Journal of Manufacturing Processes最新文献

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Exploring the application of laser thermal effect in the multilayer gradient coatings designed by electrochemical deposition: Parameters, advancements, and limitations 探索激光热效应在电化学沉积法设计的多层梯度涂层中的应用:参数、进步和局限性
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-10-31 DOI: 10.1016/j.jmapro.2024.10.059
Yucheng Wu, Zhaoyang Zhang, Jiabei Zhang, Shuai Yang, Kun Xu, Hao Zhu, Yang Liu
{"title":"Exploring the application of laser thermal effect in the multilayer gradient coatings designed by electrochemical deposition: Parameters, advancements, and limitations","authors":"Yucheng Wu,&nbsp;Zhaoyang Zhang,&nbsp;Jiabei Zhang,&nbsp;Shuai Yang,&nbsp;Kun Xu,&nbsp;Hao Zhu,&nbsp;Yang Liu","doi":"10.1016/j.jmapro.2024.10.059","DOIUrl":"10.1016/j.jmapro.2024.10.059","url":null,"abstract":"<div><div>This study presents an innovative approach distinct from conventional electrochemical deposition (ECD) techniques to produce multilayer gradient Fe-Ni coatings. This process incorporates the effective integration of laser energy fields, and the detailed thermal impact was extensively analyzed. The correlation between laser effects on the ECD process, element content, and microstructure was verified from the perspective of thermal effects. Even without altering the original face-centered cubic structure, the introduction of lasers significantly affects the distribution of element content and grain size. Therefore, this study presents two new laser-ECD processes that enable the fabrication of multilayer gradient structures. One approach involves obtaining a multilayer structure with alternating element content along the cross-section, from bottom to top. This is achieved by periodically varying current densities generated by continuously alternating thermal gradients formed through laser scanning. The second method aims to create a gradient structure prepared by adjusting the laser parameters that vary laterally or longitudinally along the substrate. Furthermore, the effectiveness of the gradient performance was demonstrated by revealing microstructure evolution and testing the microhardness. Finally, the advantages and limitations of laser thermal effects in preparing multilayer gradient structures are summarized.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 38-52"},"PeriodicalIF":6.1,"publicationDate":"2024-10-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142560552","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Multi-criteria optimization of the warm hydroforming process of an aluminum component based on the adaptive neuro-fuzzy inference system 基于自适应神经模糊推理系统的铝制部件温压成型工艺的多标准优化
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-10-31 DOI: 10.1016/j.jmapro.2024.10.075
Saeed Yaghoubi , Antonio Piccininni , Masoud Seidi , Pasquale Guglielmi
{"title":"Multi-criteria optimization of the warm hydroforming process of an aluminum component based on the adaptive neuro-fuzzy inference system","authors":"Saeed Yaghoubi ,&nbsp;Antonio Piccininni ,&nbsp;Masoud Seidi ,&nbsp;Pasquale Guglielmi","doi":"10.1016/j.jmapro.2024.10.075","DOIUrl":"10.1016/j.jmapro.2024.10.075","url":null,"abstract":"<div><div>In sheet metal forming processes, improvement of product quality and its manufacturing conditions have always been considered as key aspects. In the case of processing aluminum alloys, the manufacturing process – especially if carried out in warm conditions – and its main parameters must be properly defined also to overcome the poor formability at room temperature.</div><div>In the present work, a multi-criteria optimization approach is applied on the manufacturing of an aluminum-based component via warm sheet hydroforming. Experimental tests were carried out changing the working temperature and oil pressure rate according to a factorial plan; formed blanks were analyzed in terms of final thickness distribution and shape accuracy (expressed in terms of die cavity filling) by means of a Digital Image Correlation (DIC) system. The distribution type of the data obtained from the experiments was determined using the Chi-Square goodness of fit test and, subsequently, the expected value of the distributions for each experimental test was calculated. Data collected from the experimental tests were used to train the adaptive neuro-fuzzy inference system (ANFIS), whose outcome predictions were ranked via simple additive weighting (SAW) and entropy methods. Based on the findings, the weight of main post-forming properties – the die filling percentage, the thinning distribution and the maximum thinning – was calculated as 27.20 %, 26.81 %, and 45.99 %, respectively. The decision-making tool allowed to apply a multi-criteria optimization: by assigning a larger weight to the die cavity filling, it was demonstrated that the process temperature plays a key role and has to be increased. On the other hand, the uniformity in the thickness distribution can be preserved by increasing the applied pressure rate. The approach, therefore, allows to tailor the working conditions (in terms of temperature and oil pressure rate) according to the post-forming property to be privileged.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 75-92"},"PeriodicalIF":6.1,"publicationDate":"2024-10-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142560554","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Removal mechanism and grinding performance of ZTA nanocomposite ceramics using ternary-hybrid nanofluid minimum quantity lubrication technology 使用三元混合纳米流体最小量润滑技术的 ZTA 纳米复合陶瓷的去除机理和研磨性能
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-10-30 DOI: 10.1016/j.jmapro.2024.10.060
Xianpeng Zhang , Peng Yao , Peifa Zhou , Cheng Wang , Shuoshuo Qu , Dongkai Chu , Kailei Luo , Lin Li , Junfeng Zhang , Chuanzhen Huang
{"title":"Removal mechanism and grinding performance of ZTA nanocomposite ceramics using ternary-hybrid nanofluid minimum quantity lubrication technology","authors":"Xianpeng Zhang ,&nbsp;Peng Yao ,&nbsp;Peifa Zhou ,&nbsp;Cheng Wang ,&nbsp;Shuoshuo Qu ,&nbsp;Dongkai Chu ,&nbsp;Kailei Luo ,&nbsp;Lin Li ,&nbsp;Junfeng Zhang ,&nbsp;Chuanzhen Huang","doi":"10.1016/j.jmapro.2024.10.060","DOIUrl":"10.1016/j.jmapro.2024.10.060","url":null,"abstract":"<div><div>Zirconia toughened alumina (ZTA) nanocomposite ceramics are of high interest in the field of biomedicine due to their exceptionally high hardness and wear resistance. Severe conditions of flood grinding of ZTA nanocomposite ceramics lead to numerous defects and environmental pollution. In order to solve the aforementioned bottleneck, the ternary-hybrid nanofluid minimum quantity lubrication (TNMQL) technology incorporating polyethylene glycol (PEG), water and multilayer graphene (MGNs) with excellent heat transfer and friction reduction was first proposed. The influences of flood grinding, PEG MQL (PMQL), PEG-water (10 % vol, 40 % vol, and 70 % vol) MQL (PWMQL) and TNMQL on the removal mechanism and grinding performances of ZTA nanocomposite ceramics were investigated in this paper. The results showed that the cooling effect of TNMQL was not weaker than that of flood grinding. The TNMQL consumes 27.51 % and 39.30 % less energy compared to the PWMQL (70 % vol) and flood grinding. The TNMQL results in the minimum specific grinding force and surface roughness. The specific tangential grinding force <span><math><msubsup><mi>F</mi><mi>t</mi><mo>'</mo></msubsup></math></span>, the specific normal grinding force <span><math><msubsup><mi>F</mi><mi>n</mi><mo>'</mo></msubsup></math></span> and the surface roughness <em>S</em><sub>a</sub> from 0.46 N/mm, 5.78 N/mm and 0.244 μm for flood grinding to 0.24 N/mm, 3.72 N/mm and 0.134 μm, respectively. The TNMQL grinding method resulted in the lowest surface damage, with a 62.40 % reduction in the energy proportion of the high-frequency detail signal compared to flood grinding. The material was mainly removed in ductile mode and there were no obvious cracks and material spalling on the subsurface. The TNMQL technology boasts a straightforward preparation process, environmentally friendly properties, and minimal energy usage. This research demonstrated the feasibility of machining ZTA nanocomposite ceramics using TNMQL.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 1-13"},"PeriodicalIF":6.1,"publicationDate":"2024-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142552842","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Process design of one-step deformation to fabricate double-sided gradient structures: Principle, microstructure and mechanical properties 制造双面梯度结构的一步变形工艺设计:原理、微观结构和机械性能
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-10-30 DOI: 10.1016/j.jmapro.2024.10.048
Xingsheng Hao, Peixuan Zhong, Songqing Li, Zhuohan Zhang, Hao Shu, Wenjun Deng
{"title":"Process design of one-step deformation to fabricate double-sided gradient structures: Principle, microstructure and mechanical properties","authors":"Xingsheng Hao,&nbsp;Peixuan Zhong,&nbsp;Songqing Li,&nbsp;Zhuohan Zhang,&nbsp;Hao Shu,&nbsp;Wenjun Deng","doi":"10.1016/j.jmapro.2024.10.048","DOIUrl":"10.1016/j.jmapro.2024.10.048","url":null,"abstract":"<div><div>Double-sided gradient structures, as a method to avoid the strength-ductility dilemma, face the problem of low processing efficiency in manufacturing processes. To address this issue, this work describes a severe plastic deformation process, called plastic flow machining with array sawteeth, which enables the fabrication of double-sided gradient-structured (GS) sheets in one-step deformation. The experimental material in this work was AA1060. In this work, the principle of the process, the microstructure and the mechanical properties of the formed sheet were investigated using simulations and experiments. This process created a significant strain gradient within the sheet (strain differentials of up to 5.5). The surface of the sheet was effectively refined to ultrafine grains (average grain size of 0.819 μm). The Vickers hardness of the sheet's surface was increased by 62 %–71 %. There were significant grain size gradients and hardness gradients in the thickness direction of the sheet. The ultimate tensile strength (UTS) of the sheet could reach 166 MPa while still having reasonable ductility (elongation to failure of 20.8 %). The sheet was annealed at 350 °C for 25 min yielding a uniform elongation (27.5 %) similar to that of the initial coarse-grained sample, while the UTS was 45 % greater than that of the initial sample. These findings provide an efficient method for fabricating double-sided GS sheets with excellent properties and have promising industrial potential.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 14-26"},"PeriodicalIF":6.1,"publicationDate":"2024-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142552843","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Analysis of the effects of different milling strategies on helical milling of unidirectional CFRP under minimum quantity lubrication 在最小量润滑条件下不同铣削策略对单向 CFRP 螺旋铣削的影响分析
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-10-30 DOI: 10.1016/j.jmapro.2024.10.072
Chaosheng Li, Niancong Liu, Lei Chen, Wuyu Chen, Yanzong Liu, Miaoke Zhang
{"title":"Analysis of the effects of different milling strategies on helical milling of unidirectional CFRP under minimum quantity lubrication","authors":"Chaosheng Li,&nbsp;Niancong Liu,&nbsp;Lei Chen,&nbsp;Wuyu Chen,&nbsp;Yanzong Liu,&nbsp;Miaoke Zhang","doi":"10.1016/j.jmapro.2024.10.072","DOIUrl":"10.1016/j.jmapro.2024.10.072","url":null,"abstract":"<div><div>During the helical milling of carbon fiber-reinforced polymer (CFRP), issues such as low surface quality of workpieces and severe tool wear commonly occur. In this study, helical milling experiments were conducted on a unidirectional CFRP under minimum quantity lubrication (MQL) condition. It comparatively analyzed the effects of down/up milling, as well as the fiber cutting angle, on the cutting force, vibration, temperature, tool wear, and surface quality. It then proposed and validated a hybrid (up - down - up) milling strategy. The results indicate that, for both milling strategies, when cutting against the fiber (<em>θ</em> ∈ [90, 180°]), the cutting force is larger than along the fiber (<em>θ</em> ∈ [0, 90°]). Cutting force and vibration follow axial force <em>F</em><sub>z</sub> &gt; radial force <em>F</em><sub>n</sub> &gt; tangential force <em>F</em><sub>t</sub>, and axial vibration <em>a</em><sub>y</sub> &gt; radial vibration <em>a</em><sub>x</sub>. Compared with down milling, the temperature decreased by 22.37 % and 9.30 % in the early stages (I and II, respectively) and increased by 20.00 %, 23.74 %, and 8.47 % in the middle and later stages (III, IV, and V, respectively) for the up milling. Lower cutting forces, vibrations, and tooltip area led to a significant decrease in surface defects at the orifice. However, more defects, including fiber residues and fibers pulling out, were evident on the hole wall surface during up milling. Severe pitting and scratching were observed on the rear surface of the tool, which were absent in down milling. Compared with down/up milling, the proposed hybrid milling strategy effectively enhanced the surface quality and tool life. These findings can contribute to improvements in the helical milling process of CFRP and optimize overall machining performance.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 27-37"},"PeriodicalIF":6.1,"publicationDate":"2024-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142552844","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Research on the construction method of mechanical model for micro-hole drilling based on compression characteristics of contact area 基于接触区压缩特性的微型钻孔机械模型构建方法研究
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-10-08 DOI: 10.1016/j.jmapro.2024.09.102
Kuikui Feng , Jianyu Long , Faping Zhang , Chuan Li , Zhenhe Wu , Mengdi Zhang , Biao Wang
{"title":"Research on the construction method of mechanical model for micro-hole drilling based on compression characteristics of contact area","authors":"Kuikui Feng ,&nbsp;Jianyu Long ,&nbsp;Faping Zhang ,&nbsp;Chuan Li ,&nbsp;Zhenhe Wu ,&nbsp;Mengdi Zhang ,&nbsp;Biao Wang","doi":"10.1016/j.jmapro.2024.09.102","DOIUrl":"10.1016/j.jmapro.2024.09.102","url":null,"abstract":"<div><div>The neglect of the compression deformation of the tool-workpiece contact area in the process of micro-hole drilling leads to the low precision of the mechanical model, which brings great challenges to the accurate characterization of the cutting force. Aiming at the above problems, this paper proposes a construction method of drilling mechanics model based on compression characteristics of contact area, and evaluates the credibility of the model. Firstly, according to the characteristics of the drill tool, the drilling process is decomposed, and the calculation method of cutting force of cutting unit is proposed. Then, according to the change rule of cutting force under the action of multi-cutting mechanisms, the influence mechanism of the cutting unit on the elastic deformation of the contact surface is studied, the main parameter affecting cutting force (undeformed chip thickness, UCT) is modified, the judgment criterion of different cutting mechanism is defined, so as to construct the more accurate mechanical prediction model. Finally, the credibility of the original model without considering compression deformation and the modified model with considering compression deformation is evaluated by the maximum entropy spectrum estimation method. The results show that compared with the original model, the credibility of the modified model for predicting axial thrust and torque is increased by 7.1 % and 5.8 %, respectively, which proves the applicability of the proposed method.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1404-1422"},"PeriodicalIF":6.1,"publicationDate":"2024-10-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142423731","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
The scaling of laser peen forming: A two-experiment finite similitude approach 激光喷丸成形的缩放:双实验有限模拟法
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-10-05 DOI: 10.1016/j.jmapro.2024.09.096
Hamed Sadeghi , Jiancheng Jiang , Yongxiang Hu , Yiqiao Song , Keith Davey
{"title":"The scaling of laser peen forming: A two-experiment finite similitude approach","authors":"Hamed Sadeghi ,&nbsp;Jiancheng Jiang ,&nbsp;Yongxiang Hu ,&nbsp;Yiqiao Song ,&nbsp;Keith Davey","doi":"10.1016/j.jmapro.2024.09.096","DOIUrl":"10.1016/j.jmapro.2024.09.096","url":null,"abstract":"<div><div>Laser peen forming (LPF) utilizes laser-induced shock waves to bend and shape metal plates in what is effectively a non-thermal metal-forming process involving no hard tooling. A difficulty with the process, arising from the rapid localized physics involved, is the determination of process conditions for the establishment of desirable process outcomes. The nanosecond physical behaviors induced by the pulsed laser can make simulation impractical, effectively restricting investigations to experiments as the only practical recourse. This paper focuses on the use of scaled experimentation for LPF with the objective of making experimental outcomes more broadly applicable to a wider range of process conditions. Understanding how processes scale can in principle aid in the establishment of process parameters through timely and cost-effective experiments. Scaled experimentation has recently undergone a paradigm shift with the arrival of the <em>finite similitude</em> scaling theory. The theory provides extra degrees of freedom and facilitates the use of unlimited numbers of scaled experiments and allows for anisotropy in plate thickness. It is demonstrated in the work through experimental tests and simulation at two different scales, that geometric and loading similarities can be broken, yet the behavior of LPF can be quantified to good accuracy.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1451-1465"},"PeriodicalIF":6.1,"publicationDate":"2024-10-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142423734","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Thermal features and its effect on the properties of AISI 4140 fabricated by conventional and extreme high-speed laser material deposition 传统和极高速激光材料沉积法制造的 AISI 4140 的热特征及其对其性能的影响
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-10-04 DOI: 10.1016/j.jmapro.2024.09.092
Tianci Li , Dongyun Zhang , Lele Zhang , Thomas Schopphoven , Andres Gasser , Reinhart Poprawe
{"title":"Thermal features and its effect on the properties of AISI 4140 fabricated by conventional and extreme high-speed laser material deposition","authors":"Tianci Li ,&nbsp;Dongyun Zhang ,&nbsp;Lele Zhang ,&nbsp;Thomas Schopphoven ,&nbsp;Andres Gasser ,&nbsp;Reinhart Poprawe","doi":"10.1016/j.jmapro.2024.09.092","DOIUrl":"10.1016/j.jmapro.2024.09.092","url":null,"abstract":"<div><div>The extreme high-speed laser material deposition (EHLA) process has the potential to enable additive manufacturing for mass production by overcoming the limitations of slow scanning speed in conventional laser material deposition (LMD) processes. Thermal features are the key factors to link process and properties. A sound understanding of process-thermal-property relationships is essential for performance control and process optimization of a deposited component. In this study, we studied the thermal characteristics within a single layer and among layers for continuous processing using the numerical method, and reveal the mechanism of microstructure and hardness changes of AISI 4140 material formed by EHLA and LMD processes through the analysis of thermal properties and temperature history results. The grain size and hardness evolution for both processes during single-layer cladding and continuous forming processes were investigated. The results revealed that the grain refinement effect in continuous LMD processing is stronger than that in EHLA process (from 30.0 μm for single layer to 3.2 μm for multi layers vs. from 18.6 μm for single layer to 2.2 μm for multi layers). Similar hardness values were obtained by LMD and EHLA processes, with mean values of 511 HV and 472 HV, respectively. The yield and tensile strengths of EHLA were superior to the conventional cast material, but inferior to those of the conventional material quenched and tempered at lower temperatures. The enhanced tensile results of EHLA process were found similar to those prepared through conventional method with quench and tempering at 600 °C.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1372-1387"},"PeriodicalIF":6.1,"publicationDate":"2024-10-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142423753","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Springback behavior after air bending of pre-strained AA 6016-T4 sheets: Influence of dislocation density and backstress on model accuracy 预应变 AA 6016-T4 板材空气弯曲后的回弹行为:位错密度和背应力对模型精度的影响
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-10-04 DOI: 10.1016/j.jmapro.2024.09.055
Md Zahidul Sarkar , Dane Sargeant , Rishabh Sharma , Marko Knezevic , David T. Fullwood , Michael P. Miles
{"title":"Springback behavior after air bending of pre-strained AA 6016-T4 sheets: Influence of dislocation density and backstress on model accuracy","authors":"Md Zahidul Sarkar ,&nbsp;Dane Sargeant ,&nbsp;Rishabh Sharma ,&nbsp;Marko Knezevic ,&nbsp;David T. Fullwood ,&nbsp;Michael P. Miles","doi":"10.1016/j.jmapro.2024.09.055","DOIUrl":"10.1016/j.jmapro.2024.09.055","url":null,"abstract":"<div><div>Predicting springback in sheets of aluminum alloys is challenging, particularly for complex strain path deformation used to form the material. This paper presents experimental and modeling results for air bending of AA 6016-T4 sheet material. Prior to bending, pre-strains were applied to the specimens in uniaxial tension, plane-strain tension, and biaxial tension. Specimens were then cut from the pre-strained material and were subjected to air bending using three different bend angles in a v-die, after which springback was measured. It was found that greater levels of pre-strain result in larger springback magnitudes, and that the biaxial pre-strained specimens generally exhibited greater springback than the others. A CPFE – EPSC model with phenomenological backstress component in the hardening law was used to predict springback magnitude across the different pre-strain paths, pre-strain levels, and imposed air bend angles. It was observed that the more significant the strain path change, as was seen in the case of biaxial tension pre-strain followed by bending, the greater the influence of backstress on model accuracy, owing to the activation of new slip systems. When backstress was excluded from the model, a 3.2 % prediction error in springback angle was observed in the worst case, versus an error of 0.8 % when backstress was included. Backstress was correlated to more rapid dislocation density development on both the tensile surface of the sheet, and also through the thickness, after the strain path change. On the other hand, for the case of plane-strain pre-strain followed by bending, dislocation density development was more gradual and the backstress impact on model prediction was less significant, with the same slip systems active during both pre-strain and bending. Therefore, it is seen that the influence of backstress on accuracy springback modeling in AA 6016-T4 varies significantly depending on the strain path. Thus, the use of a phenomenological backstress law within the CPFE-EPSC framework is seen to be an accurate and efficient approach for modeling springback after strain path changes that can occur during industrial forming applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1437-1450"},"PeriodicalIF":6.1,"publicationDate":"2024-10-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142423733","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Analysis of fatigue damage of hot rolling work rolls coupled with wear effect 热轧工作辊疲劳损伤与磨损效应耦合分析
IF 6.1 1区 工程技术
Journal of Manufacturing Processes Pub Date : 2024-10-04 DOI: 10.1016/j.jmapro.2024.09.119
Jiapo Wang , Jiaze Chang , Menghao Zhang , Wei Li , Yan Peng
{"title":"Analysis of fatigue damage of hot rolling work rolls coupled with wear effect","authors":"Jiapo Wang ,&nbsp;Jiaze Chang ,&nbsp;Menghao Zhang ,&nbsp;Wei Li ,&nbsp;Yan Peng","doi":"10.1016/j.jmapro.2024.09.119","DOIUrl":"10.1016/j.jmapro.2024.09.119","url":null,"abstract":"<div><div>During the hot rolling process, the work roll experiences cyclic contact stress due to the deformation of the strip steel, as well as thermal stress from periodic heating and cooling. The surface failure of the work roll results from the combined effects of wear and fatigue damage. This study proposes a comprehensive approach to analyzing coupled wear and fatigue damage using a method based on the Manson-Coffin equation, modified slope formula, and the Miner criterion. Finite element models were developed to simulate simplified heat transfer and thermal coupling, taking into account the actual rolling parameters and high-temperature material properties of the work roll. The evolution of the physical field of the work roll during the rolling process was analyzed. The analysis of these models revealed that the maximum strain on the work roll occurred at the rolling exit and was predominantly influenced by temperature. The effects of rolling speed and temperature on work roll strain varied, with fatigue damage being significantly reduced when wear was considered compared to scenarios where wear was not accounted for, under the same number of cycles.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1423-1436"},"PeriodicalIF":6.1,"publicationDate":"2024-10-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142423732","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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