaba, Meguro-ku, Tokyo 153-8505, Japan Search for more papers by this author and SATOSHI HIROSEInstitute of Industrial Science, University of Tokyo, 4-6-1 Komaba, Meguro-ku, Tokyo 153-8505, Japan Search for more papers by this author https://doi.org/10.1142/S1465876304002356Cited by:0 Next AboutSectionsPDF/EPUB ToolsAdd to favoritesDownload CitationsTrack CitationsRecommend to Library ShareShare onFacebookTwitterLinked InRedditEmail AbstractThe elasto-viscoplastic constitutive equation considering damage is formulated, based on the concept of continuum damage mechanics. It employs the viscoplastic strain, which was originally given by Perzyna and extended by Murakami to consider the effect of damage. The unified form of damage evolution equation given by Lemaitre is extended to consider the effect of damage type and strain rate. The constitutive modeling is identified, based on static/dynamic tensile tests and fatigue tests for steel (SM490A) and aluminum (2219-T87). The identified models are used to predict the static/dynamic, tensile behaviors of pre-strained steel and pre-fatigued aluminum. The predicted results have agreed well with the corresponding experimental results. References J. Lemaitre , A Course on Damage Mechanics , 2nd edn. ( Springer , 1996 ) . Crossref, Google Scholar J. Skrzypek and A. Ganczarski , Modeling of Material Damage and Failure of Structures (Theory and Applications) ( Springer , 1999 ) . Crossref, Google ScholarD. Krajcinovic, Int. J. Solids Structures 37, 267 (2000). Crossref, Google ScholarM. Itabashi and H. Fukuda, Technology, Law and Insurance 4, 37 (1999). Crossref, Google ScholarM. Itabashiet al., Sino-Japanese Symp. Deformation/Fracture of Solids 41 (1997). Google ScholarM. Itabashi and H. Fukuda, Journal of Materials Processing Technology 117-3, (2001). Google ScholarP. Perzyna, Arch. Mech. 32-3, 403 (1986). Google ScholarS. Murakami, Transactions of the JSME 60-578, 230 (1994). Google ScholarJ. Lemaitre, Comput. Methods Appl. Mech. Engrg. 51, 31 (1985). Crossref, Google ScholarJ. Lemaitre and J. P. Sermage, Computational Mechanics 30, 84 (1997). Google ScholarY. Toi and S. Hirose, Transactions of the Japan Society of Mechanical Engineers, Series (A) 69-679, 530 (2003). Google Scholar FiguresReferencesRelatedDetails Recommended Vol. 05, No. 02 Metrics History PDF download

NUMERICAL INVESTIGATION OF MICRO-SCALE SHEET METAL BENDING USING LASER BEAM SCANNING

International Journal of Computational Engineering ScienceVol. 05, No. 02, pp. 345-355 (2004) No AccessNUMERICAL INVESTIGATION OF MICRO-SCALE SHEET METAL BENDING USING LASER BEAM SCANNINGX. M. TAN, Z. Q. ZHANG, and G. R. LIUX. M. TANInstitute of High Performance Computing, 1 Science Park Road, #01-01 The Capricorn, Singapore Science Park II, Singapore 117528, Singapore Search for more papers by this author , Z. Q. ZHANGDepartment of Mechanical Engineering, National University of Singapore, 10 Kent Ridge Crescent, Singapore 119260, Singapore Search for more papers by this author , and G. R. LIUDepartment of Mechanical Engineering, National University of Singapore, 10 Kent Ridge Crescent, Singapore 119260, Singapore Search for more papers by this author https://doi.org/10.1142/S1465876304002423Cited by:2 PreviousNext AboutSectionsPDF/EPUB ToolsAdd to favoritesDownload CitationsTrack CitationsRecommend to Library ShareShare onFacebookTwitterLinked InRedditEmail AbstractNumerical methods such as the finite element analysis (FEA) are revolutionizing the conventional trial-and error methods for laser beam scanning industry today. These methods have proven to be very useful in product development and process design. With simulation procedure being proposed, 3D numerical simulations on a micro-scale suspension flexure due to laser beam scanning have been carried out, which includes a non-linear transient indirect coupled thermal-mechanical analysis accounting for the temperature dependency of the thermal and mechanical properties of materials. From the simulation results, relationships between the permanent bending angle of the flexure and the scanning parameters are established and this will help to predict the bending angle of the micro-scale sheet metal under any other scanning condition. References F. Vollertsen, M. Geiger and W. M. Li, in Adv. Tech. of Plasticity III, Ed. Z. R. Wang et al., (1993), p. 1793 . Google Scholar T. B. Kermanidis, A. K. Kyrsanidi, and S. G. Pantelakis, in metallic plates, Proc. 3rd Int. Conf. on Surface Treatmen'97, (Oxford, UK, 1997), p. 307 . Google ScholarW. Li, M. Geiger and F. Vollertsen, J. Laser. 25, 859 (1998). Google ScholarZ. Huet al., Int. J Mach. Tool Manu. 41, 589 (2001). Crossref, Google ScholarG. Gutierrez and T. C. Jen, Int. J. Heat Mass Tran. 43, 2177 (2000). Crossref, Google ScholarZ. Ji and S. Wu, J. Mater. Process. Tech. 74, 89 (1998). Crossref, Google ScholarT. L. Chenet al., J. Mater. Process. Tech. 63, 546 (1997). Crossref, Google ScholarB. S. Yilbas, M. Sami and S. Z. Shuja, Opt. Laser. Eng. 30, 25 (1998). Crossref, Google ScholarA. K. Kyrsanidi, T. B. Kermanidis and S. G. Pantelakis, J. Mater. Process. Tech. 87, 281 (1999). Crossref, Google Scholar P. D. Harvey (Ed.), Engineering Properties of Steel American Society for Metals. (Metals Park, OHIO 44073, 1982) . Google Scholar E. A. Brandes and G. B. Brook (eds.) , Smithells Metals Reference Book seventh ed. ( Reed Educational and Professional Publishing Ltd , 1998 ) . Google Scholar J. R. Davis (ed.) , Stainless steels, ASM specialty handbook ( ASM International , Ohio , 1994 ) . Google Scholar FiguresReferencesRelatedDetailsCited By 2Laser Micro Bending Process of Ti6Al4V Square BarGang Chen and Peng Zhang11 June 2014 | Micromachines, Vol. 5, No. 2Laser micro-bending process based on the characteristic of the laser polarizationYanjin Guan, Hongmei Zhang, Jie Liu and Shen Sun1 Mar 2012 | Journal of Materials Processing Technology, Vol. 212, No. 3 Recommended Vol. 05, No. 02 Metrics History PDF download

Review of Intelligent Grinding and Dressing Operations

Abstract With the increased use of advanced materials, grinding processes become a popular means in the processing of parts, particularly in fabricating products from brittle materials such as ceramics and composites. At present grinding appears to be the only practical and economical means of shaping the parts into the final products with fine surface finish, acceptable surface integrity, and high geometric accuracy (Kovach, J. (1987 Kovach, J. 1987. Improved grinding of ceramic components. Proceedings of the Department of Defence, Machine Tool/Manufacturing Development Conference. 1987. Vol. 7, pp.72–100. AFWAL-TR-4137 [Google Scholar]). Improved grinding of ceramic components. In: Proceedings of the Department of Defence, Machine Tool/Manufacturing Development Conference. AFWAL-TR-4137, Vol. 7, 72–100). In the machining of conventional materials, grinding is also usually used as a finishing operation when high accuracy and surface finish is required, and usually determines the major portion of the processing cost. Despite this importance and popularity, grinding still remains as one of the most difficult to control processes. Unlike machining processes where cutting is performed by a defined single/multiple cutting edge(s), grinding is performed by a number of abrasive grits, which are randomly oriented within a grinding wheel. Therefore, it is impossible to maintain or control the shape of these hard grits, which are active in the cutting process (Malkin, S. (1989 Malkin, S. 1989. Grinding Technology, Theory and Applications of Machining with Abrasives Chister, , England: Ellis Horwood Limited. [Google Scholar]). Grinding Technology, Theory and Applications of Machining with Abrasives, Chister, England: Ellis Horwood Limited; Okafor, A. C., Marcus, M., Tipirneni, R. (1990 Okafor, A. C., Marcus, M. and Tipirneni, R. 1990. Multiple sensor integration via neural networks for estimating surface roughness and bore tolerance in circular end milling. Transaction of NAMRI/SME, : 128–136. [CSA] [Google Scholar]). Multiple sensor integration via neural networks for estimating surface roughness and bore tolerance in circular end milling. Transaction of NAMRI/SME 128–136). Grinding is a very complicated process, consisting of complex interactions between a large numbers of variables. These variables can be grouped into four major categories: (a) machine tool, (b) workpiece material, (c) grinding wheel, and (d) operating parameters (Allor, R. L. Whalen, T. J., Baer, J. R., Kumar, K. V. (1993 Allor, R. L., Whalen, T. J., Baer, J. R. and Kumar, K. V. Machining of silicon nitride: experimental determination of process/property relationships. Proceedings of the International Conference on Machining of Advanced Materials. Washington, DC. pp.223–234. [Google Scholar]). Machining of silicon nitride: experimental determination of process/property relationships. In: Proceedings of the International Conference on Machining of Advanced Materials. Washington, DC, 223–234; Lezanski, P., Rafalowicz, J., Jedrzejewski, J. (1993 Lezanski, P., Rafalowicz, J. and Jedrzejewski, J. 1993. An intelligent monitoring system for cylindrical grinding. Annals of the CIRP, 42(1): 393–396. [Google Scholar]). An intelligent monitoring system for cylindrical grinding. Annals of the CIRP 42(1):393–396; Li, K., Liao, T. W. (1997 Li, K. and Liao, T. W. 1997. Modelling of ceramic grinding processes, number of cutting points and grinding forces per grit. Journal of Materials Processing Technology, 65(1–3): 1–10. [CROSSREF][CSA] [Google Scholar]). Modelling of ceramic grinding processes, number of cutting points and grinding forces per grit. Journal of Materials Processing Technology 65(1–3):1–10). The dressing and truing processes used to prepare the wheel have an important effect on the grinding wheel variables and consequently on the output of the grinding process. To achieve this understanding, many researchers focused on the modeling of grinding processes. Some of these models are completely theoretical, and others are practical with theoretical explanations and empirical equations. The aim of this research was to find the relationship between the process variables, the process parameters, and workpiece quality. This review presents the theoretical and experimental models used, process design algorithms, expert systems, artificial intelligent algorithms, fuzzy logic and neural network algorithms, process monitoring and control, and in particular artificial intelligence control systems.

An energy approach for predicting springback of metal sheets after double-curvature forming, Part I: axisymmetric stamping

In our previous study (Xue P, Yu TX, Shu E. International Journal of Materials Processing Technology 1999; 89-90:65-71.), based on the membrane theory of shells of revolution and an energy method a mechanics model and corresponding analytical procedure have been proposed to predict springback of circular and square metal sheets after a double-curvature forming operation. The strain hardening of the material is incorporated into the mechanics model. In the present paper, the method is extended to the cases, in which bending effect, as well as bending-and-unbending effect are taken into account. It is shown that the procedure developed is capable of quantitatively predicting the strain distribution and springback of metal sheets after axisymmetric stamping with a relatively minor effort of calculation and a good accuracy. The effect of stretching force applied at the edge of the plate on springback is also considered. Excellent agreement is found between the theoretical prediction of springback and experiment results.