editorial board contents - cmti-india · 2017-08-18 · s usha n balashanmugam s arumugasamy b r...

Contents Vol. 16 No. 7 July 2017

Technical Papers

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Editorial Board

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Bank: State Bank of India, Yeshwanthpur Branch, APMC Yard, BengaluruIFSC Code: SBIN0003297Nature of Account: Current AccountAccount No: 10521862015

Disclaimer: Technical Data presented and views expressed by the authors are their own. CMTI does not assume any responsibility for the same.

ChairmanS Satish Kumar

Technical Paper Review PanelK K RajagopalM ChellamalaiV ShanmugarajV G Yoganath S K Verma

EditorMallikarjun G

Editorial AssistantsShashi Rekha NMala RC

Editorial Advisory Committee

S UshaN BalashanmugamS Arumugasamy B R MohanrajDr. C K Srinivasa, Honorary Member

• Effect of bonding temperature on microstructure and mechanical properties of AISI 304 to Ti–6Al–4V diffusion bonded joints

A Arun Negemiya, S Rajakumar and V Balasubramanian

3

• Experimental Investigation and Analysis of Effect of Process Parameters on Surface Roughness of AISI 4340 during MQL turning with nano fluid

Patole PB and Kulkarni VV

11

Technology Trends 21

Select Bibliography: Hard Turning 24

Calendar of Events 28

Photo Gallery: Vintage Machine: Plano Drilling Machine, Darling and Sellers, 1905

31

Manufacturing Technology Abstracts 32

Patent Abstracts: Turning of Alloy Material 52

IPR News: Filing of Design Application 58

Manufacturing Technology Today (MTT) Journal hosted Online @ "i-Scholar" digital library

URL: http://www.i-scholar.in/index.php/MTT/index

Events

Manufacturing Technology Today, Vol. 16, No. 7, July 201728

NATIONAL

10 - 13 Aug 2017Delhi Machine Tool Expo - 2017'Empower Manufacturing'Pragati Maidan, New DelhiContact: IMTMA, 10th Mile, Tumkur Road, BengaluruTel: +91 80-6624 6600 Fax: +91 80-66246661Email: [email protected] Web: www.mtx.co.in, www.biec.in

21 - 23 Aug 2017International Exhibition on Packaging Material and TechnologyPragati Maidan Exhibition Center,Mathura Road, New Delhi - 110002Contact: Koelnmesse YA Tradefair Pvt. Ltd.Office 1102, 11th Floor DLH Park, S. V. Road400067 MumbaiTel: +91 (0)22 28715200 Fax: +91 (0)22 28715222Email: [email protected] Web: www.koelnmesse-india.com

27 Aug 2017ASAR-International Conference on Civil, Mechanical and Industrial Engineering (ICCMIE)Hotel Trinity Isle, # 139, Subedar Chatram Road, Swastik Circle, Sheshadripuram, BengaluruContact: ASAR, Tel: +08280047516 Email: [email protected] Web: http://www.asar.org.in

08 - 10 Sep 2017CWE 2017: Cutting & Welding Equipment ExpoBombay Convention & Exhibition CentreNesco Compound, Off Western Express Highway, Goregaon East, Opp. Mahananda Dairy, MumbaiContact: International Trade and Exhibitions India Pvt Ltd (ITEI), B 309, 3rd Floor, 29, Statesman House, Minto Road Complex, Barakhamba, Delhi, 110001Tel: 011 4082 8282 Email: [email protected]: www.itei.in, www.ite-exhibitions.com

08 - 10 Sep 2017IMEX 2017 - International Machine Tools ExpoBombay Convention & Exhibition CentreNesco Compound, Off Western Express Highway, Goregaon East, Opp. Mahananda Dairy, Mumbai -400063, Maharashtra

Contact: ITEI International Trade and Exhibitions India Pvt. Ltd., E519 Floral Deck Plaza, Central MIDC Road, Opp SEEPZ, 400093 MumbaiTel: +91 (0)22 28398000 Fax: +91 (0)22 28390502Email: [email protected] Web: www.itei.in

08 - 10 Sep 2017Trade fair for used machineryBombay Convention & Exhibition Centre BCEC,Western Express Highway, Mumbai - 400063 MaharashtraContact: ITEI International Trade and Exhibitions India Pvt. Ltd., E519 Floral Deck Plaza, Central MIDC Road, Opp SEEPZ, Mumbai - 400093Tel: +91 (0)22 28398000 Fax: +91 (0)22 28390502Email: [email protected] Web: www.itei.in

08 - 10 Sep 2017CWE 2017: Cutting & Welding Equipment ExpoBombay Convention & Exhibition CentreNesco Compound, Off Western Express Highway, Goregaon East, Opp. Mahananda Dairy, MumbaiContact: International Trade and Exhibitions India Pvt Ltd (ITEI), B 309, 3rd Floor, 29, Statesman House, Minto Road Complex, Barakhamba, Delhi, 110001Tel: 011 4082 8282 Email: [email protected]: www.itei.in, www.ite-exhibitions.com

08 - 10 Sep 2017International Exhibition on Engineering and ManufacturingBombay Convention & Exhibition Centre BCEC,Western Express Highway, 400063 Mumbai, MaharashtraContact: International Trade and Exhibitions India Pvt. Ltd.11th Floor, Kailash Building Kasturba Gandhi Marg110001 New DelhiEmail: [email protected] Web: itei.in

14 - 16 Sep 2017IndiaCorr Expo Greater Noida: The corrugated manufacturing showIndia Exposition Center,Plot No. 25, 27, 28, 29, KnowledgePark, 201306 Greater Noida, Uttar PradeshContact: Reed Manch Exhibitions Ltd.1st Floor, A 78, Sector -4201301 NoidaTel: +91 (0)120 4273921 Fax: +91 (0)120 4273922Email: [email protected] Web: www.reedmanch.com

Events

Manufacturing Technology Today, Vol. 16, No. 7, July 2017 29

INTERNATIONAL

25 - 28 Aug 2017International fair of the manufacturing industryDiamond Island Convention and Exhibition Center,Diamond Island opposite the Hun Sen Park, Phnom Penh, Phnom Penh, CambodiaContact: Chan Chao International Co., Ltd., 3F, No.185, Kangchien Road, 10041 Taipei, TaiwanTel: +886 (2) 26596000 Fax: +886 (2) 26597000Email: [email protected] Web: www.chanchao.com.tw

03 - 06 Sep 2017International trade fair for machinery, machine parts and toolsErbil International Fair Ground,Sami Abdel Rahman Park, Erbil, Arbil, IraqContact: Pyramids Grup Fuarcilik A.S.Kucukbakkalkoy Mah. Kocasinan Cad.Gumrukcu Sok.No.8, 34750 Istanbul, TurkeyEmail: [email protected] Web: www.pyramidsfair.com

12 - 14 Sep 2017Metalworking and Manufacturing Exposition and ConferenceLos Angeles Convention Center, 1201 S Figueroa St, 90015 Los Angeles, California, USAContact: Society of Manufacturing Engineers SMEOne SME Drive, MI 48121 Dearborn, USATel: +1 (3)13 4253000 Fax: +1 (3)13 4253400Email: [email protected] Web: www.sme.org

12 - 15 Sep 2017Trade fair for metal-mechanical industriesMegacentro Expoville, Rua 15 de Novembro, 4.305, 89216-202 Joinville, Santa Catarina, BrazilContact: Messe Brasil, Rua Araranguá, 77 - Térreo89204-310 Joinville, BrazilTel: +55 (0)47 34513000 Fax: +55 (0)47 34513001Email: [email protected] Web: http://www.tradefairdates.com

18 - 20 Sep 2017Trade fair for heat treatmentExpocentre Fairgrounds,Krasnopresenskaya nab., 14, 123100 Moscow,

29 – Sep to 01 Oct 2017Globtech Engineering Expo 2017Auto Cluster Exhibition CentreH-Block, Plot No. C-181, Auto Cluster Exhibition Center, Pimpri-Chinchwad, PuneContact: GlobeTech Media Solutions, B 502, Sanskruti Darshan, Keshav Nagar, Kasarwadi, Pune, Maharashtra 411034Tel: 098230 12162 Email: [email protected] Web: http://www.enggexpo.in

29 Sep - 01 Oct 2017Engineering Expo Pune: International trade fair for mechanical engineeringAuto Cluster Exhibition Center,Pune, Maharashtra, IndiaContact: Network18 Media & Investments Ltd.15 Kasturba Gandhi Marg110001 New Delhi, IndiaTel: +91 (011) 41506112 Fax: +91 (011) 41506115Email: [email protected] Web: https://www.tradefairdates.com/Engineering-Expo-M13227/Pune.html

06 - 10 Dec 2017International trade fair for machine tools and engineeringThe Exhibition Centre, Vibran Gujarat Exhibition Ground, 3382107 Gandhinagar, GujaratContact: K & D Communication Ltd.4th Floor, Chinubhai House, 7-B Amrutbaug Society380014 AhmedabadTel: +91 (0)79 26469725 Fax: +91 (0)79 26403087Email: [email protected] Web: kdclglobal.com

07 - 09 Dec 201710th International Conference on Precision, Micro, Miso and Nano Engineering COPEN 10, 2017Chennai, Tamil NaduContact: Manufacturing Engineering SectionDepartment of Mechanical EngineeringIndian Institute of Technology MadrasChennai – 600 036, INDIATel: +91-44-2257 5705 Email: [email protected] Web: www.iitm.ac.in

Events


1-5-102, Nanko-kita, Suminoe-ku, Osaka, JapanContact: Reed Exhibitions Japan Ltd., 1-26-2 Nishishinjuku163-0570 Tokyo, JapanTel: + 81 (3) 33498501 Fax: + 81 (3) 33498599Email: [email protected] Web: www.reedexpo.co.jp

10 - 13 Oct 2017International specialized exhibition for materials, equipment and technologies for weldingSokolniki Exhibition and Convention Centre,7/1 5-iy Luchevoy prosek, 107014 Moscow, Moscow, Russian FederationContact: ITE Moscow, 15, Building 1, Zubarev Per129164 Moscow, Russian FederationTel: +7 (4)95 9357350 Fax: +7 (4)95 9357351Email: [email protected] Web: www.ite-expo.ru

11 - 13 Oct 2017Metal and hardware fairGTIEC - Greater Taichung International Expo Center,No 161, Gaotie 5th Rd., Wuri District, Taichung, Taichung, TaiwanContact: Kaigo Co., Ltd., 8F -3, No. 9, Dehuei Street10461 Taipei, TaiwanEmail: [email protected] Web: www.kaigo.com.tw

12 - 14 Oct 2017International Exhibition for Machine Tools and Metalworking TechnologySECC Saigon Exhibition & Convention Center,Nguyen Van Linh Parkway, Ho Chi Minh City, Ho Chi Minh, VietnamContact: Reed Tradex, 32nd fl., Sathorn Nakorn Tower, 100/68-69 North Sathon Road Silom10500 Bangkok, ThailandTel: +66 (0)2 6867299 Fax: +66 (0)2 6867288Email: [email protected] Web: www.reedtradex.com

17 - 21 Oct 2017Intl Trade Fair of Metallurgy, Electronics, Non-Metals and Build & Construction, Security & ProtectionSkopje Fair, Belasica, 2, Skopje, Centar, MacedoniaContact: Skopje Fair, 1130 Skopje, MacedoniaTel: +389 (0)2 3218388 Fax: +389 (0)2 3218375Email: [email protected] Web: www.skopjefair.com.mk ◘

Moscow, Russian FederationContact: Mir-Expo, Yury Andropov`s avenue, 22115533 Moscow, Russian FederationTel: +7 (4)99 6180565 Fax: +7 (4)99 6183688Email: [email protected] Web: www.mirexpo.ru

18 - 23 Sep 2017World trade fair for machine tools and metalworkingMesse Hannover, Messegelände, 30521 Hanover, Lower Saxony, GermanyContact: VDW e.V., Corneliusstr. 4, Frankfurt, GermanyTel: +49 (0)69 7560810 Fax: +49 (0)69 75608111Email: [email protected] Web: www.vdw.de

19 - 21 Sep 2017Trade fair for automotive test, evaluation and quality engineeringShanghai Everbright Convention & Exhibition Center, 5F, B Block, 66 Caobao Road, Xuhui district, 200235 Shanghai, Shanghai, ChinaContact: UKIP Media & Events Ltd., Abinger House Church Street, RH41DF Dorking, United Kingdom of Great Britain and Northern IrelandTel: +44 (0)1306 743744 Fax: +44 (0)1306 742525Email: [email protected] Web: www.ukipme.com

25 - 30 Sep 2017International Exhibition of Machine BuildingInternational Fair, 37, Tzar Boris III Obedinitel Blvd., 4003 Plovdiv, Plovdiv, BulgariaContact: International Fair Plovdiv, 37, Tzar Boris III - Obedinitel Blvd., 4003 Plovdiv, BulgariaTel: +359 (0)32 903600 Fax: +359 (0)32 902432Email: [email protected] Web: www.fair.bg

26 - 29 Sep 2017Nano Innovation Rome: Exhibition of micro and nanotechnologyFiera Roma, Via Portuense 1645/1647, I-00148 Rome, Rome, Lazio, ItalyContact: ITER S.r.l., Via dei Valtorta 620127 Milan, ItalyEmail: [email protected] Web: www.iter.it

04 - 06 Oct 2017Trade fair for mechanical components and materials technologyIntex Osaka International Exhibition Center,

Abstracts


MANUFACTURING TECHNOLOGY ABSTRACTS

CASTING & FOUNDRY PRACTICE 33

COATING & FINISHING 34

FORMING 35

COLD FORMING 43

ELECTROMAGNETIC FORMING 44

INDUSTRIAL ENGINEERING 44

JOINING & ASSEMBLY 45

LASERS 51

Abstracts


MANUFACTURING TECHNOLOGY ABSTRACTS

CASTING & FOUNDRY PRACTICE

111241 Effect of hot rolling on the microstructure, texture and mechanical properties of twin roll cast AZ31Mg

Young, JP; Ayoub, G; Mansoor, B; Field, DP [J of Materials Processing Technology, v 216, Feb 2 0 1 5 , S t a r t i n g Page 315,

Pages 13] In this study, a commercially available twin roll cast AZ31 Mg sheet was hot rolled at 400 °C to investigate the influence of rolling parameters (speed and percent thickness reduction) on microstructure, texture and mechanical properties. As compared to the twin roll cast condition, the microstructure of the successfully rolled materials was much finer and relatively less bimodal but contained profuse twinning and varying fractions of dynamically recrystallized grains. The extent of dynamic recrystallization (DRX) during rolling was found to be significantly influenced by percent thickness reduction. In the parameters investigated here, the rolling speed had a weak effect on DRX. The results showed that hot rolling strengthened the weak basal texture of the twin roll cast material and in addition to necklace grain formations at grain boundaries, DRX inside the twins was also identified as a key recrystallization mechanism. Mechanical testing revealed that at room temperature hot rolling improved the yield strength with retention of limited tensile ductility (<15%). However at 200 °C, the rolled material exhibited more a balanced mechanical properties with large tensile elongations. Microstructural analysis of the failed tensile tested specimens showed that the deformation behavior was dependent on grain size and crystallographic texture.

111242 Investigations of Al–SiC AMC prepared by vacuum moulding assisted stir castingRupinder Singh; Gagandeep Singh [J of Manufacturing Processes, v 19, Aug 2015,

Starting Page 142, Pages 6] The dry sliding wear is one of the m o s t i m p o r t a n t properties of metal matrix composite to

highlight the performance of the material. In this research work an attempt has been made for improving dry sliding wear properties of aluminium matrix composite (AMC) consisting of Al-6063 matrix and SiC reinforcement prepared through vacuum moulding assisted stir casting (VMASC) as process development for various industrial applications. The study of VMASC for preparing AMC highlights the novel method (being a green process) for improving the material performance. The controllable process parameters of stir casting (namely: particle size of solute (SiC), proportion of SiC) and vacuum moulding process (namely: vacuum pressure and sand grain size) were studied to find out their affect on wear properties of AMC. Wear was examined on ‘pin-on-disc type tribological tester’. The results of the study highlights that as regards to dry sliding wear; sand grain size, vacuum pressure, particle size, and proportion of SiC; have contributed 5.95%, 10.14%, 10.71% and 73.2%, respectively. The improvement in material performance of the AMC prepared by using VMASC was counter verified with microstructure analysis.

111243 Compaction behavior of Al6061 and SiC binary powder mixture in the mushy state

Wu, Yufeng; Gap-YongKim [J of Materials P r o c e s s i n g Te c h n o l o g y , v 216, Feb 2015, Starting Page 484, Pages 8] Synthesis of ceramic particle reinforced metal composites in

the semi-solid state enables fabrication of fully dense composites at relatively low pressures. Only

Abstracts


limited study, however, has been found on the compaction behavior and mechanism of the ceramic-metal, binary powder system in the semi-solid state. In this study, the effects of silicon carbide (SiC) volume fraction (0–60%) and aluminum alloy 6061 (Al6061) liquid fraction (0–100%) on the compaction behavior of Al6061–SiC binary powder mixture were investigated. The results showed that the Al6061 liquid fraction significantly influenced the liquid factor (KL), reinforcement factor (KH), and final density of the powder compact. The liquid factor decreased exponentially as the liquid fraction of Al6061 increased. Higher liquid content can weaken the powder structure and lower the reinforcement factor. On the other hand, excessive amount of liquid will lower the final density because of the squeeze out of the liquid from the die. A full density, Al6061–50 vol.% SiC composite can be obtained with 150 MPa compaction pressure when the liquid fraction is between 25% and 40%.

COATING & FINISHING

111244 Investigations on metallization in FDM build ABS part using electroless deposition method

Equbal, Azhar; Sood, Anoop Kumar [J of Manufacturing Processes, v 19, Aug 2015, Starting Page 22, Pages 10] E l e c t r o l e s s metallization of ABS parts has

been studied on flat part surface. These parts are fabricated on fused deposition modelling machine using ABS (acrylonitrile–butadiene–styrene) as part material. Copper deposition on ABS parts using two different surface conditioning processes namely ABS parts prepared using chromic acid for etching and ABS parts prepared using solution mixture of sulphuric acid and hydrogen peroxide (H2SO4/H2O2) for etching has been performed. After surface preparation using these routes, Cu (copper) is deposited by electroless method using four different acidic baths. The acidic baths used are 5 wt% CuSO4 (copper sulphate) with 15 wt% of individual HF (hydrofluoric acid), H2SO4 (sulphuric acid), H3PO4 (phosphoric acid) and CH3COOH (acetic acid) acids. Cu deposition under different

acidic baths for different routes is presented and compared based on their electrical performance, scanning electron microscopy (SEM) and energy dispersive X-ray spectrometry (EDS). The result shows that chromic acid etched samples shows better electrical performance and Cu deposition in all acidic baths in comparison to sample etched via H2SO4/H2O2.

111245 Investigation of melting in the Al–Si coating of a boron steel sheet by differential scanning calorimetry

Grauer, SJ; Caron, EJFR; Chester, NL; Wells, MA; Daun, KJ [J of Materials Processing Technology, v 216, Feb 2015, Starting Page 89, Pages 6] This paper investigates the veracity of claims, reported in the literature, that slow heating of Al–Si coated boron steel blanks in a roller hearth furnace can allow sufficient diffusion of iron from the steel substrate to the coating and prevent liquefaction of the Al–Si layer. The results of differential scanning calorimetry experiments conducted at various heating rates indicate that melting cannot be avoided under realistic industrial heating conditions. Heating rates as low as 0.08 K/s as well as isothermal heat treatments at 550 °C for 60 min are insufficient to prevent melting of the binary Al–Si layer at the eutectic temperature. A two-stage treatment in which the coating was pre-treated up to 650 °C to form solid Al–Si–Fe intermetallics is investigated. Intermetallic formation at 650 °C is shown to occur very quickly due to the enhanced iron diffusion in the liquid Al–Si phase. The coating of pre-treated blanks does not melt during the second stage of the heat treatment; however the properties of the final component obtained via this two-stage heat treatment remain to be assessed.

111246 Empirical modeling for processing parameters’ effects on coating properties in plasma spraying processWu, Zhenhua [J of Manufacturing Processes, v 19, Aug 2015, Starting Page 1, Pages 13] In order to model the effects of processing parameters (primary gas flow rate, stand-off distance, powder flow rate, and arc current) on

Abstracts


the plasma spraying coating properties (thickness, porosity and micro-hardness), adaptive neural fuzzy inference system (ANFIS) and neural

network (NN) based empirical models were proposed to estimate process parameters and understand the spraying process. To overcome the difficulty of the small size of sample data, and to balance the trade-off between model complexity and prediction accuracy, the bootstrap method was applied for the resampling technique, and cross validation was applied for the performance evaluation. The ANFIS and NN models were compared on the performance metrics of (1) mean square error (MSE), and (2) determination coefficient (R2). With the limited size of experiment data, both models illustrated high accuracy. In the training stage: on the R2, ANFIS has the value of 1, and NN has the minimum value of 0.84; on the MSE, ANFIS has the minimum value of 1.3e-5, and NN has the minimum value of 0.32. In the validation stage: on the R2, ANFIS has the minimum mean value of 0.42, and NN has the minimum mean value of 0.512; on the MSE, ANFIS has the minimum mean value of 23.67, and NN has the minimum mean value of 89.50. The comparisons illustrated that ANFIS model showed significant superiority over the NN model. This may be due to the fact that ANFIS combines the strength of NN’s learning capability and fuzzy logic’s knowledge interpretation ability. With the obtained ANFIS model, the physical mechanisms – including (1) melting states of particles, (2) loading effect, and (3) oxidation – were interpreted as processing parameters’ effects on the coating properties. The empirical models and that physical mechanism are viable to be effectively integrated with feedback control strategy to regulate the coating quality in plasma spraying process.

111247 Size-dependent distributions of particle velocity and temperature at impact in the cold-gas dynamic-spray processPrisco, Umberto [J of Materials Processing Technology, v 216, Feb 2015, Starting Page 302, Pages 13] A mathematical model, which describes the particle velocity and temperature of impact in the cold-gas dynamic-spray process and accounts for varying drag and heat transfer coefficients, is developed and validated. Using the proposed model, the distributions of impact velocity and

temperature as function of particle diameter are predicted and their dependence on process parameters, standoff distance and the particular trajectory of the particle in the jet is analyzed. These distributions must be taken into account if a correct description of the required impact conditions for successful deposition in cold-gas spraying is to be understood and modelled.

111248 Inductive heating effects on friction surfacing of stainless steel onto an aluminium substrate

Stegmueller, MJR; Schindele, P; Grant, RJ [J of Materials Processing Technology, v 216, Feb 2015, Starting Page 430, Pages 10] An experimental setup was designed to compare the principal process parametric relationships with the classical approach to friction surfacing with the addition of inductive heating. The production of the flash is described quantitatively and its influence on coating geometry and mass is presented. It was found that the coating mass and thickness decreased for an increase in the rotational speed of the consumable rod; the amount of flash produced by the consumable rod also increased. However, the effect of an increase in this rod contact pressure on the coating thickness is insignificant, whilst the coating mass decreases with rising pressure and the coating width increases coupled with an increase in flash production. Cross sections showed good bonding quality and mechanical interlocking at the bond interface. The substrate-coating interface showed a varying degree of mechanical interlocking and the presence of cavitations. Bond strength values applying shear and push-off testing of up to 106 MPa and 96 MPa, respectively, could be identified.

FORMING

111249 Modelling of mandrel rotary draw bending for accurate twist springback prediction of an asymmetric thin-walled tubeXue, X; Liao, J; Vincze, G; Gracio, JJ [J of Materials Processing Technology, v 216, Feb 2015, Starting Page 405, Pages 13] Of particular interest and complexity are twist springback of an asymmetric thin-walled tube in mandrel rotary

Abstracts


draw bending (MRDB), which is a complex non-linear physical process with coupling multi-factor interactive

effects. The aim of this paper is to explore the source of twist springback and develop a more effective numerical model. First, this paper analyses the torsion moment and twist angle relationship subjected to non-homogeneous loading. Second, non-quadratic anisotropic yield criterion (Yld2000-2d) integrated with mixed isotropic and kinematic hardening can be used to describe the material properties including anisotropy and Bauschinger effect. The corresponding mechanical tests are performed through uniaxial tension tests and monotonic and forward–reverse shear tests. Third, to improve the accuracy of the finite element model, the surface-based coupling HINGE constraint for flexible mandrel is developed and compared with the previous models. The frictions on various die–tube interfaces are identified by means of numerical inverse model. The validity of the FE model is assessed by comparing the predicted twist springback with the experimental one. The results show that the developed FE model with surface-based HINGE constraint has higher precision of twist springback prediction. The interfacial frictions have significant effects on twist springback of asymmetric thin-walled tube.

111250 Probabilistic Force Prediction in Cold Sheet Rolling by Bayesian InferenceNelson, Andrew W; Malik, Arif S; Wendel, John C; Zipf, Mark E [J of Manufacturing Sci & Engg:ASME Trans, v 136, n 4, Aug 2014, Starting Page 041006, Pages 11] A primary factor in manufacturing high-quality cold-rolled sheet is the ability to accurately predict the required rolling force. Rolling force directly influences roll-stack deflections, which correlate to strip thickness profile and flatness. Accurate rolling force predictions enable assignment of efficient pass schedules and appropriate flatness actuator set-points, thereby reducing rolling time, improving quality, and reducing scrap. Traditionally, force predictions in cold rolling have employed deterministic, two-dimensional analytical models such as those proposed by Roberts and Bland and Ford. These simplified methods are prone to inaccuracy, however, because of several uncertain, yet influential, model parameters that cannot be established deterministically

under diverse cold rolling conditions. Typical uncertain model parameters include the material’s strength coefficient, strain-hardening exponent, strain-rate dependency, and the roll-bite friction characteristics at low and high mill speeds. Conventionally, such parameters are evaluated deterministically by comparing force predictions to force measurements and employing a best-fit regression approach. In this work, Bayesian inference is applied to identify posterior probability distributions of the uncertain parameters in rolling force models. The aim is to incorporate Bayesian inference into rolling force prediction for cold rolling mills to create a probabilistic modeling approach that learns as new data are added. The rolling data are based on stainless steel types 301 and 304, rolled on a 10-in. wide, 4-high production cold mill. Force data were collected by observing load-cell measurements at steady rolling speeds for four coils. Several studies are performed in this work to investigate the probabilistic learning capability of the Bayesian inference approach. These include studies to examine learning from repeated rolling passes, from passes of diverse coils, and by assuming uniform prior probabilities when changing materials. It is concluded that the Bayesian updating approach is useful for improving rolling force probability estimates as evidence is introduced in the form of additional rolling data. Evaluation of learning behavior implies that data from sequential groups of coils having similar gauge and material is important for practical implementation of Bayesian updating in cold rolling.

111251 Numerical determination of the forming limit curves of anisotropic sheet metals using GTN damage model

Kami, Abdolvahed; Dariani, Bijan Mollaei; Vanini, Ali Sadough; Comsa, Dan Sorin; Banabic, Dorel [J of Materials P r o c e s s i n g Technology, v 216,

Feb 2015, Starting Page 472, Pages 12] In this paper, the Gurson–Tvergaard–Needleman (GTN) damage model is used to determine the forming limit curve of anisotropic sheet metals. The mechanical behavior of the matrix material is described using Hill’48 quadratic yield criterion and an isotropic hardening rule. For this purpose, a VUMAT subroutine has been developed and

Abstracts


used inside the ABAQUS/Explicit finite element code. The implementation of the constitutive model in the finite element code is presented in detail. Finally, the forming limit curve of an AA6016-T4 sheet metal is constructed using the developed VUMAT subroutine and running numerical simulation of Nakjima tests. The quality of the numerical results is evaluated by comparison with an experimental forming limit curve. Furthermore, theoretical forming limit curves of the AA6016-T4 sheet are obtained using Marciniak–Kuczynski (M–K) and modified maximum force criterion (MMFC) models. The results show that the forming limit curve predicted by the anisotropic GTN model is in better agreement with the experimental results especially in the biaxial tension region. This fact indicates that the GTN model is a useful tool in analyzing the formability of anisotropic sheet metals.

111252 Forming micro channels on aluminum foils by using flexible die forming process

Gau, Jenn-Terng; Gu, Hao; Liu, Xinhui; H u a n g , Kun-Min; Lin, Bor-Tsuen [J of Manufacturing P r o c e s s e s , v 19, Aug 2015, Starting Page

102, Pages 10] A flexible die forming process is proposed to form aluminum micro channels with channel widths not larger than 1 mm. Three micro channel dies and two different polyurethanes (40A and 90A) were used to form micro channels on the annealed and as-received aluminum foils (50 and 75 µm). For understanding the influences of size effects, polyurethane hardness and channel width on forming micro channels, a series of experiments were conducted. Through using different annealing conditions, different grain sizes were obtained such that different T/D, the ratio of thickness and average grain size, could be obtained. T/D ratio is used as a parameter to model the size effects in the two models proposed in this paper. These two models can predict the depths of the micro channels formed by the proposed process, so they can be used by industry as a design tool for product design, process design and development, annealing process, etc.

111253 Void closure criteria for hot metal forming: A reviewSaby, M; Bouchard, PO; Bernacki, M [J of Manufacturing Processes, v 19, Aug 2015, Starting Page 239, Pages 12] Void elimination through mechanical closure remains of prime importance for industrial applications. This paper presents a critical review on a large number of studies dealing with void closure in hot metal forming processes. In the literature, two main approaches were identified at two different scales: a macroscopic approach at the process scale and a micro-analytical approach at the void scale. Using the macroscopic approach, entire processes are generally considered with workpieces containing one or several voids, dealing with hot forging, hot rolling and related processes. Qualitative results, as well as empirical criteria and empirical prediction models are presented and discussed in this paper. Using the micro-analytical approach, an isolated void in an infinite matrix is considered and its evolution is analytically predicted. Analytical and semi-analytical prediction models involve a certain number of assumptions that are discussed in an industrial context. This paper presents a comparison between seven prediction models, in terms of void volume evolution under conditions that are typical for industrial applications. Stress triaxiality ratios are over the range [-1.2, 0] and several material behaviours are considered. It is shown that empirical models. Empirical models are hardly generalizable, as they are based on particular case studies involving one given void state or one given process. On the other hand, analytical and semi-analytical models suffer from strong assumptions. Consequently, their use in an industrial context remains limited. The use of a meso-scale approach is shown as a potentially powerful approach, as it may take advantage of both existing approaches from literature.

111254 Characteristic and formation mechanism of matt surface of double-rolled copper foil

Wang, Xiyong; Liu, Xuefeng; Shi, Laixin; Li, Jingkun; Xie, Jianxin [J of M a t e r i a l s P r o c e s s i n g Te c h n o l o g y ,

v 216, Feb 2015, Starting Page 463, Pages 9] Copper foils for flexible printed circuit boards were prepared by double rolling, and the matt surface of double-rolled copper foil was

Abstracts


characterized by atomic force microscope, scanning electron microscope, 3D optical interferometer, optical microscope and surface profiler. The morphology characteristics of matt surface were studied, and the formation mechanism of matt surface was discussed. The results showed that the matt surface of the double-rolled copper foil presented rough and relatively homogeneous morphology, and the morphologies of upper and lower matt surfaces were practically coincident. As the copper strips just entered into the deforming zone, the roughening of laminated surface occurred, but the roughness was relatively small. When the copper strips passed through the neutral plane, the roughness of the laminated surface increased significantly. In the backward slip zone, the initial micro-dimples between the two laminated surfaces were connected in the rolling direction, which led to the formation of larger and airtight dimples; when the copper strips moved toward the neutral plane and entered into the forward slip zone, the pressure of fluid in the airtight dimples increased rapidly, which enhanced the depths of the dimples; meanwhile, the depression corrugations with certain depth and larger width were formed on the laminated surface because of the dimple connection in the width direction. The copper foils with thickness of 36–54 µm were fabricated by double rolling, and the Rz value of their matt surfaces was 1.0–1.3 µm, which meet the requirements for directly using as adhesive surface of resin substrate, and therefore multiple roughening treatments during the traditional production process of flexible printed circuit board might be omitted. The formation mechanism of the matt surface of double-rolled copper foil proposed on the basis of the metal flow and deformation mechanics theory could explain the representative characteristics of the length direction of corrugations on matt surface being perpendicular to the rolling direction, several corrugations within a grain on the matt surface and the coincident morphologies of the upper and lower matt surfaces.

111255 Investigation of the effect of roller inclination angle on the forming forces during a splined mandrel flow forming operationVriens, BC; Haghshenas, M; Klassen, RJ [J of Manufacturing Processes, v 19, Aug 2015, Starting Page 183, Pages 4] Splined mandrel flow forming (SMFF) process is prone to premature failure of the splined mandrels. Such a failure is thought to be related to the magnitude of the forming forces exerted on the mandrel by the forming rollers. The multi-parametric nature of SMFF processes requires the use of a multi-variable

analysis technique (i.e. Taguchi method) in order to assess different process parameters. In the present study, we demonstrated that there is an optimal inclination angle for the rollers that minimizes the forming forces and, therefore, optimizes the service life of the splined mandrel.

111256 Experimental and numerical investigation on 6082 0 temper aluminium alloy cartridge tubes drawing

Trana, Eugen; Rotariu, Adrian-N i c o l a e ; Lixandru, Paul; Matache, Liviu-Cristian; Enache, C o n s t a n t i n ; Zecheru, Teodora [J of Materials

Processing Technology, v 216, Feb 2015, Starting Page 59, Pages 12] In order to test and evaluate the drawing efficiency of 6082 0 temper aluminium alloy for cartridge tubes, both experimental and numerical analyses were conducted. The theoretical assessment validation was performed by overlapping the graph of stress triaxiality ratio vs. plastic strain and the graph of 6082 0 temper aluminium alloy fracture envelope for a zero Lode parameter. The numerical simulation in Ls-Dyna® gave the stress triaxiality ratio vs. plastic strain correlation. With the view to defining the constitutive material model and fracture envelope, both experimental determinations and numerical simulations for plane stress and plane strain specimens were performed (tensile, shear and compression tests for various samples). The simulation results were compared with the experimental observations. The possibility of using the concept of triaxiality for a constant Lode parameter and an isotropic elastic/plastic material model in the field of drawing was also considered.

111257 Effect of flow forming on mechanical properties of high density polyethylene pipes

Abedini, Amin; R a h i m l o u , Payam; Asiabi, Taghi; Ahmadi, Samrand Rash; Azdast, Taher [J of Manufacturing Processes, v 19,

Aug 2015, Starting Page 155, Pages 8] Flow forming is a single rotary-contact-point cold-forming process, in which the thickness of a tubular pre-form is reduced while its length

Abstracts


increases without any change in internal diameter. Although metal flow forming has been studied by many researchers and industries, there does not appear to be any published study on the flow forming of polyethylene pipes. The main purpose of this study was to find out the applicability of flow forming on polyethylene pipes and the effects of process parameters on mechanical properties of polyethylene flow formed parts. The experiments were carried out using HDPE80 tubular pre-forms. Thickness reduction ratio, feed rate and rotation speed of mandrel were considered as variables. An L9 orthogonal array of Taguchi method was applied to carry out the experiments. Tensile and impact tests were performed to examine the failure behavior of specimens. Scanning electron microscopy (SEM) was implemented to find out the relation between mechanical properties and microstructure of the material. Stress at break, yield Stress, percentage of elongation at break and impact endurance were measured as indicators of mechanical properties. It was found that mechanical properties of HDPE increase significantly during flow forming. The solid state deformation makes material more oriented and anisotropic that leads to an enhancement in mechanical properties of HDPE. Through SEM it was found that the material experiences a transformation from an isotropic spherulite structure into an anisotropic lamellar-fibrous structure at large deformation.

111258 On instabilities of force and grain size predictions in the simulation of multi-pass hot rolling processesBambach, M; Seuren, S [J of Materials Processing Technology, v 216, Feb 2015, Starting Page 95, Pages 19] In multi-pass rolling processes such as plate rolling, accurate predictions of roll force and torque over all roll passes are desired, so that the pre-calculated roll pass schedule can be put into practice without exceeding the limits of the roll stand. In this context, the grain size has two roles; the final grain size determines the product properties, and the evolution of grain size influences the force predictions. Since the grain size predicted after each roll pass enters the recrystallization kinetics and grain size evolution equations of the subsequent pass, a feed-back loop for the grain size calculation is created, which may become unstable so that the computed roll force and grain size become very sensitive to small variations in the input parameters. Although models for the evolution of grain size in multi-stage hot rolling have been applied in the industry for decades, their mathematical stability has not been given much

attention, which poses difficulties for force and grain size predictions in cases subject to partial recrystallization. In this paper, the stability of a common semi-empirical model for static recrystallization and grain growth is investigated. The conditions under which instabilities occur are analyzed both for an industrial plate rolling pass schedule and for idealized load cycles. It is shown that complete recrystallization between roll passes leads to a stable grain size evolution, and that some states of partial recrystallization are unstable and hence problematic for force and grain size predictions. Instabilities in force and grain size predictions of an industrial pass schedules are analyzed by computing sensitivities using automatic differentiation of the model, showing that large amplification factors may occur if the states of partial recrystallization are treated by average strains and grain sizes. The instabilities are an inherent property of the closed-form equations for microstructure evolution for some states of partial recrystallization. However, the side effects of the instabilities can be reduced if the microstructure is not represented by average values of grain size and accumulated strain but by substructures generated by partial recrystallization. This way, the accuracy of roll force predictions can be considerably improved.

111259 Effect of a non-circular drawing sequence on spheroidization of medium carbon steel wiresJoo, Ho Seon; Hwang, Sun Kwang; Baek, Hyun Moo; Yong-TaekIm, Son, Il-Heon; Bae, Chul Min [J of Materials Processing Technology, v 216, Feb 2015, Starting Page 348, Pages 9] A non-circular drawing (NCD) sequence was applied as a prior cold working to improve spheroidization in a medium carbon steel wire. To investigate the effect of the NCD sequence on spheroidization behavior of the medium carbon steel wire, numerical simulations and experiments were carried out up to the fourth pass and were compared with the results of the conventional wire drawing (WD). From the three-dimensional numerical results, it was found that the NCD sequence could impose higher and relatively more homogeneous plastic deformation on the wire than the WD process. Spheroidization annealing at subcritical temperature of 705 °C for 2, 4, and 8 h was applied for the specimens that were produced by the WD and NCD processes, respectively. Tension and Vickers micro-hardness tests were conducted to measure mechanical properties of the annealed specimens. The annealed specimen processed by the NCD sequence showed the reduced ultimate tensile strength and micro-hardness, and the enhanced

Abstracts


reduction of area compared to those values for the WD process. According to upsetting test results, it was found that cold workability was also improved for the annealed specimen processed by the NCD process compared to the one produced by the WD process. Scanning electron microscopy (SEM) was employed to investigate the microstructure change and to quantitatively measure the spheroidization ratio of the annealed specimens processed by both processes. Owing to the SEM results, the spheroidization of the annealed specimens processed by the NCD sequence was improved compared to the one produced by the WD process. It can be construed from the current investigation that the NCD sequence might be helpful in improving the spheroidization of cementite and cold workability of medium carbon steel wires during the subcritical annealing.

111260 Nonlinear Dynamic Analysis of a Parametrically Excited Cold Rolling Mill

Kapil, Sajan; Eberhard, Peter; D w i v e d y , Santosha K [J of Manufacturing

Sci & Engg:ASME Trans, v 136, n 4, Aug 2014, Starting Page 041012, Pages 10] In this work, a four high cold rolling mill is modeled as a spring-mass-damper system considering horizontally and vertically applied time-dependent forces due to the interaction between the strip and the working rolls. The effect of vibration of the moving strip on the work roll vibration is also considered for developing the governing equation of motion of the system which is found to be that of a nonlinear parametrically excited system. The governing equation of motion is solved by using the method of multiple scales to find the instability regions and frequency-response curves of the system. The critical amplitude of horizontal load in roll bite is calculated and the frequency-response is studied in detail considering the effect of various process parameters, such as velocity, thickness of strip, time delay, amplitude, and frequency of horizontal load in roll bite. This work can find application in the design and development of high speed and chatter free rolling mills.

111261 Strain heterogeneities in the rolling direction of steel sheets submitted to the skin pass: A finite element analysisGiarola, AM; Pereira, PHR; Stemler, PA; Pertence, AEM; Campos, HB; Aguilar, MTP; Cetlin, PR [J of Materials Processing Technology, v 216,

Feb 2015, Starting Page 234, Pages 14] Hot rolled, annealed or galvanized low

carbon steel sheets display yield points in tensile testing. These are associated with deformation heterogeneities along the test specimen, known as Lüders bands, which cause an unacceptable surface appearance in steel sheet formed products. This problem is usually eliminated through a light cold rolling pass (“skin-pass”) in the material as a last step in its industrial manufacturing, imposing a reduction of thickness of about 1–2.0% on the sheet. Existing experimental results for these strain heterogeneities along the rolling direction are analyzed, as well as corresponding finite element analyses. The constitutive behavior of the material is described by a curve displaying an initial stress peak followed by the work hardening of the material. The FEAs led to distributions and shapes of Lüders bands in the sheets similar to the experimental ones. The bands nucleate intermitently and propagate from the surface of the sheets, at the initial contact region between the material and the rolls. For low and high friction between the material and the roll and for low sheet thickness reductions (0.5% and 1.0%), a limited influence of the roll diameter on the Lüders bands distribution was found. For sheet thickness reductions of 2.0% and higher, high friction between the roll and the material and large roll diameters, the distribution of LBs in the sheets was different from that obtained for small roll diameters and low friction between the rolls and the material. Increasing thickness reductions in the skin-pass led to changes in the Lüders bands distribution, involving an increasing homogeneity in the deformation. It is suggested that the critical thickness reduction in the skin-pass is associated to a minimum volume fraction of material deformed above a certain strain level.

111262 Anomalies in precipitation hardening process of 7075 aluminum alloy extruded by KOBO method

Korbel, A; Bochniak, W; Borowski; Blaz, L; Ostachowski, P; Lagoda, M [J of Materials P r o c e s s i n g Te c h n o l o g y ,

Abstracts


v 216, Feb 2015, Starting Page 160, Pages 9] In this paper the influence of the initial conditions of KOBO method extrusion of 7075 aluminum alloy on the structural and mechanical parameters of the products is presented; in particular the paper focuses on how heat treatment affects the course of the post deformation process. Moreover, our fundamental purpose is to attempt to answer the question regarding the role of point defects and their potential usage to control the material’s properties. The impetuses to conduct this research were the previous experimental studies of the kinetics of metal extrusion by KOBO method and the results of mechanical properties measurements and microstructural observations of the products. They allowed to formulate the thesis that the point defects generated in metals subjected to large and rapid plastic deformation, forming nano-dimensional clusters, constitute the dominant element of deformation mechanism and structural phenomena that take place both during and after the process. In this paper it is shown that, based on the analysis of the experimental results, the clusters of point defects have a significant thermal stability which remains after extrusion, slows down or completely inhibit the process of diffusion of alloying elements at aging temperature (150 °C). On the other hand, a very fast decay of clusters occurring at high temperature (annealing / solutioning at 470 °C/5 min) creates an excess of point defects, which result in increased diffusion during subsequent aging at 150 °C.

111263 Bio-based lubricants for forming of magnesium

R a m e z a n i , Maziar; Schmid, Steven R [J of Manufacturing Processes, v 19, Aug 2015,

Starting Page 112, Pages 6] For a number of reasons, magnesium is being used increasingly often in applications where weight savings are desired. However, magnesium is difficult to form, so that warm or hot forming are generally necessary. Lubricants are recognized as essential in these processes, but the lubricants used to date for magnesium forming have environmental drawbacks. This paper evaluates the tribological behavior and rheology of four types of bio-based metal working fluids. Using an elastohydrodynamic lubrication apparatus, their traction behavior was measured and their piezoviscous behavior was determined by applying

the well-known Hamrock–Dowson equation to measured film thickness profiles. The results showed that the investigated bio-lubricants have good ability to generate lubricant films in forming of magnesium. Traction tests showed low friction values, indicating the investigated bio-lubricants are suitable for metal forming applications where effective lubrication is desired.

111264 Experimental and numerical investigation of a short, thin-walled steel tube incremental forming process

Raujol-Veillé, J; Toussaint, F; Tabourot, L; Vautrot, M; Balland, P [J of M a n u f a c t u r i n g Processes, v 19, Aug 2015, Starting Page 59,

Pages 8] This paper concerns the forming of a short, thin-walled steel tube by means of an innovative incremental forming process close to spinning. Material characterization necessary for model calibration was carried out through tensile tests at different angles with respect to the rolling direction and simple shear tests. These data were used to identify material parameters of suitable behavior law taking into account the Baushinger effect but neglecting anisotropy. Thus, two different models were built in order to virtually reproduce the forming process. The obtained results are compared amongst themselves but also with experimental data coming from an industrial partner. It has been highlighted that the multidimensional model gives a good representation of the forming process both in terms of part geometry and applied load on tooling. The two-dimensional model is advantageous to predict qualitatively only part geometry with short CPU time. Special attention is paid to springback that occurs as a function of the studied part geometry.

111265 Microstructure investigation and flow behavior during thixoextrusion of M2 steel grade

Gu, Guochao; Pesci, Raphaël; L a n g l o i s , L a u r e n t ; Becker, Eric; Bigot, Régis

[J of Materials Processing Technology, v 216, Feb 2015, Starting Page 178, Pages 11] The microstructure investigation and flow behavior during thixoforging of M2 steel parts were investigated. Partial remelting was performed at processing temperatures ranging from 1290 °C to 1340 °C corresponding to a liquid

Abstracts


fraction range between 10% and 30% (according to differential scanning calorimetry measurements and quantitative image analyses). A conventional microstructure for thixoforming process was obtained: spherical solid grains surrounded by liquid phase. The microstructure across the heated billets was relatively homogeneous with bigger grain size near the surface. Successful thixoextrusion for producing parts was finally achieved at processing temperatures. By investigating the microstructure and load-displacement curves, different mechanisms in various forming stages were proposed.

111266 Ultrasonic microforming process for thin sheet metals and its replication abilities

Luo, Feng; Li, Kai-hui; Zhong, Jin-ming; Gong, Feng [J of Materials Processing Technology, v 216, Feb 2015, Starting Page 10, Pages 9] In this paper an ultrasonic microforming process for thin sheet metals is proposed, in which the plastic powder is instantly plasticized by the friction effect induced

by ultrasonic vibration to form molten plastic, and the molten plastic as a flexible punch transmits pressure and ultrasonic vibration onto thin sheet metal to form it as a micro workpiece. A trapezoidal cross-section micro channel of 697.2 µm width and 248.4 µm depth was successfully replicated on thin T2 copper sheet of initial thickness 50 µm by using this process. The research results showed that when the ultrasonic power was 1750 W the replication degree increased with increasing of the ultrasonic action duration time from 0.1 s to 0.6 s. The optimal ultrasonic action duration time was 0.5 s, under which the replication degree could reach up to 98%. The process has also shown a better replication ability for local micro structures with 20–50 µm in width and 1–7 µm in height, as their replication degree could reach 84%. The replication mechanism of micro channel with larger size is different from that of local micro structures with smaller size. The former is stretching and bending of thin sheet metal in a larger area, whereas the latter is equivalent to bulk metal forming in a smaller local area.

111267 Improved fracture criterion to chain

forming stage and in use mechanical strength computations of metallic parts – Application to half-blanked components

Gachet, JM; Delattre, G; Bouchard, PO [J of Materials Processing Technology, v 216, Feb 2015, Starting Page 260, Pages 18] Forming processes stages usually affect final components mechanical properties. Accounting for material processing effect is required to analyze final component’s mechanical strength and optimize products design. Accounting for both the forming stage and the structural analysis of the final product requires dealing with complex multi-stages and non-proportional loading configurations. The development of improved material models and numerical methods is needed. In the present paper, in-use mechanical behavior of half-blanked components is modeled by means of the finite element method. The complete methodology to chain metal forming computations (Forge® software) and in-use parts mechanical loading computations (LS-Dyna® software) is described. An improved fracture criterion, suited for the non-proportional loading observed during products lifecycle, was developed and used to model fracture of high-strength low-alloy steel S420MC. Ductility is modeled by a damage variable which can grow during the forming stage allowing the modeling of the relative loss of ductility induced by this step. The proposed fracture criterion is based on the definition of stress state functions, by parts in the stress states space, which allows modeling fracture under a wide range of loading conditions. Laboratory tests and industrial case computations results are assessed by comparison with experiment. Influence of forming stage and ductile fracture is analyzed. It is shown that accounting for the manufacturing process and modeling fracture are mandatory if one wants to predict accurately the observed failure modes as well as the load-carrying capacity of half-blanked components.

111268 Deformation behavior in boss forming with small punch/die diameter ratioHirota, Kenji; Michitsuji, Kota [J of Materials Processing Technology, v 216, Feb 2015, Starting

Abstracts


Page 294, Pages 8] Sheet metal parts with bosses or small pins can be manufactured by half blanking. This paper focuses on deformation in small boss forming on a sheet metal by half blanking at small punch/die diameter ratios of 1–1.8. In the case that the boss diameter is less than the sheet thickness, the boss height became lower than the depth of punch penetration at a punch/die diameter ratio of 1. The mechanism of decrease in the boss height and countermeasures to the problem were investigated through the FE analysis. The results showed that the boss height was improved up to the same level as the depth of punch penetration by both increasing punch/die diameter ratio and applying an appropriate blank holding force. The boss height was also affected by the material ductility and a higher boss was formed for the not-annealed sheet under the same forming conditions. The punch/die diameter ratio did not make a big difference in the mean punch pressure although a larger force was needed by using a larger diameter punch.

111269 Lightweight dense/porous bi-layered ceramic tiles prepared by double pressing

Novais, Rui M; Seabra, MP; Labrincha, JA [J of Materials Processing Technology, v 216, Feb 2015, Starting 9, Pages 9] This work reports the production process of bi-layered ceramics tiles, formed from two layers with different densities – dense and porous – and with adjustable thickness. The novel production method comprises a double pressing action, fast and easy to implement industrially, that ensures the development of a perfect interface bonding between layers. The bi-layered ceramic tile is formed by an upper layer with density similar to a conventional porcelain stoneware tile, and a porous bottom layer, which promotes weight reduction of the product maintaining suitable mechanical strength. The introduction of porosity is achieved by means of the incorporation of pore forming agent – polypropylene (PP) – into the ceramic formulation, which undergoes complete and non-harmful thermal decomposition during firing. For comparison, polymethyl methacrylate (PMMA) was also tested as porogen. The rapid and complete combustion of PP is suitable for fast-firing ceramic products, such as porcelain

stoneware. In addition, the polymer decomposition does not induce defects in the ceramic pieces, and is environmentally acceptable. The produced tiles are lighter than conventional porcelain stoneware tiles, thus decreasing their transport and distribution costs. Additionally, the thermal attenuation provided by the porous layer could be valuable in innovative applications, such as ventilated facades.

COLD FORMING

111270 Comparative study of three ductile damage approaches for fracture prediction in cold forming processes

Cao, TS; Bobadilla, C; Montmitonnet, P; Bouchard, PO [J of Materials P r o c e s s i n g

Technology, v 216, Feb 2015, Starting Page 385, Pages 20] Damage growth and ductile fracture prediction is still an open question for complex stress state applications. A lot of models, both phenomenological and micromechanical, have been extensively developed. There is a real need to compare them to choose the best suitable for complex loading applications. This is done here taking examples in cold metal forming, namely wire drawing and wire flat rolling. In the present study, the prediction of damage for the ultimate wire drawing and the wire flat rolling processes of a high carbon steel is investigated, using three different approaches of ductile damage: uncoupled phenomenological models (or fracture criteria), coupled phenomenological models (accounting for the softening effect of damage), and micromechanical models (accounting for damage associated microstructure evolution). These models were first implemented in a finite element code dedicated to forming process simulations, then calibrated via different mechanical tests exhibiting different stress states. Numerical results of the applications of these models to the two above-mentioned forming processes simulations were compared with experimental ones. These applications help comparing different approaches for fracture prediction in multi-stage forming processes and also in the process that involves important shear effect. The present study supplies important data for the characterization of ductile failure in forming processes, as well as an effective assessment of different phenomenological and micromechanical models, characterizing their performance for different stress states. It also suggests the use of “modular” models for complex

Abstracts


loading cases, by combining different driving factors of damage accumulation at different stress states.

ELECTROMAGNETIC FORMING

111271 Geometric issues in V-bending electromagnetic forming process of 2024-T3 aluminum alloy

Xiong, Weiren; Wang, Wenping; Wan, Min; Li, Xinjun [J of Manufacturing Processes, v 19, Aug 2015, Starting 1, Pages 12] As one of the high speed forming technologies, electromagnetic forming (EMF) has the ability to solve low formability problems in such lightweight alloys as aluminum and magnesium during the conventional forming process. However, one of the drawbacks of EMF is that shape deviation exists between the formed part and the desired part. In order to control this deviation, an in-depth study has been carried out so as to determine the causes of geometrical deviation during the EMF process and possible improvement methods. A series of V-bending electromagnetic forming experiments with rectangular samples of 2024-T3 were carried out using a flat spiral coil and V-shaped die at various voltages. Furthermore, not only the geometrical issues, especially the saddle issue, were quantitatively analyzed, but also a numerical model is established so as to analyze the origin and progression of geometric issues in the part. In the analysis, four major aspects were considered, namely the electromagnetic force distribution, the update of electromagnetic force distribution, the collision impact between sheet and die, and the duration of coil current pulse. It has been observed that electromagnetic force intensifies at the edges from which the distance to the eddy current center is shorter, and that the non-uniformity of force distribution deteriorates with increasing voltage, resulting in further non-uniformity of sheet deformation. In addition, the update of force distribution in sheet plays a useful role in

obtaining the desired shape and a proper impact helps to weaken the saddle-like geometrical issue. Moreover, widening the duration of coil current pulse can suppress the rebound of the part in forming with a shallow die.

INDUSTRIAL ENGINEERING

111272 Mapping workers’ performance to analyse workers heterogeneity under different workflow policiesFolgado, R; Peças, P; Henriques, E [J of Manufacturing Systems, v 36, Jul 2015, Starting Page 27, Pages 8] Manual work in assembly lines allows one to benefit from human reasoning capabilities and to assure the flexibility to adapt to fluctuations in production volume, products mix and reduced product lifecycles. With the objective of quantifying and systematizing the knowledge about the heterogeneity of workers’ performance, data was collected in an industrial setting. The results demonstrate a significant variation in workers’ performance in terms of speed and variability of the task completion time. A mapping approach is proposed aiming to quantify the workers’ performance and visualize performance patterns. Since the human performance is influenced by the setting where the workers perform their job, two real assembly line pacing mechanisms were set and studied: pacing derived from the manual assembly system rhythm and pacing imposed by a fixed time constraint. The type of pacing clearly influences workers’ performance (i.e., speed and variability) and revealed a significant influence in the assembly line output. In particular, imposing a fixed and equal time constraint for every worker reduces the heterogeneity of workers’ performance and improves the assembly line output.

111273 Developing a bi-objective model of the closed-loop supply chain network with green supplier selection and disassembly of products: The impact of parts reliability and product greenness on the recovery networkGhayebloo, Sima; Tarokh, Mohammad Jafar; Venkatadri, Uday; Diallo, Claver [J of Manufacturing Systems, v 36, Jul 2015, Starting Page 76, Pages 11] Closed-loop supply chain network (CLSCN) design aims to incorporate environmental considerations into the traditional supply chain design by including recycling, disassembly and reuse activities. A CLSCN incorporates the use and reuse of environmentally friendly products and materials supported by the design of an

Abstracts


appropriate recovery, disassembly, and refurbishing network. In the design process, a trade-off must often be made between the need to maximize profit and maximize greenness. The latter is considered for several reasons including regulatory requirements, corporate responsibility and corporate image. In this paper, a bi-objective mixed integer programming model is developed and solved for a forward/reverse logistic network including three echelons in the forward direction (suppliers, assembly centers and customer zones) and two echelons in the reverse direction (disassembly and recycling center). A set of Pareto optimal solutions is obtained to show the trade-off between the profit and the greenness objectives. Some useful managerial insights are developed through various computational experiments.

111274 Two-echelon multi-product multi-constraint product returns inventory model with permissible delay in payments and variable lead timePriyan, S; Uthayakumar, R [J of Manufacturing Systems, v 36, Jul 2015, Starting Page 244, Pages 19] Supply chain is not limited to delivering products to the end-costumers since the defective products that are returned back to the producers by the consumers. The producers should be superior knowledge to utilize the return products effectively so as to maintain our natural resources and to provide better service to customers. In this paper, a distributor and a warehouse consisting of a serviceable part and a recoverable part supply chain problem is considered in which there are several products, the distributor has limited space capacity and budget to purchase all products. In this supply chain, the defective products are returned back to the warehouse by the distributor and the warehouse recovered those defective products into perfect products having the same value as the procured products. The lead-time of receiving products from a warehouse to a distributor is a variable which is controllable by adding extra crashing cost. For each product, a fraction of the shortage is backordered and the rest are lost. A mathematical model is employed in this study for optimizing the order quantity, lead time and total number of deliveries with the objective of minimizing system total cost. We show that the model of this problem is a constrained non-linear programme and present a simple Lagrangian multiplier technique to solve it. Numerical and sensitivity analysis are given to show the applicability of the proposed model in real-world product returns inventory problems.

JOINING & ASSEMBLY

111275 Mutual effects of defective components in assembliesEben-Chaime, Moshe [J of Manufacturing Systems, v 36, Jul 2015, Starting Page 1, Pages 6] The focus of this study is a known and disturbing actual problem. The industry will soon celebrate a century of quality awareness and efforts. Still, according to field data, many new products exit the manufacturing systems defective. This study proposes mutual effects among assembly’s components as an explanation to this phenomenon – many defective new products. While each item in a serial manufacturing process moves individually, items are joined to others in assemblies. There, a single defective component suffices to disqualify a whole assembled unit! Surprisingly, few studies have focused on the repercussions of defective items on production. Particularly, there appears to be no study that quantifies these mutual effects of components which arrive from different sources with different defect rates. Thus, this study is also a first attempt to analyze and quantify these mutual effects. Apparently, the mutual effects of their components amplify the defect rates of assemblies dramatically, to the extent that defects due to common or random causes become significant.

111276 Enhanced tensile properties of Fe–Ni–C steel resulting from stabilization of austenite by friction stir welding

Miura, Takuya; Ueji, Rintaro; Fujii, Hidetoshi [J of M a t e r i a l s P r o c e s s i n g T e c h n o l o g y , v 216, Feb 2015, Starting Page 216, Pages 7] The austenite in the

stir zone (SZ) of Fe–24wt%Ni–0.1%C alloy fabricated by friction stir welding (FSW) was successfully stabilized. The volume fraction of austenite increases with decreasing rotation speed of the FSW tool. Electron backscatter diffraction (EBSD) measurements clarified the Kurdjumov–Sachs orientation relationship between the retained austenite and the martensite phase; this orientation relationship indicated that a phase transformation occurs after stirring and that austenite is plastically deformed during this

Abstracts


transformation. Additional EBSD measurements clarified that more dislocations remain and that the austenite grain is refined when the rotation speed is decreased. These lattice defects provide a barrier to the martensite transformation. The retained austenite exhibited the transformation-induced plasticity (TRIP) effect when the SZ was evaluated using tensile tests. As a result, SZs with a substantial amount of retained austenite exhibit both high strength and ductility.

111277 Effect of welding processes on the residual stress and distortion in type 316LN stainless steel weld joints

Vasantharaja, P; Vasudevan, M; Palanichamy, P [J of Manufacturing Processes, v 19, Aug 2015, Starting Page 187, Pages 7] The

effect of welding processes on the microstructure, residual stresses and distortion in 16 mm thick 316LN stainless steel weld joints made by TIG and A-TIG (activated flux tungsten inert gas) welding processes involving different joint configurations have been studied. The joint configurations employed were double V-groove edge preparation for double side TIG welding, square-butt preparation for double side ATIG welding and Y groove preparation for weld joint made by both TIG and ATIG welding processes. All the weld joints passed radiographic examination. Microstructural characterization was carried out using optical microscope. Residual stresses were determined using ultrasonic technique employing LCR waves, and distortion measurements were carried out using height gauge. The three weld joints exhibited different microstructures, peak tensile residual stress values and distortion. The weld joint fabricated by double side A-TIG welding exhibited the lowest peak tensile residual stress value and also minimum distortion.

111278 Micro-friction stir welding of titan zinc sheets

Papaefthymiou, S; Goulas, C; Gavalas, E [J of M a t e r i a l s P r o c e s s i n g Te c h n o l o g y, v 216, Feb

2015, Starting Page 133, Pages 7] Aim of this research is first to evaluate the applicability of

micro-friction stir welding (µFSW) to wrought zinc alloy sheets and then to improve the structural integrity of such joints. µFSW tool design was based on an algorithm that considers material and process limitations. Joining trials were performed at different feed rates. It is proven that joining by µFSW thin ZnTiCu sheets is possible and it offers extremely fine microstructures and ß-phase distribution due to the mechanical fragmentation which is the outcome of the stirring. The ß-phase particles were homogenized and precipitated inside deformed zinc grains and not at the grain boundaries, where they used to be in fusion welds. Electron microscopy showed that its size was limited to 150 nm, which is in average 13 times smaller than the size of the 2 µm that they get when sheets are TIG welded. Macroscopically, the µFSW joint mechanical properties are comparable with industrially fusion-welded material. The relative low elongation achieved, similar to fusion-welded sheets, is explained by the occurrence of three main defects: root opening, thinning and kissing bond.

111279 Evolution of microstructure and corrosion behavior in 2205 duplex stainless steel GTA-welding joint

Geng, Shaoning; Sun, Junsheng; Guo, Lingyu; Wang, Hongquan [J of M a n u f a c t u r i n g Processes, v 19,

Aug 2015, Starting Page 32, Pages 6] The microstructure, microhardness and corrosion behavior in five zones from the weld metal to base metal of a 2205 duplex stainless steel joint, which was welded by double-pass tungsten inert gas arc welding with filler wire, were investigated systematically. Results indicated that a great deal of secondary austenite appeared in weld metal due to the reheat of second pass welding and coarse ferrite grains were formed near the fusion line, while other zones had the similar microstructures with a different austenite content. It also revealed the microhardness was determined by the partitioning of alloying elements (Cr, Mo, Ni and N) and precipitates such as chromium nitride. Austenite was harder than ferrite from weld metal to fusion line, while it reversed from fusion line to base metal. Electrochemical measurement indicated the zone containing fusion line was the easiest to suffer pitting attack, followed by weld metal zone. Moreover, the surface morphologies were in

Abstracts


good agreement with the electrochemical measurements.

111280 Development of novel form-locked joints for textile reinforced thermoplastices and metallic components

Gude, Maik; Hufenbach, W e r n e r ; K u p f e r , R o b e r t ; F r e u n d , A n d r e a s ; V o g e l ,

Christian [J of Materials Processing Technology, v 216, Feb 2015, Starting Page 140, Pages 6] Lightweight constructions in multi-material-design, especially the application of textile reinforced composites in combination with metallic components, gain increasing relevance, e.g., in automotive engineering. To ensure an optimal load bearing capability of the hybrid structure, it is essential to provide adapted joining technologies. In this paper a new joining technology to produce hybrid structures with continuous fibre reinforced thermoplastics and metallic components is introduced, adapting the concept of classical clinching for thermoplastic composites. The technological concept of the thermoclinching process was successfully tested by manufacturing, testing and both non-destructive and destructive analyses of firstthermoclinched joints.

111281 Characterisation of transient out-of-plane distortion of nipple welding with header component

Selvan, R Vetri; Sathiya, P; Ravichandran, G [J of Manufacturing Processes, v 19, Aug 2015, Starting Page 67, Pages 6] Welding distortions are experienced during the manufacture of boiler components using welding processes. Header is one of the significant boiler components currently fabricated using shielded metal arc welding (SMAW) process. Header is fabricated by welding tubes called nipple with thick-walled pipe called header using SMAW multipass circumferential fillet welding with T-joint orientation. The transient out-of-plane distortion of nipple experienced during welding with header is investigated in

this paper. The analysis is carried out using the transient displacement and thermal cycle data obtained for two weld sequences. The thermal cycle and transient displacement data obtained during the investigation is having correlation with each other. The transient analysis reveals the influence of weld start/stop points. The out-of-plane distortion in X and Y directions is quantified. The distortion in X direction is influenced by weld start/stop points. The distortion in Y direction is influenced by welding direction. The influence of weld start/stop points over welding direction on distortion is quantified from the analysis. The transient analysis details are presented.

111282 Prediction of welding deformation in stiffened structure by introducing thermo-mechanical interface element

Li, Yongzhi; Wang, Kaiyun; Jin, Yujing; Xu, Mengjia; Lu, Hao [J of Materials Processing Technology, v 216, Feb 2015, Starting Page 440, Pages 7] A thermo-mechanical interface element was developed to describe the effective penetration, the fillet weld size and the contact relationship between the skin plate and the stiffener during welding distortion simulation. Based on the interface element formulation, welding distortion in stiffened structures was predicted by means of thermal elastic–plastic finite element analysis. Comparisons between the traditional model and the interface element model were conducted. The results indicate that the calculated data of the interface element model are in better agreement with the experimental measurements. The influences of the welding sequence were discussed numerically based on these two models. The interface element model is more suitable for describing the effect of the welding sequence, which are of great importance on accurately predicting distortion in large scale structure welding. Simulations and experiments upon large scale structures were also carried out to verify the effectiveness of the developed numerical analysis procedure.

111283 Microstructure evolution during magnetic pulse welding of dissimilar aluminium and magnesium alloysChen, Shujun; Jiang, Xiaoqing [J of Manufacturing

Abstracts


Processes, v 19, Aug 2015, Starting Page 14, Pages 8] Microstructure evolution has been investigated for magnetic pulse welding of dissimilar aluminium and magnesium alloys using optical microscopy, laser confocal microscopy and electron backscatter diffraction. The welded joints were made with discharge voltages of 4 kV, 4.5 kV and 5 kV and they are characterised by the aluminium region, the weld interface and the magnesium region. The interfacial waves become more regular and much smoother with increasing discharge voltage from 4 kV to 5 kV. The grains were extremely refined and the grain size became larger with increasing distance to the weld interface at a discharge voltage of 5 kV. The gradual grain refinement closer to the weld interface can be attributed to dynamic recrystallization. Different recrystallization behaviour was observed for the aluminium region and the magnesium region near the weld interface. The occurrence of the extension twinning {} in the dynamic recrystallized grains indicating twin related dynamic recrystallization behaviour in the magnesium region near the weld interface.

111284 Cyclic scheduling of flexible mixed model assembly lines with parallel stationsÖztürk, Cemalettin; Tunali, Semra; Hnich, Brahim; Örnek, Arslan [J of Manufacturing Systems, v 36, Jul 2015, Starting Page 147, Pages 12] In this paper, the problem of balancing and cyclic scheduling of flexible mixed model assembly lines with parallel stations is studied. To exploit the connection between balancing and cyclic scheduling problems for an efficient line management, they are considered simultaneously. A novel constraint programming model including problem specific symmetry breaking constraints is proposed to solve this problem. Experiments on extensive number of test instances with various sizes are also presented.

111285 Frequency control of the drop detachment in the automatic GMAW process

Tipi, Ali Reza Doodman; Sani, Seyed Kamal Hosseini; Pariz, Naser [J of M a t e r i a l s P r o c e s s i n g Te c h n o l o g y , v 216, Feb 2015,

Starting Page 248, Pages 12] A method was introduced for control of the detachment

frequency in automatic GMAW process to achieve more regularity in drop detaching. The deposition area, heat input and voltage to current ratio were regulated as the performance indicators. This method was designed based on a three-layer cascade control strategy. A four-input four-output matrix transfer function was assigned to the system using the experimental data. A decoupling MIMO controller was designed for the internal loop. In the middle control loop, a pattern was introduced to neutralize the angle effects on the drop detachment. In the external control loop, the detachment frequency was estimated by a Short Time Fourier Transform (STFT) block. A controller was designed to track the desired frequency reference. The results were evaluated by implementation on an automatic industrial pipeline GMAW system.

111286 Surface lubrication influence on electrode degradation during resistance spot welding of hot dip galvanized steel sheets

Spitz, M; Fleischanderl, M; Sierlinger, R; Reischauer, M; Perndorfer, F; Fafilek, G [J of Materials P r o c e s s i n g Technology,

v 216, Feb 2015, Starting Page 339, Pages 9] The material uptake mechanism of a resistance spot welding electrode is presented for two selected surface conditions of hot-dip galvanized steel sheets, i.e., lubricated and non-lubricated. The evolution of material deposition varies according to the different surface states. Spot welding of lubricated sheet results in a more uniform and reduced alloyed material uptake that deposits on the welding electrode cap. Accordingly, the low deposition of material on the electrode surface enhances the weldability of hot-dip galvanized steel sheets. A reproducible current flow and a stable energy input is thus ensured along the electrode cap surface during resistance spot welding. Furthermore, lubrication leads to a considerably reduced sticking of welding electrodes.

111287 A branch and bound method for the line balancing problem in U-shaped assembly lines with equipment requirementsOgan, Dilek; Azizoglu, Meral [J of Manufacturing Systems, v 36, Jul 2015, Starting Page 46, Pages 9] In this study we consider a U-shaped

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assembly line balancing problem where each task uses a specified set of equipments and each type of equipment has a specified cost. Our problem is to assign the tasks together with their equipments to the workstations so as to minimize the total equipment cost. We formulate the problem as a mixed integer linear programming model that is capable of solving small sized instances. We propose a branch and bound algorithm that uses efficient precedence relations and lower bounds. We find that the algorithm is able to solve moderate sized problem instances in reasonable times.

111288 Study of mechanical properties for copper alloy H62 sheets joined by self-piercing riveting and clinching

X i n g , Baoying; He, X i a o c o n g ; Wang, Yuqi; Y a n g , H u i y a n ;

Deng, Chengjiang [J of Materials Processing Technology, v 216, Feb 2015, Starting Page 28, Pages 9] Self-piercing riveting (SPR) and clinching are new high-speed mechanical fastening techniques which are suitable for point joining lightweight sheet materials. The joinabilities of copper alloy H62 by SPR and clinching are discussed in this paper. Mechanical tests were conducted to study the static and fatigue properties of joints, and the properties of joints using SPR and clinching technologies were investigated. The effectiveness of experimental data was validated statistically, using Student’s t test and a two-parameter Weibull distribution. The fatigue load (F) and fatigue life (N) results were plotted against log–log axes. Lines were fitted using least square methods and the two-parameter power function equations of F–N curves were obtained. The results showed that SPR joints had superior static and fatigue properties, but the clinched joints also presented favorable fatigue performance.

111289 Surface reinforcement of AA5083-H111 by friction stir processing assisted by electrical current

S a n t o s , Telmo G; Lopes, N; M a c h a d o,

Miguel; Vilaça, Pedro; Miranda, RM [J of Materials Processing Technology, v 216, Feb 2015, Starting Page 375, Pages 6] This paper

presents a variant of friction stir processing (FSP) assisted by electric current for the production of surface composites in aluminium, reinforced with alumina particles. The main objective was to improve the overall material surface reinforcing process by using this variant. Numerical simulations were performed to study the electrical current density and flow patterns in the FSP tool, and in the processed zone. The FSP tool was adapted to the specificities of the application. The concept was experimentally validated by pre-placing alumina particles with median sizes of 45 µm, over AA5083-H111 plates and friction stir process these. Tests were performed with and without an electrical current of about 500 A for comparison purposes. The pre-deposition of alumina produced an increase in surface hardness of around 40%. Using this electrical current variant, a higher extension and depth of reinforced layer were observed, with an increase of about 500% and 40% in depth and in width, respectively, while the surface substrate hardness dropped by 10%. The particles were more uniformly distributed and sparser.

111290 Assembly sequence planning of rigid and flexible partsGhandi, Somayé; Masehian, Ellips [J of Manufacturing Systems, v 36, Jul 2015, Starting Page 128, Pages 19] Assembly sequence planning (ASP) is the process of computing a sequence of assembly motions for constituent parts of an assembled final product. ASP is proven to be NP-hard and thus its effective and efficient solution has been a challenge for the researchers in the field. Despite the fact that most assembled products like ships, aircrafts and automobiles are composed of rigid and flexible parts, no work exists for assembly/disassembly sequence planning of flexible parts. This paper lays out a theoretical ground for modeling the deformability of flexible assembly parts by introducing the concept of Assembly stress matrix (ASM) to describe interference relations between parts of an assembly and the amount of compressive stress needed for assembling flexible parts. Also, the Scatter Search (SS) optimization algorithm is customized for this problem to produce high-quality solutions by simultaneously minimizing both the maximum applied stress exerted for performing assembly operations and the number of assembly direction changes. The parameters of this algorithm are tuned by a TOPSIS-Taguchi based tuning method. A number of ASP problems with rigid and flexible parts were solved by the presented SS and other algorithms like Genetic

Abstracts


and Memetic algorithms, Simulated Annealing, Breakout Local Search, Iterated Local Search, and Multistart Local Search, and the results and their in-depth statistical analyses showed that the SS outperformed other algorithms by producing the best-known or optimal solutions with highest success rates.

111291 Dynamic Stress Analysis of Battery Tabs Under Ultrasonic Welding

Kang, Bongsu; Cai, Wayne; Tan, Chin-An [J of Manufacturing Sci & Engg:ASME Trans, v 136, n 4, Aug 2014, Starting Page 041011, Pages 8] Ultrasonic metal welding is widely used for joining multiple layers of

dissimilar metals, such as aluminum/copper battery tabs welding onto copper busbars. It is therefore important to have a robust product/process design using ultrasonic metal welding that ensures consistent welds with desired quality. In this work, the effects of longitudinal and flexural vibrations of the battery tab during ultrasonic welding on the development of axial normal stresses that occasionally cause cracks near the weld area are studied by applying a one-dimensional continuous vibration model for the battery tab. Analysis results indicate that fracture could occur near the weld area, due to low cycle fatigue as a result of large dynamic stresses induced by resonant flexural vibration of the battery tab during welding. This study provides a fundamental understanding of battery tab dynamics during ultrasonic welding and its effects on weld quality, and can be used to develop guidelines for product/process design of ultrasonically welded battery tabs.

111292 Assembly oriented control algorithm of collaborative disassembly and assembly operation in collaborative virtual maintenance processLi, Xiangyang; Zhang, Zhili; Gao, Qinhe; Liang, Feng; Huang, Xianxiang [J of Manufacturing Systems, v 36, Jul 2015, Starting Page 95, Pages 19] Maintenance data and information processing is an essential and important problem in collaborative virtual maintenance of complex equipments. Significant research has been done in this paper to provide an efficient approach to performing the data and information processing of collaborative virtual disassembly and assembly

operations. Assembly oriented mathematical model of collaborative virtual maintenance operation process is presented with the behavior representation and information description of each component in an assembly based on single object oriented modeling of collaborative maintenance operation as well as assembly oriented modeling of disassembly and assembly operations. Assembly oriented control algorithms of disassembly and assembly operations in collaborative virtual maintenance process are also designed to perform the required data and information processing. With the object information template based on Extensible Markup Language, proposed mathematical models and control algorithms are utilized in a technical experiment system with high reliability and efficiency. Experimental implementation has been done to find appropriate and efficient mathematical models and control algorithms can support effectively the data and information processing of collaborative virtual disassembly and assembly operations of complex products. Methodologies developed in this paper extend the previous work on mathematical modeling and information processing complexity, and improve the reliability and efficiency of required data and information processing in collaborative virtual maintenance process.

111293 Effect of Aging on the Strength of Clinching Galvanized SAE1004 Steel-to-Aluminum AA6111 Joints

Gao, Yang; Liu, Zhong-Xia; Wang, Pei-Chung [J of Manufacturing Sci & Engg:ASME Trans, v 136, n 4, Aug 2014, Starting Page 041016, Pages 8] Mechanical clinching method has been shown to be a feasible alternative to self piercing riveting (SPR)

for joining dissimilar materials, particularly for vehicle assemblies made in aluminum-to-steel. While a great deal of effort has been focused on studying the process development, there is an urgent need to understand the effects of aged aluminum on the strengths of the clinching steel-aluminum joints. To evaluate exactly the influence of mechanical properties of aged aluminum alloy on the strength of the clinching joint, 1.0?mm thick AA6111-T4 aluminum was firstly solution heat-treated at 550?°C for 30?min

Abstracts


followed by nature ageing treatment for various times and then clinching to 0.7?mm thick galvanized SAE1004 steel with SKB die. The section parameters and strength of the clinching joints were measured. The effect of mechanical properties of aged AA6111-T4 aluminum was analyzed using an analytical model. The results showed that aged aluminum affected little the clinchability but influenced the section parameters and strength of the clinching workpieces. The strength of the clinching SAE1004-to-AA6111-T4 joints increased with increasing the strength of AA6111-T4 aluminum. This can be primarily attributed to the fact that the strengthening AA6111-T4 aluminum resulted in larger residual press stress developed during the clinching.

111294 Predictive Control for Manual Plasma Arc Pipe Welding

Li, Xiangrong; Zhang, Yu Ming [J of Manufacturing Sci & Engg:ASME Trans, v 136, n 4, Aug 2014, Starting Page 041017,

Pages 8] Plasma arc welding (PAW) has several advantages over traditional gas tungsten arc welding (GTAW) process. However, due to its sensitivity to welding parameters, this process has not been widely used in industry, especially for manual welding applications where variations in welding parameters are substantial. This paper introduces and implements a model predictive control (MPC) method to adjust welding current in order to compensate the effects from these variations during manual plasma welding operation. A linear model with adequate accuracy has been selected for the design of control system. Closed-loop control experiments verified the effectiveness of developed control system.

111295 Microstructure, tensile properties of Ti-6Al-4V by ultra high pulse frequency GTAW with low duty cycle

Yang, Zhou; Qi, Bojin; Cong, Baoqiang; Liu, Fangjun; Yang,

Mingxuan [J of Materials Processing Technology, v 216, Feb 2015, Starting Page 37, Pages 11] The paper compares the characteristics of Ti-6Al-4V titanium alloy for conventional gas tungsten arc welding (C-GTAW) process with ultra high frequency pulse gas tungsten arc welding (UHFP-GTAW) on the conditions of 50% and 20%

duty cycles. The effects of heat input on average intercept of grain size in the fusion zone (FZ), microstructure, tensile properties and fracture behavior were determined. These findings suggest that a lower heat input by UHFP-GTAW process was responsible for better grain size, microstructure and tensile properties except for the effect of ultra high frequency pulse current. In contrast with C-GTAW process, the average intercept of grain size in FZ decreased by 30% at most with 20% duty cycle. The morphology of basketweave structure predominated in the microstructure of FZ by UHFP-GTAW, moreover, a large density and uniform distribution of resultant basketweave were obtained with 20% duty cycle. The samples obtained by UHFP-GTAW generally displayed better ductility, in particular, when the duty cycle was reduced to 20%, the elongation and percentage reduction of area were respectively increased by 140% and 275%. The fractures with 20% duty cycle were mainly located in the base metal, such fractograph showed development of intense shear and deep dimple aggregation, which might be caused by improvement of the ductility.

LASERS

111296 Semi-empirical model of deposit size and porosity in 420 stainless steel and 4140 steel using laser engineered net shaping

Ferguson, JB; Schultz, Benjamin F; M o g h a d a m , Afsaneh Dorri; Rohatgi, Pradeep K [J of Manufacturing Processes, v 19, Aug 2015, Starting Page 163, Pages 8] Laser engineered net shaping (LENS™)

samples were fabricated from two technologically important steel alloys, 420 and 4140, in order to study how processing parameters such as powder feed rate and laser traverse velocity affected porosity and deposit dimensions. For both steels, it was found that many possible combinations of laser traverse velocity and powder feed rate will result in negligible porosity provided that the ratio of powder feed rate to laser traverse velocity does not exceed a maximum level. Based on measurements of deposit size and shape in the various experiments, a semi-empirical model is presented that predicts the trend in deposit sizes for various processing parameters ◘

editorial board contents - cmti-india · 2017-08-18 · s usha n balashanmugam s arumugasamy b r...

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