Advances in Industrial and Manufacturing Engineering最新文献

{"title":"Numerical analysis of the dependence of damage on friction during deep drawing of asymmetric geometries","authors":"Martina Müller ,&nbsp;Lars Uhlmann ,&nbsp;Tim Herrig ,&nbsp;Thomas Bergs","doi":"10.1016/j.aime.2024.100136","DOIUrl":"10.1016/j.aime.2024.100136","url":null,"abstract":"<div><p>The manufacturing of three-dimensional sheet metal components, such as car body parts, heavily relies on deep drawing. With the increasing demand for lightweight measures in the automotive industry due to CO₂ limitation requirements, various methods are currently employed to reduce the weight of deep drawn components. However, these methods often overlook the potential for influencing the stress-strain dependent damage state within the component, even though it can greatly affect its performance in subsequent applications, and thus offers lightweight potentials. Friction between the deep drawing tools and the sheet metal is a key factor influencing the stress-strain state, and hence, represents a lever that can be utilized to manipulate the damage state in the component. This paper focuses on the numerical analysis of the dependence of damage on friction during deep drawing. Therefore, a rectangular geometry with an asymmetrical material flow is numerically investigated. A friction ratio is introduced with different constant friction coefficients for the corner of the tools and the straight sides. The established load paths at a chosen reference point are then considered in the form of selected stress and strain characteristics and the numerically predicted damage state is compared. The results are used to derive a recommended friction ratio that leads to less damage in the corner of the geometry. Afterwards strip drawing tool surfaces are modified to manipulate their friction properties using machine hammer peening. Subsequently, the influence of the structures of the strip drawing tool surfaces is quantified using strip drawing tests. The identified contact normal stress dependent friction coefficients are then implemented in the numerical simulation and the established numerical predicted damage state is examined to gain a more comprehensive understanding of how the friction ratio and the structure of the tool surfaces influence the damage state.</p></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"8 ","pages":"Article 100136"},"PeriodicalIF":0.0,"publicationDate":"2024-01-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S2666912924000011/pdfft?md5=1d07bc30d93fc2aabad1e7c24620e132&pid=1-s2.0-S2666912924000011-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139454335","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A gear grinding allowance stochastic simulation model","authors":"Natalia Lishchenko ,&nbsp;Vasily Larshin ,&nbsp;Garret O'Donnell","doi":"10.1016/j.aime.2023.100135","DOIUrl":"https://doi.org/10.1016/j.aime.2023.100135","url":null,"abstract":"<div><p>The paper proposes a method and technique that allow, using a minimum sample (3 units) from a batch (30 units) of real gears, to obtain stochastic information about the actual distribution of the gear grinding allowance both on the left and right flanks of the gear gaps for all gears in the batch. The proposed gear grinding allowance stochastic model is based on the representation of the distribution of the gear grinding allowance along the gear periphery as a superposition of a sinusoidal component with a random amplitude and a random component of the white noise type. The conditions for the equivalence of the stochastic characteristics of real (measured) and virtual (not actually measured) gears are formulated, namely the ratio between the amplitude of the sinusoidal component and the average amplitude of the high-frequency harmonic components of the gear grinding allowance distribution along the gear periphery. The gear grinding allowance stochastic model adjusted according to the proposed method makes it possible to predict the distribution of the gear grinding allowance on the left and right flanks of the gear gaps for a batch of gears and, taking into account the information obtained (replacing the experimental data), both evaluate the existing technology and optimize the gear grinding allowance value. As a result, it becomes possible to assess the quality of the technological process of manufacturing the gear, taking into account the effect random deformations to gear grinding allowance at the stage of their heat treatment (hardening), which is performed before the gear grinding operation. In turn, optimization of the grinding allowance (based on its actual distribution along the periphery of the gear) makes it possible to reduce both defects in burns (with increased allowance) and defects in unground teeth (with insufficient allowance).</p></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"8 ","pages":"Article 100135"},"PeriodicalIF":0.0,"publicationDate":"2023-12-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S2666912923000247/pdfft?md5=a8f1beddc03f66f0213b633fa4339783&pid=1-s2.0-S2666912923000247-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"138550218","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Integration of a void healing criterion in multi-scale modeling of hot rolling","authors":"Dorothea Czempas ,&nbsp;Conrad Liebsch ,&nbsp;Gerhard Hirt","doi":"10.1016/j.aime.2023.100134","DOIUrl":"https://doi.org/10.1016/j.aime.2023.100134","url":null,"abstract":"<div><p>After closure, voids need to be healed through bonding and interface dissolution to restore the mechanical properties and produce a sound product. For the prediction of void healing and the respective process optimization, a void healing criterion, spanning all three phases is needed. While hot rolling is generally suited for void healing, with large deformations at hydrostatic pressure as well as high temperatures, not all regions in the workpiece offer the same void healing conditions. Due to gradients of these metrics e. g. along the normal direction, a space-resolved approach is needed. Previously, a practical void healing criterion combining void closure and subsequent recrystallization has been proposed and applied to exemplary hot rolling processes. Besides a broader application of the criterion, adding the process parameters roll diameter and temperature, the present paper mainly aims for the experimental validation of this criterion. In bonding trials, a positive influence of temperature and strain on the bond strength has been found. While no clear correlation of the holding time on the bond strength was detectible without concurrent contact pressure the experiments suggested a saturation strain as an indicator for void healing instead. Accordingly, the criterion has been revised and a strain-based criterion proposed, applied, and compared to the previously introduced recrystallization-based void healing criterion.</p></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"8 ","pages":"Article 100134"},"PeriodicalIF":0.0,"publicationDate":"2023-11-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S2666912923000235/pdfft?md5=2534afacef496be7ae07740212111f6d&pid=1-s2.0-S2666912923000235-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"138475251","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Monitoring the evolution of dimensional accuracy and product properties in property-controlled forming processes","authors":"Sophie Charlotte Stebner ,&nbsp;Juri Martschin ,&nbsp;Bahman Arian ,&nbsp;Stefan Dietrich ,&nbsp;Martin Feistle ,&nbsp;Sebastian Hütter ,&nbsp;Rémi Lafarge ,&nbsp;Robert Laue ,&nbsp;Xinyang Li ,&nbsp;Christopher Schulte ,&nbsp;Daniel Spies ,&nbsp;Ferdinand Thein ,&nbsp;Frank Wendler ,&nbsp;Malte Wrobel ,&nbsp;Julian Rozo Vasquez ,&nbsp;Michael Dölz ,&nbsp;Sebastian Münstermann","doi":"10.1016/j.aime.2023.100133","DOIUrl":"10.1016/j.aime.2023.100133","url":null,"abstract":"<div><p>As recent trends in manufacturing engineering disciplines show a clear development in the sustainable as well as economically efficient design of forming processes, monitoring techniques have been gaining in relevance. In terms of monitoring of product properties, most processes are currently open-loop controlled, entailing that the microstructure evolution, which determines the final product properties, is not considered. However, a closed-loop control that can adjust and manipulate the process actuators according to the required product properties of the component will lead to a considerable increase in efficiency of the processes regarding resources and will decrease postproduction of the component. For most forming processes, one set of component dimensions will result in a certain set of product properties. However, to successfully establish closed-loop property controls for the processes, a systematic understanding of the reciprocity of the dimensions after forming and final product properties must be established. This work investigates the evolution of dimensional accuracy as well as product properties for a series of forming processes that utilize different degrees of freedom for process control.</p></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"8 ","pages":"Article 100133"},"PeriodicalIF":0.0,"publicationDate":"2023-11-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S2666912923000223/pdfft?md5=357d157fd36e1be8e4f6d4b888800fd0&pid=1-s2.0-S2666912923000223-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135671180","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Lateness in production systems - In a nutshell: How to determine the causes of lateness at work systems?","authors":"Alexander Mütze,&nbsp;Tobias Hiller,&nbsp;Peter Nyhuis","doi":"10.1016/j.aime.2023.100132","DOIUrl":"10.1016/j.aime.2023.100132","url":null,"abstract":"<div><p>Adherence to customer due dates is the yardstick for the performance of manufacturing companies. In the era of same-day delivery, consumers expect reliable delivery of ordered goods and short delivery times. Also, in the field of business-to-business supply, it is evident that adherence to delivery dates is a fundamental logistical objective for companies. Contract manufacturers, in particular, are confronted with significant challenges: strong fluctuations in customer demand, shorter requested delivery times, and high competitive pressure require appropriate organisation, planning and control of production. However, companies often miss their schedule reliability targets and fail to identify the right causes for these failures. This raises the question of what factors influence the failure to meet schedule reliability targets, how to identify such factors, and what options are available to counteract them. This contribution addresses this issue and focuses on ways to analyse the emerging lateness at work systems in production areas as a deviation of the actual form the planned throughput time. We present existing approaches to analysing the lateness behaviour at work systems and extend the current theory of logistical modelling to determine the three drivers of the so-called relative lateness – planning influences, variance of work-in-process (WIP) and sequence deviations – at work systems systematically. Through this analysis, we enable the practical applicator to initiate target-oriented countermeasures to improve the schedule reliability of their work systems with acceptable analysis expenditure.</p></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"8 ","pages":"Article 100132"},"PeriodicalIF":0.0,"publicationDate":"2023-11-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S2666912923000211/pdfft?md5=922e597f1cedb5793cce759943d95376&pid=1-s2.0-S2666912923000211-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135510683","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Grinding EB-PBF based additive manufactured Ti6Al4V: A surface integrity study","authors":"C.S. Rakurty ,&nbsp;Manigandan K ,&nbsp;Blake Bowser ,&nbsp;Nithin Rangasamy ,&nbsp;Satya Kakaraparthi ,&nbsp;Ryan Dippolito ,&nbsp;Riley Myers","doi":"10.1016/j.aime.2023.100131","DOIUrl":"https://doi.org/10.1016/j.aime.2023.100131","url":null,"abstract":"<div><p>Grinding is a finishing process typically done in most metallic manufacturing centers, primarily to achieve precision and surface improvement. Currently, the grinding process of titanium alloys generally requires flood coolant application. Electron Beam Powder Bed Fusion (EB-PBF) is an additive manufacturing process that uses an electron beam as the heat source to melt and fuse powder particles to build layer by layer to build a three-dimensional component. Grinding is a major secondary process applied to additively manufactured metals, but with the current methodologies, grinding may impart tensile residual stress on the surface, and thus the performance of the material under fatigue conditions is reduced. In this paper, a targeted cutting fluid application approach for grinding an additively manufactured titanium alloy is used to possibly impart a compressive residual stress upon the subsurface while also providing an improved surface roughness. This study uses samples ground with a traditional flood coolant and samples with targeted cutting fluid applications developed by the researchers. Metrics such as surface residual stress, surface roughness, microstructure, and microhardness were used to determine imparted qualities using the various grinding cooling methodologies. The results show that the subsurface maximum principal residual stresses decreased by 108%, the average surface roughness decreased by 33%, and the microhardness at 5 μm increased by 1% using targeted air as the cutting fluid compared to flood cooling while grinding additively manufactured Ti6Al4V. Overall, the targeted grinding cooling fluid application induced compressive subsurface residual stresses and reduced the average surface roughness.</p></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"7 ","pages":"Article 100131"},"PeriodicalIF":0.0,"publicationDate":"2023-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S266691292300020X/pdfft?md5=380c8090a4e205efeb9066ba6bbf48f0&pid=1-s2.0-S266691292300020X-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"91992423","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Low cycle fatigue of components manufactured by rod extrusion: Experiments and modeling","authors":"Kai Langenfeld ,&nbsp;Lars Lingnau ,&nbsp;Jan Gerlach ,&nbsp;Patrick Kurzeja ,&nbsp;Robin Gitschel ,&nbsp;Frank Walther ,&nbsp;Tobias Kaiser ,&nbsp;Till Clausmeyer","doi":"10.1016/j.aime.2023.100130","DOIUrl":"https://doi.org/10.1016/j.aime.2023.100130","url":null,"abstract":"<div><p>The performance of formed components is significantly influenced by the initiation of ductile damage. Preceding forming operations, for instance, affect the service life determined in fatigue tests. In the current investigation, the effect of ductile damage in forming is isolated by changing the shoulder opening angle in forward rod extrusion. Forming-induced ductile damage is then related to measurements of void area fraction, density and Young’s modulus. Subsequent fatigue tests in the low cycle range indicate that the service life of the extruded components can be improved through a reduction of the forming-induced damage. A novel constitutive model considering forming-induced damage and fatigue damage is proposed to account for the observed behavior in axial fatigue tests of extruded components. The non-local ductile damage formulation is formulated in the framework of Generalized Standard Materials. Kinematic and isotropic hardening are considered. Based on earlier work of Lemaitre and Desmorat, the fatigue damage initiation criterion is extended to take the observed mechanical behavior in low cycle axial fatigue tests of formed components into account. The extended model is able to capture the effect of forming-induced damage on the service life.</p></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"7 ","pages":"Article 100130"},"PeriodicalIF":0.0,"publicationDate":"2023-10-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49714983","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":"Damage and fracture in thin metal sheets: New biaxial experiments","authors":"Steffen Gerke ,&nbsp;Fabuer R. Valencia ,&nbsp;Roman Norz ,&nbsp;Wolfram Volk ,&nbsp;Michael Brünig","doi":"10.1016/j.aime.2023.100129","DOIUrl":"https://doi.org/10.1016/j.aime.2023.100129","url":null,"abstract":"<div><p>In the paper new biaxial specimen geometries for thin ductile sheet metals are proposed. The design focuses on the stress-dependent damage and failure behavior. A plastic anisotropic material model based on Hill’s yield criterion and corresponding associated flow rule is presented and the related material parameters are given. Accompanying numerical simulations reveal the stress state and relate the damage mechanisms to the loading condition. The different proposed specimen geometries indicate various effects on the localization of inelastic strains, the material orientation as well as on the damage and fracture processes. During the biaxial tests strain fields in regions of interest are monitored by digital image correlation and after the experiments pictures of the fracture surfaces are taken by scanning electron microscopy and related to the stress dependent damage and failure precesses. The experimental and numerical results demonstrate the high potential of the newly developed biaxially loaded specimens.</p></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"7 ","pages":"Article 100129"},"PeriodicalIF":0.0,"publicationDate":"2023-09-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49714980","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":"Effect of uncertainty of material parameters on stress triaxiality and Lode angle in finite elasto-plasticity—A variance-based global sensitivity analysis","authors":"M. Böddecker ,&nbsp;M.G.R. Faes ,&nbsp;A. Menzel ,&nbsp;M.A. Valdebenito","doi":"10.1016/j.aime.2023.100128","DOIUrl":"https://doi.org/10.1016/j.aime.2023.100128","url":null,"abstract":"<div><p>This work establishes a computational framework for the quantification of the effect of uncertainty of material model parameters on extremal stress triaxiality and Lode angle values in plastically deformed devices, whereby stress triaxiality and Lode angle are accepted as key indicators for damage initiation in metal forming processes. Attention is paid to components, the material response of which can be represented as elasto-plastic with proportional hardening as a prototype model, whereby the finite element method is used as a simulation approach generally suitable for complex geometries and loading conditions. Uncertainty about material parameters is characterized resorting to probability theory. The effects of material parameter uncertainty on stress triaxiality and Lode angle are quantified by means of a variance-based global sensitivity analysis. Such sensitivity analysis is most useful for apportioning the variance of the stress triaxiality and Lode angle to the uncertainty on material properties. The practical implementation of this sensitivity analysis is carried out resorting to a Gaussian process regression, Bayesian probabilistic integration and active learning in order to decrease the associated numerical costs. An example illustrates the proposed framework, revealing that parameters governing plasticity affect stress triaxiality and Lode angle the most.</p></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"7 ","pages":"Article 100128"},"PeriodicalIF":0.0,"publicationDate":"2023-09-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49715313","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 software for research and education in ductile damage","authors":"R.F.V. Sampaio ,&nbsp;N.S.M. Alexandre ,&nbsp;J.P.M. Pragana ,&nbsp;I.M.F. Bragança ,&nbsp;C.M.A. Silva ,&nbsp;P.A.F. Martins","doi":"10.1016/j.aime.2023.100127","DOIUrl":"10.1016/j.aime.2023.100127","url":null,"abstract":"<div><p>This paper gives insight into the development and utilization of a computer software that uses raw experimental data from the load cells and DIC systems to obtain the instant of time at fracture <span><math><mrow><msub><mi>t</mi><mi>f</mi></msub></mrow></math></span>, the loading paths in principal strain space <span><math><mrow><msub><mi>ε</mi><mn>1</mn></msub><mo>=</mo><mi>f</mi><mrow><mo>(</mo><msub><mi>ε</mi><mn>2</mn></msub><mo>)</mo></mrow></mrow></math></span>, and their conversion into the space of effective strain vs. stress triaxiality <span><math><mrow><mover><mi>ε</mi><mo>‾</mo></mover><mo>=</mo><mi>f</mi><mrow><mo>(</mo><mi>η</mi><mo>)</mo></mrow></mrow></math></span>. Special emphasis is given to the different assumptions and stress triaxiality measures that can be used to convert the loading paths from principal strain space into the space of effective strain vs. stress triaxiality. Results for double-action radial extrusion show the differences of treating the loading paths as linear or non-linear from beginning until the onset of failure by fracture. Results also allow concluding on the importance of accounting for the stress triaxiality derived from individual experimental measurements in an average sense over the entire loading paths, to avoid overestimation and mislocation of the fracture forming limits. The applicability of the software for education and training of students in formability is also discussed.</p></div>","PeriodicalId":34573,"journal":{"name":"Advances in Industrial and Manufacturing Engineering","volume":"7 ","pages":"Article 100127"},"PeriodicalIF":0.0,"publicationDate":"2023-08-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"41542993","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}