Journal of Manufacturing and Materials Processing最新文献

{"title":"Efficiency and Microstructural Forecasts in Friction Stir Extrusion Compared to Traditional Hot Extrusion of AA6061","authors":"S. Bocchi, Marco Zambelli, G. D’Urso, Claudio Giardini","doi":"10.3390/jmmp8040172","DOIUrl":"https://doi.org/10.3390/jmmp8040172","url":null,"abstract":"Conventional aluminum recycling consumes a substantial amount of energy and has a negative impact on secondary alloys. To address this challenging topic, Friction Stir Extrusion has been patented, which represents an innovative solid-state recycling technique that enables the direct extrusion of components from recyclable materials. In recent years, developing simulation models for Friction Stir Extrusion has become essential for gaining a deeper understanding of its underlying physics. Simultaneously, control of the microstructure evolution of extruded profiles is required, as it has a considerable influence on mechanical properties. This research involves a single Lagrangian model, adapted for both the FSE and the traditional hot extrusion processes. The simulations explored various rotational speeds and feed rates, revealing significant effects on grain size and bonding quality. To this model were applied different sub-routines, to investigate the impact of the FSE process with respect to the traditional hot extrusion process in terms of energy demands, quality and microstructure of the extruded pieces. The findings demonstrated that optimal grain refinement occurs at intermediate rotational speeds (600–800 rpm) combined with lower feed rates (1 mm/s). The energy analyses indicated that FSE requires lower total energy compared to traditional hot extrusion, primarily due to the reduced axial thrust and more efficient thermal management. As a result, it was possible to ensure the ability of the developed simulative model to be fully adapted for both processes and to forecast the microstructural changes directly during the process and not only at the end of the extrusion. The study concludes that FSE is a highly efficient method for producing high-quality extruded rods, with the developed simulation model providing valuable insights for process optimization. The model’s adaptability to various starting materials and conditions highlights its potential for broader applications in extrusion technology.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.3,"publicationDate":"2024-08-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141924081","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A New Grinding Wheel Design with a 3D Internal Cooling Structure System","authors":"S. Costa, Paulina Capela, Maria S. Souza, José R. Gomes, L. Carvalho, Mário Pereira, Delfim Soares","doi":"10.3390/jmmp8040159","DOIUrl":"https://doi.org/10.3390/jmmp8040159","url":null,"abstract":"This work discusses challenges in conventional grinding wheels: heat-induced tool wear and workpiece thermal damage. While textured abrasive wheels improve heat dissipation, the current surface-only methods, such as those based on laser and machining, have high renewal costs. The proposed manufacturing technology introduces an innovative 3D cooling channel structure throughout the wheel, enabling various channel geometries for specific abrasive wheel applications. The production steps were designed to accommodate the conventional pressing and sintering phases. During pressing, a 3D organic structure was included in the green body. A drying cycle eliminated all present fluids, and a sintering one burnt away the structure, revealing channels in the final product. Key parameters, such as binder type/content and heating rate, were optimized for reproducibility and scalability. Wear tests showed a huge efficiency increase (>100%) in performance and durability compared of this system to conventional wheels. Hexagonal channel structures decreased the wear rates by 64%, displaying superior wear resistance. Comprehensive CFD simulations evaluated the coolant flow through the cooling channels. This new design methodology for three-dimensionally structured grinding wheels innovates the operation configuration by delivering the coolant directly where it is needed. It allows for increasing the overall efficiency by optimizing cooling, reducing tool wear, and enhancing manufacturing precision. This 3D channel structure eliminates the need for reconditioning, thus lowering the operation costs.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.3,"publicationDate":"2024-07-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141800087","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Holistic Framework for the Implementation and Validation of PBF-LB/M with Risk Management for Individual Products through Predictive Process Stability","authors":"Hajo Groneberg, Sven Oberdiek, Carolin Schulz, Andreas Hofmann, Alexander Schloske, Frank Doepper","doi":"10.3390/jmmp8040158","DOIUrl":"https://doi.org/10.3390/jmmp8040158","url":null,"abstract":"The additive manufacturing technology powder bed fusion of metal with a laser beam (PBF-LB/M) is industrially established for tool-free production of complex and individualized components and products. While the in-processing is based on a layer-by-layer build-up of material, both upstream and downstream process steps (pre-processing and post-processing) are necessary for demand-oriented production. However, there are increasing concerns in the industry about the efficient and economical implementation and validation of the PBF-LB/M. Individual products for mass personalization pose a particular challenge, as they are subject to sophisticated risk management, especially in highly regulated sectors such as medical technology. Additive manufacturing using PBF-LB/M is a suitable technology but a complex one to master in this environment. A structured system for holistic decision-making concerning technical and economic feasibility, as well as quality and risk-oriented process management, is currently not available. In the context of this research, a framework is proposed that demonstrates the essential steps for the systematic implementation and validation of PBF-LB/M in two structured phases. The intention is to make process-related key performance indicators such as part accuracy, surface finish, mechanical properties, and production efficiency controllable and ensure reliable product manufacturing. The framework is then visualized and evaluated using a practice-oriented case study environment.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.3,"publicationDate":"2024-07-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141802620","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Material Parameter Identification for a Stress-State-Dependent Ductile Damage and Failure Model Applied to Clinch Joining","authors":"J. Friedlein, M. Böhnke, Malte Schlichter, M. Bobbert, Gerson Meschut, J. Mergheim, Paul Steinmann","doi":"10.3390/jmmp8040157","DOIUrl":"https://doi.org/10.3390/jmmp8040157","url":null,"abstract":"Similar to bulk metal forming, clinch joining is characterised by large plastic deformations and a variety of different 3D stress states, including severe compression. However, inherent to plastic forming is the nucleation and growth of defects, whose detrimental effects on the material behaviour can be described by continuum damage models and eventually lead to material failure. As the damage evolution strongly depends on the stress state, a stress-state-dependent model is utilised to correctly track the accumulation. To formulate and parameterise this model, besides classical experiments, so-called modified punch tests are also integrated herein to enhance the calibration of the failure model by capturing a larger range of stress states and metal-forming-specific loading conditions. Moreover, when highly ductile materials are considered, such as the dual-phase steel HCT590X and the aluminium alloy EN AW-6014 T4 investigated here, strong necking and localisation might occur prior to fracture. This can alter the stress state and affect the actual strain at failure. This influence is captured by coupling plasticity and damage to incorporate the damage-induced softening effect. Its relative importance is shown by conducting inverse parameter identifications to determine damage and failure parameters for both mentioned ductile metals based on up to 12 different experiments.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.3,"publicationDate":"2024-07-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141808995","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Evaluation of Material Extrusion Printed PEEK Mold Inserts for Usage in Ceramic Injection Molding","authors":"Thomas Hanemann, Alexander Klein, Heinz Walter, David Wilhelm, Steffen Antusch","doi":"10.3390/jmmp8040156","DOIUrl":"https://doi.org/10.3390/jmmp8040156","url":null,"abstract":"The rapid tooling of mold inserts for injection molding allows for very fast product development, as well as a highly customized design. For this, a combination of rapid prototyping methods with suitable polymer materials, like the high-performance thermoplastic polymer polyetheretherketone (PEEK), should be applied. As a drawback, a huge processing temperature beyond 400 °C is necessary for material extrusion (MEX)-based 3D printing; here, Fused Filament Fabrication (FFF) requires a more sophisticated printing parameter investigation. In this work, suitable MEX printing strategies, covering printing parameters like printing temperature and speed, for the realization of two different mold insert surface geometries were evaluated, and the resulting print quality was inspected. As a proof of concept, ceramic injection molding was used for replication. Under consideration of the two different test structures, the ceramic feedstock could be replicated successfully and to an acceptable quality without significant mold insert deterioration.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.3,"publicationDate":"2024-07-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141808527","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A Study of Drilling Parameter Optimization of Functionally Graded Material Steel–Aluminum Alloy Using 3D Finite Element Analysis","authors":"Ahmed M. Galal, Abdallah. A. Elsherbiny, M. A. Aboueleaz","doi":"10.3390/jmmp8040155","DOIUrl":"https://doi.org/10.3390/jmmp8040155","url":null,"abstract":"Composite materials, such as aluminum alloy FGMs, provide advantageous weight reduction properties compared to homogenous pure structures while still preserving sufficient stiffness for diverse applications. Despite various research on drilling simulation concepts and ideas for these materials, there still needs to be an agreement on the process modeling. Researchers have looked into a lot of different numerical methods, including Lagrangian, Eulerian, arbitrary Lagrangian–Eulerian (ALE), and coupled Eulerian–Lagrangian (CEL), to find solutions to problems like divergence issues and too much mesh distribution, which become more of a problem at higher speeds. This research provides a global analysis of bottom-up meshing for eleven 1 mm layers using ABAQUS® software. It combines the internal surface contact approach with the Lagrangian domain’s kinematic framework. The model uses the Johnson–Cook constitutive equation to precisely predict cutting forces, stress, and strain distributions, optimizing cutting parameters to improve drilling performance. According to Taguchi analysis, the most favorable parameters for reducing cutting force and improving performance are a rotational speed of 700 rpm, a feed rate of 1 mm/s, and a depth of cut of 3 mm. The findings suggest that increasing the feed rate and depth of cut substantially affects the cutting force, while the rotational speed has a comparatively little effect. These ideal settings serve as a foundation for improving FGM drilling efficiency.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.3,"publicationDate":"2024-07-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141812003","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Shape Memory Polymers in 4D Printing: Investigating Multi-Material Lattice Structures","authors":"David Pokras, Yanika Schneider, Sohail H. Zaidi, Vimal K. Viswanathan","doi":"10.3390/jmmp8040154","DOIUrl":"https://doi.org/10.3390/jmmp8040154","url":null,"abstract":"This paper evaluates the design and fabrication of a thermoplastic polyurethane (TPU) shape memory polymer (SMP) using fused deposition modeling (FDM). The commercially available SMP filament was used to create parts capable of changing their shape following the application of an external heat stimulus. The characterization of thermal and viscoelastic properties of the SMP TPU revealed a proportional change in shape fixity and recovery with respect to heating and cooling rates, as well as a decreasing softening temperature with increasing shape memory history due to changes in the polymer microstructure. Inspired by the advancements in 3D and 4D printing, we investigated the feasibility of creating multi-material lattice structures using SMP and another thermoplastic with poor adhesion to TPU. A variety of interlocking lattice structures were evaluated by combining SMP with another thermoplastic that have poor adhesion with TPU. The tensile strength and failure modes of the fabricated multi-material parts were compared against homogenous SMP TPU specimens. It was found that the lattice interface failed first at approximately 41% of the ultimate strength of the homogenous part on average. The maximum recorded ultimate strength of the multi-material specimens reached 62% of SMP TPU’s ultimate strength. These characterizations can make 4D printing technology more accessible to common users and make it available for new markets.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.3,"publicationDate":"2024-07-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141817468","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Property Evaluation of AA2014 Reinforced with Synthesized Novel Mixture Processed through Squeeze Casting Technique","authors":"Venkatraman Manokaran, Anthony Xavior Michael","doi":"10.3390/jmmp8040153","DOIUrl":"https://doi.org/10.3390/jmmp8040153","url":null,"abstract":"Aluminum alloy–graphene metal matrix composite is largely used for structural applications in the aerospace and space exploration sector. In this work, the preprocessed powder particles (AA 2014 and graphene) were used as a reinforcement material in a squeeze casting process. The powder mixture contained aluminum alloy powder 2014 with an average particle size of 25 μm and 0.5 wt% graphene nano powder (Grnp) with 10 nm (average) particle size. The powder mixture was mixed using the high-energy planetary ball milling (HEPBM) technique. The experimental results indicated that the novel mixture (AA 2014 and graphene powder) acted as a transporting agent of graphene particles, allowing them to disperse homogeneously in the stir pool in the final cast, resulting in the production of an isotropic composite material that could be considered for launch vehicle structural applications. Homogeneous dispersion of the graphene nanoparticles enhanced the interfacial bonding of 2014 matrix material, which resulted in particulate strengthening and the formation of a fine-grained microstructure in the casted composite plate. The mechanical properties of 0.5 wt% graphene-reinforced, hot-rolled composite plate was strengthened by the T6 condition. When compared to the values of unreinforced parent alloy, the ultimate tensile strength and the hardness value of the composite plate were found to be 420 MPa and 123 HRB, respectively.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.3,"publicationDate":"2024-07-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141826067","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Experimental and FEA Simulations Using ANSYS on the Mechanical Properties of Laminated Object Manufacturing (LOM) 3D-Printed Woven Jute Fiber-Reinforced PLA Laminates","authors":"Sazidur Shahriar, Lai Jiang, Jaejong Park, Md Shariful Islam, Bryan Perez, Xiaobo Peng","doi":"10.3390/jmmp8040152","DOIUrl":"https://doi.org/10.3390/jmmp8040152","url":null,"abstract":"The mechanical properties of woven jute fiber-reinforced PLA polymer laminates additively manufactured through Laminated Object Manufacturing (LOM) technology are simulated using the finite element method in this work. Woven jute fiber reinforcements are used to strengthen bio-thermoplastic PLA polymers in creating highly biodegradable composite structures that can serve as one of the environmentally friendly alternatives for synthetic composites. A LOM 3D printer prototype was designed and built by the authors. All woven jute/PLA biocomposite laminated specimens made using the built prototype in this study had their tensile and flexural properties measured using ASTM test standards. These laminated structures were modeled using the ANSYS Mechanical Composite PrepPost (ACP) module, and then both testing processes were simulated using the experimentally measured input values. The FEA simulation results indicated a close match with experimental results, with a maximum difference of 9.18%. This study served as an exemplary case study using the FEA method to predict the mechanical behaviors of biocomposite laminate materials made through a novel manufacturing process.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.3,"publicationDate":"2024-07-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141828697","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Investigation of Metal Powder Blending for PBF-LB/M Using Particle Tracing with Ti-6Al-4V","authors":"Ina Ludwig, Anatol Gerassimenko, Phillip Imgrund","doi":"10.3390/jmmp8040151","DOIUrl":"https://doi.org/10.3390/jmmp8040151","url":null,"abstract":"Laser-based powder bed fusion of metals (PBF-LB/M) is the most used additive manufacturing (AM) technology for metal parts. Nevertheless, challenges persist in effectively managing metal powder, particularly in blending methodologies in the choice of blenders as well as in the verification of blend results. In this study, a bespoke laboratory-scale AM blender is developed, tailored to address these challenges, prioritizing low-impact blending to mitigate powder degradation. As a blending type, a V-shape tumbling geometry meeting the requirements for laboratory AM usage is chosen based on a literature assessment. The implementation of thermal oxidation as a powder marking technique enables particle tracing. Blending validation is achieved using light microscopy for area measurement based on binary image processing. The powder size and shape remain unaffected after marking and blending. Only a small narrowing of the particle size distribution is detected after 180 min of blending. The V-shape tumbling blender efficiently yields a completely random state in under 10 min for rotational speeds of 20, 40, and 60 rounds per minute. In conclusion, this research underscores the critical role of blender selection in AM and advocates for continued exploration to refine powder blending practices, with the aim of advancing the capabilities and competitiveness of AM technologies.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.3,"publicationDate":"2024-07-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141643348","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}