This paper gives a review of the finite element techniques (FE) applied in the area of material processing. The latest trends in metal forming, non‐metal forming, powder…
Abstract
This paper gives a review of the finite element techniques (FE) applied in the area of material processing. The latest trends in metal forming, non‐metal forming, powder metallurgy and composite material processing are briefly discussed. The range of applications of finite elements on these subjects is extremely wide and cannot be presented in a single paper; therefore the aim of the paper is to give FE researchers/users only an encyclopaedic view of the different possibilities that exist today in the various fields mentioned above. An appendix included at the end of the paper presents a bibliography on finite element applications in material processing for 1994‐1996, where 1,370 references are listed. This bibliography is an updating of the paper written by Brannberg and Mackerle which has been published in Engineering Computations, Vol. 11 No. 5, 1994, pp. 413‐55.
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R. Shivpuri, X. Cheng, K. Agarwal and S. Babu
To investigate the ProMetal 3D printing technique for its application to dies, for low volume hot forging of 7075 aluminum helicopter parts.
Abstract
Purpose
To investigate the ProMetal 3D printing technique for its application to dies, for low volume hot forging of 7075 aluminum helicopter parts.
Design/methodology/approach
Thermo‐mechanical and tribological behavior of the ProMetal 3D printed tools were characterized by hot upset and ring tests. Finite element simulations of the test application were conducted using special purpose metal forming simulation software FORGE3. Results obtained from the tests along with finite element analysis were used to validate behavior of the printed dies during forging trials.
Findings
ProMetal‐printed materials exhibited relatively low thermal conductivity and high friction. Cavities were printed, machined and evaluated in hot forging trials. Dies exhibited substantial settling during the manufacturing (3D printing) process. Some collapse of dies was also observed at locations where forging pressures were high.
Practical implications
After initial plastic settling, the printed dies provide satisfactory part tolerance for die temperatures and pressures up to 338°C and 689 MPa, respectively. Low thermal conductivity observed indicate a potential to forge aluminum with cooler dies. Coating or secondary polishing is necessary to achieve acceptable surface finish for forging of aluminum.
Originality/value
This paper demonstrates a need in RP industry to methodically match capabilities of the rapid prototyping process to the needs of the intended application through the use of finite element method and some fundamental characterization.
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This paper gives a review of the finite element techniques (FE)applied in the area of material processing. The latest trends in metalforming, non‐metal forming and powder…
Abstract
This paper gives a review of the finite element techniques (FE) applied in the area of material processing. The latest trends in metal forming, non‐metal forming and powder metallurgy are briefly discussed. The range of applications of finite elements on the subjects is extremely wide and cannot be presented in a single paper; therefore the aim of the paper is to give FE users only an encyclopaedic view of the different possibilities that exist today in the various fields mentioned above. An appendix included at the end of the paper presents a bibliography on finite element applications in material processing for the last five years, and more than 1100 references are listed.
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Yusuf Sahin and A. Riza Motorcu
This paper presents a study of the development of surface roughness model when turning the mild steel hardened up to 484 HV with mixed alumina ceramic (KY1615) and coated alumina…
Abstract
This paper presents a study of the development of surface roughness model when turning the mild steel hardened up to 484 HV with mixed alumina ceramic (KY1615) and coated alumina ceramic cutting tools (KY4400). The model was developed in terms of main cutting parameters such as cutting speed, feed rate and depth of cut, using response surface methodology. The established equation indicated that the feed rate affected the surface roughness the most, but other parametres remined stable for arithmetic average height parametre (Ra). However, it decreased with increasing the cutting speed, and with the starting and finishing point of cut for ten point height parametre (Rz). The cutting speed and the depth of cut had a slight effect on surface roughness values of Ra, Rz when using KY4400 cutting tools. Furthermore, the average surface roughness value of Ra was about 0.926 um, 1.089 um for KY1615, KY4400 cutting tools, respectively. The predicted surface roughness was found to be very close to experimentally observed ones at 95% confidence level. Moreover, analysis of variance indicated that squares terms were significant but interaction terms were insignificant for both cutting tools.
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Amir Asgharzadeh and Siamak Serajzadeh
The purpose of this paper is to develop a mathematical solution to estimate the deformation pattern and required power in cold plate rolling using coupled stream function method…
Abstract
Purpose
The purpose of this paper is to develop a mathematical solution to estimate the deformation pattern and required power in cold plate rolling using coupled stream function method and upper bound theorem.
Design/methodology/approach
In the first place, an admissible velocity field and the geometry of deformation zone are derived from a new stream function. Then, the optimum velocity field is obtained by minimizing the corresponding power function. Also, to calculate the adiabatic heating during high speed rolling operations, a two-dimensional conduction-convection problem is sequentially coupled with the mechanical model. To verify the predictions, rolling experiments on aluminum plates are conducted and also, a finite element analysis is performed by Abaqus/Explicit. The predicted deformation zone is then compared with the experimentally measured region as well as with the results of the finite element analysis.
Findings
The results show that the predicted deformation zone and the temperature distribution fit reasonably with the experimental data while much lower computational cost needs comparing to the fully finite element analysis.
Originality/value
A new stream function is proposed to properly describe the velocity field and deformation pattern during plate rolling considering the neutral point. Furthermore, the employed algorithm can be simply coupled with the thermal finite element analysis.
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To provide a selective bibliography for researchers working with bulk material forming (specifically the forging, rolling, extrusion and drawing processes) with sources which can…
Abstract
Purpose
To provide a selective bibliography for researchers working with bulk material forming (specifically the forging, rolling, extrusion and drawing processes) with sources which can help them to be up‐to‐date.
Design/methodology/approach
A range of published (1996‐2005) works, which aims to provide theoretical as well as practical information on the material processing namely bulk material forming. Bulk deformation processes used in practice change the shape of the workpiece by plastic deformations under forces applied by tools and dies.
Findings
Provides information about each source, indicating what can be found there. Listed references contain journal papers, conference proceedings and theses/dissertations on the subject.
Research limitations/implications
It is an exhaustive list of papers (1,693 references are listed) but some papers may be omitted. The emphasis is to present papers written in English language. Sheet material forming processes are not included.
Practical implications
A very useful source of information for theoretical and practical researchers in computational material forming as well as in academia or for those who have recently obtained a position in this field.
Originality/value
There are not many bibliographies published in this field of engineering. This paper offers help to experts and individuals interested in computational analyses and simulations of material forming processes.
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Alberto Sanchez Ramirez, Manuel Enrique Islán Marcos, Fernando Blaya Haro, Roberto D’Amato, Rodolfo Sant and José Porras
The purpose of this paper is to analyze the aerodynamic improvements obtained in a wing section with a NACA 0018 airfoil manufactured using the fused deposition modeling (FDM…
Abstract
Purpose
The purpose of this paper is to analyze the aerodynamic improvements obtained in a wing section with a NACA 0018 airfoil manufactured using the fused deposition modeling (FDM) technique with regard to a smooth surface made by milling. The creation of micro-riblets on the surface of the airfoil, due to the deposition of the material layer by layer, improves the general aerodynamic performance of the parts, provided that the riblets are parallel to the flow line. The incidence of the thickness of the thread deposited in each layer – to be the variable on which the geometry of the riblets is based – was studied.
Design/methodology/approach
The wing section was designed using 3D software. Three different models were designed by rapid prototyping, using additive and subtractive manufacturing. Two of the profiles were manufactured using FDM varying the thickness of the layer to be able to compare the aerodynamic improvements. The third model was manufactured using a subtractive rapid prototyping machine generating a smooth surface profile. These three models were tested inside the wind tunnel to be able to quantify the aerodynamic efficiency according to the geometry and the riblets size.
Findings
The manufacture of an aerodynamic profile using FDM provides, in addition to the lightness and the ability to design parts with complex geometries, an improvement in the aerodynamic efficiency of 10 per cent compared with profiles with a smooth surface.
Practical implications
With the aerodynamic advantage gained through the use of FDM positions, the additive manufacturing serves as an excellent alternative for the manufacture of lightweight aerodynamic parts, with low structural loading and with low Reynolds number (∼5·105). This technological advantage would be applied to the UAV (unmanned aerial vehicle) industry.
Originality/value
The study carried out in this article demonstrates that the use of FDM as a manufacture process of end-used parts that are subject to movement generates an additional advantage that had not been considered. The additive manufacturing allows us to directly manufacture riblets by creating the necessary surface so as to reduce the aerodynamic drag.
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Archana Rethinam, Vinoo D. Shivakumar, L. Harish, M.B. Abhishek, G.V. Ramana, Madhusudana R., R. Sah and S. Manjini
The application of new technologies requires, however, modern rolling mills. Indeed, in manufacturing plants of older types, strict compliance with the developed rolling regimes…
Abstract
Purpose
The application of new technologies requires, however, modern rolling mills. Indeed, in manufacturing plants of older types, strict compliance with the developed rolling regimes is not always feasible. Improving the mechanical properties in such cases is possible only by means of cooling. Compressive deformation behavior of carbon–manganese (C-Mn) grade has been investigated at temperatures ranging from 800-900°C and strain rate from 0.01-50 s−1 on Gleeble-3800, a thermo-mechanical simulator. Simulation studies have been conducted mainly to observe the microstructural changes for various strain rate and deformation temperatures at a constant strain of 0.5 and a cooling rate of 20°C s−1.
Design/methodology/approach
The project begins with simulation of a hot rolling condition using the thermo-mechanical simulator; this was followed by microstructural examination and identification of phases present by using an optical microscope for hot-rolled coil and simulated samples; grain size measurement and size distribution studies; and optimization of finishing temperature, coiling temperature and cooling rate by mimicking plant processing parameters to improve the mechanical properties.
Findings
As the strain rate and temperature increase, pearlite banding decreases gradually and finally gets completely eliminated, thereby improving the mechanical properties. True stress–strain curves were plotted to extrapolate the effect of strain-hardening and strain rate sensitivity on austenite (γ) and austenite–ferrite (γ-a) regions. To validate the effect of strain rate and temperature over the grain size, the hardness of simulated samples was measured using the universal hardness tester and the corresponding tensile strength was found from the standard hardness chart.
Practical implications
The results of the study carried out have projected a new technology of thermo-mechanical simulation for the studied C-Mn grade. These results were used to optimize the plant processing parameter like finishing and coiling temperature and finishing stands strain rate.
Originality/value
By controlling the hot rolling conditions like finishing, coiling temperature and cooling rate, structures differing in mechanical properties can be obtained for the same material. Accurate understanding of a structure being formed when different temperatures are applied enables the control of the process that assures intended structures and mechanical properties are achieved.
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Yabao Hu, Hanning Chen, Xiaodan Liang and Jianbo Lei
Studies on titanium implants have shown that the mechanical properties of the parts are affected by the microstructure characteristic derived from the manufacturing process. The…
Abstract
Purpose
Studies on titanium implants have shown that the mechanical properties of the parts are affected by the microstructure characteristic derived from the manufacturing process. The properties of different orientations of specimens under the same process parameters will be different, which should be considered in the application of bone implants. This paper aims to understand the influence of microstructure on micro-hardness, wear and corrosion resistance in different orientations.
Design/methodology/approach
The authors manufactured titanium parts and carried out micro-hardness, wear tests and electrochemical corrosion of different orientations under the same process conditions. Then, finally studied the evolution mechanism of the microstructure in different orientations and its influence mechanism on wear and corrosion mechanism.
Findings
The melting method makes the grains on the surface in XY orientation finer. The wear mechanism of XY orientation is abrasive wear, that of XZ and YZ orientations are adhesive wear. During corrosion, XY orientation forms a stable passivation film earlier. Compared with XZ and YZ orientations, XY orientation has higher micro-hardness, better wear and corrosion resistance.
Originality/value
In this paper, the microstructure, wear and corrosion resistance of selective laser melted parts were discussed and the differences in different orientations under the same experimental conditions were discussed. The evolution mechanism of the microstructure in different orientations and its influence mechanism on wear mechanism and corrosion mechanism was studied. The mechanical anisotropy of selective laser melted components was discussed.
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Akhil Garg and Kang Tai
Generalization ability of genetic programming (GP) models relies highly on the choice of parameter settings chosen and the fitness function used. The purpose of this paper is to…
Abstract
Purpose
Generalization ability of genetic programming (GP) models relies highly on the choice of parameter settings chosen and the fitness function used. The purpose of this paper is to conduct critical survey followed by quantitative analysis to determine the appropriate parameter settings and fitness function responsible for evolving the GP models with higher generalization ability.
Design/methodology/approach
For having a better understanding about the parameter settings, the present work examines the notion, applications, abilities and the issues of GP in the modelling of machining processes. A gamut of model selection criteria have been used in fitness functions of GP, but, the choice of an appropriate one is unclear. In this work, GP is applied to model the turning process to study the effect of fitness functions on its performance.
Findings
The results show that the fitness function, structural risk minimization (SRM) gives better generalization ability of the models than those of other fitness functions.
Originality/value
This study is of its first kind where two main contributions are listed addressing the need of evolving GP models with higher generalization ability. First is the survey study conducted to determine the parameter settings and second, the quantitative analysis for unearthing the best fitness function.