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Multi-sensor in process monitoring for WAAM: Detection of process instability in electrical signals WAAM 过程监控中的多传感器：检测电信号中的过程不稳定性
Materials Research Proceedings Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-42
Sarra Oueslati
{"title":"Multi-sensor in process monitoring for WAAM: Detection of process instability in electrical signals","authors":"Sarra Oueslati","doi":"10.21741/9781644903131-42","DOIUrl":"https://doi.org/10.21741/9781644903131-42","url":null,"abstract":"Abstract. Wire Arc Additive Manufacturing (WAAM) is a promising process for producing medium to large scale metallic parts at a low cost and with a high deposition rate. However, the multitude of process parameters and physical phenomena involved makes it complex and hard to master. Therefore, monitoring the process becomes crucial for unraveling complexities and attaining a more profound comprehension of the intricacies inherent in WAAM, hence ensuring process stability. In order to produce a defect-free part, while keeping a stable process, the operating parameters must be carefully selected. Nonetheless, one of the significant hurdles in WAAM is the variability of the deposited layers height. The accumulation of these geometrical inaccuracies induces instabilities in the process which results into the appearing of defects on the deposited part. The aim of this study is to investigate the correlations between process instabilities and electrical signals obtained by a deposition monitoring system. A monitoring criterion is then extracted from experimental data. Correlation with instabilities will be confirmed using a thermal camera.","PeriodicalId":515987,"journal":{"name":"Materials Research Proceedings","volume":"15 8","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140974061","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}
引用次数: 0
Forming of thermoplastic polymer and magnesium alloy-based fiber metal laminates at elevated temperatures 在高温下成型热塑性聚合物和镁合金纤维金属层压板
Materials Research Proceedings Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-54
Z. Liu
{"title":"Forming of thermoplastic polymer and magnesium alloy-based fiber metal laminates at elevated temperatures","authors":"Z. Liu","doi":"10.21741/9781644903131-54","DOIUrl":"https://doi.org/10.21741/9781644903131-54","url":null,"abstract":"Abstract. This paper illustrates the thermoforming process carried out on thermoplastic polymer and magnesium-based fiber metal laminates (FMLs). Flat laminates were formed at elevated temperatures into a hat-shape part. The forming force was acquired and, after forming, the thickness of each constituent of the FMLs in different zones was measured. A non-uniform thickness distribution was found in the formed parts, with a significant reduction of the prepreg thickness at the part bottom radii. Moreover, it was observed that the higher the blank-holder force the higher the forming force and the more significant the prepreg thickness variation.","PeriodicalId":515987,"journal":{"name":"Materials Research Proceedings","volume":"2 7","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140974553","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}
引用次数: 0
Mesh sensitivity study in the random cellular automata finite element model of dynamic recrystallization 动态再结晶随机蜂窝自动机有限元模型的网格敏感性研究
Materials Research Proceedings Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-250
M. Sitko
{"title":"Mesh sensitivity study in the random cellular automata finite element model of dynamic recrystallization","authors":"M. Sitko","doi":"10.21741/9781644903131-250","DOIUrl":"https://doi.org/10.21741/9781644903131-250","url":null,"abstract":"Abstract. Predicting microstructure morphology evolution under hot forming conditions and determining final material properties are essential for optimizing metal-forming processes. Cellular Automata (CA) is a widely employed full-field method for modeling microstructure morphology changes during various metal-forming processes. However, at higher temperatures and under conditions of substantial microstructure evolution, the CA method encounters limitations related to computational domain geometry changes. The use of random cellular automata (RCA) offers a more realistic representation of this phenomenon, although it requires additional effort in algorithm optimization for acceptable execution times. This paper contributes to an overarching research effort focused on developing a discontinuous dynamic recrystallization model (DRX) by directly incorporating RCA into the finite element (FE) framework. Different mesh sizes and their impact on the quality of the results are analyzed, and the minimum number of elements that do not degrade the results in the CA model are selected. The investigation aims to enhance the practicality of the proposed model, striking a balance between realistic microstructure representation and computational efficiency.","PeriodicalId":515987,"journal":{"name":"Materials Research Proceedings","volume":"138 6","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140977013","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}
引用次数: 0
Electrically-assisted forming of 5754 aluminium alloy under different strain conditions 不同应变条件下 5754 铝合金的电辅助成形
Materials Research Proceedings Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-156
D. Dobras
{"title":"Electrically-assisted forming of 5754 aluminium alloy under different strain conditions","authors":"D. Dobras","doi":"10.21741/9781644903131-156","DOIUrl":"https://doi.org/10.21741/9781644903131-156","url":null,"abstract":"Abstract. Electricity-assisted forming processes can significantly improve material ductility and process efficiency. However, further research into different strain conditions is necessary, for example, in stamping processes. In this study, tensile and deep drawing tests of the 5754 aluminium alloy were carried out with the application of current pulses on a specially constructed experimental setup. The study showed that it is possible to increase the plasticity of the material. The main cause responsible for the increase in plasticity was dynamic recovery.","PeriodicalId":515987,"journal":{"name":"Materials Research Proceedings","volume":"19 4","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140976033","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}
引用次数: 0
Fast prediction of the material displacement in open die forging using neural networks 利用神经网络快速预测开模锻造中的材料位移
Materials Research Proceedings Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-253
Nikhil Vijay Jagtap
{"title":"Fast prediction of the material displacement in open die forging using neural networks","authors":"Nikhil Vijay Jagtap","doi":"10.21741/9781644903131-253","DOIUrl":"https://doi.org/10.21741/9781644903131-253","url":null,"abstract":"Abstract. This paper presents a data-driven approach to predict the material displacement in open die forging using neural networks. Training data for different process parameters and workpiece geometries is generated using finite element simulations. A neural network architecture is designed that takes the process parameters and the coordinates of a point in the geometry as inputs and outputs the displacement of that point after the deformation. This is systematically implemented for open die forging, using relevant process information. The neural network model is trained and tested on various FEA-simulations for different process parameters and shows good accuracy and generalization. The model is also able to simulate multiple strokes of a single pass in a fast and efficient way. It is demonstrated how the neural network model can enable building a digital material shadow of open die forging processes. The advantages and limitations of the approach are then further discussed.","PeriodicalId":515987,"journal":{"name":"Materials Research Proceedings","volume":"142 29","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140976459","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}
引用次数: 0
Effectiveness of machining equipment user guides: A comparative study of augmented reality and traditional media 加工设备用户指南的有效性：增强现实与传统媒体的比较研究
Materials Research Proceedings Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-255
Mina Ghobrial
{"title":"Effectiveness of machining equipment user guides: A comparative study of augmented reality and traditional media","authors":"Mina Ghobrial","doi":"10.21741/9781644903131-255","DOIUrl":"https://doi.org/10.21741/9781644903131-255","url":null,"abstract":"Abstract. In the rapidly evolving landscape of manufacturing and material forming, innovative strategies are imperative for maintaining a competitive edge. Augmented Reality (AR) has emerged as a groundbreaking technology, offering new dimensions in how information is displayed and interacted with. It holds particular promise in the panel of instructional guides for complex machinery, potentially enhance traditional methods of knowledge transfer and operator training. Material forming, a key discipline within mechanical engineering, requires high-precision and skill, making it an ideal candidate for the integration of advanced instructional technologies like AR. This study aims to explore the efficiency of three distinct types of user manuals—video, paper, and augmented reality (AR)—on performance and acceptability in a material forming workshop environment. The focus will be on how AR can be specifically applied to improve task execution and understanding in material forming operations. Participants are mechanical engineering students specializing in material forming. They will engage in a series of standardized tasks related to machining processes. Performance will be gauged by metrics like task completion time and error rates, while task load will be assessed via the NASA Task Load Index (NASA-TLX) [1]. Acceptability of each manual type will be evaluated using the System Usability Scale (SUS) [2]. By comparing these various instructional formats, this research seeks to shed light on the most effective mediums for enhancing both operator performance and experience.","PeriodicalId":515987,"journal":{"name":"Materials Research Proceedings","volume":"59 12","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140973583","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}
引用次数: 0
An innovative method to model run-out phenomena in micro-milling by using cutting force signal 利用切削力信号模拟微铣削跳动现象的创新方法
Materials Research Proceedings Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-207
Greta Seneci
{"title":"An innovative method to model run-out phenomena in micro-milling by using cutting force signal","authors":"Greta Seneci","doi":"10.21741/9781644903131-207","DOIUrl":"https://doi.org/10.21741/9781644903131-207","url":null,"abstract":"Abstract. This work deals with the modeling of micro-milling processes by considering the phenomena generated by the transition from conventional size to the micro-scale machining. The concomitant effects of different cutting regimes, and the deviation of the cutting edges from their theoretical trajectories due to tool run-out, are important aspects to be considered during the process modeling. Several models are available in literature to describe how ploughing and shearing regimes influence cutting forces and how the tool run-out impacts on the actual chip thickness. In a previous authors research, a comprehensive model was published achieving a good agreement with the experimental data, but its calibration requires the measurement of the width of the micro-milled slots. This practice is time consuming and subjected to experimental errors, while a calibration of the model based only on the elaboration of the cutting force signal appears a promising strategy. Starting from the mathematical description of the geometrical model, a new equation to compute the tool run-out parameters was found. The parameters depend on eight variables that must be calculated from tool geometry, material composition, cutting parameters and the cutting force signal. An experimental procedure was developed to compare the prediction achieved by the new method and the conventional technique.","PeriodicalId":515987,"journal":{"name":"Materials Research Proceedings","volume":"7 8","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140974434","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}
引用次数: 0
A solid-beam approach for mesoscopic analysis of textile reinforcements forming simulation 用于纺织品加固成型模拟介观分析的固体梁方法
Materials Research Proceedings Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-50
Baptiste Lacroix
{"title":"A solid-beam approach for mesoscopic analysis of textile reinforcements forming simulation","authors":"Baptiste Lacroix","doi":"10.21741/9781644903131-50","DOIUrl":"https://doi.org/10.21741/9781644903131-50","url":null,"abstract":"Abstract. Draping and forming of textile reinforcements are usually performed thanks to finite element models with continuous media assumption. The specific purpose of mesoscale model is to faithfully reproduces defects like yarn buckling or gapping during the process. Such defects are crucial outputs because they have huge impacts on mechanical and permeability properties of the whole textile. However, mesoscopic analysis usually leads to expensive computation cost and needs to be optimized to propose a cost-effective response to this problem. Thus, this document aims to develop a solid-beam approach for mesoscale model, with coarse geometric assumption but with finite element and constitutive law formulation taking into account the fibrous aspect of the fabric.","PeriodicalId":515987,"journal":{"name":"Materials Research Proceedings","volume":"16 4","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140974885","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}
引用次数: 0
Design of an experimental simulator of void closure during hot rolling process 设计热轧过程中空隙闭合的实验模拟器
Materials Research Proceedings Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-91
A. Gopakumar
{"title":"Design of an experimental simulator of void closure during hot rolling process","authors":"A. Gopakumar","doi":"10.21741/9781644903131-91","DOIUrl":"https://doi.org/10.21741/9781644903131-91","url":null,"abstract":"Abstract. The shrinkage porosities produced during the casting of steel blooms has to be fixed by the subsequent hot rolling process. To design the rolling route, finite element simulations integrating void closure models are necessary. However, these models have to be validated by experimental results. Because experiments under industrial conditions are hardly achievable, experimental simulations at lower scale can be considered. However, the experiment must be designed so as to reproduce industrial like conditions concerning the thermomechanical loading and microstructure with respect to void closure. Among the main parameters driving void closure are the equivalent plastic strain and the mean triaxiality. This paper is dedicated to the design of an experimental simulator of void closure during hot rolling. The simulator consists of several strokes performed on a sample containing a real shrinkage porosity, between shaped anvils and with alternations of the forming direction.","PeriodicalId":515987,"journal":{"name":"Materials Research Proceedings","volume":"139 14","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140976458","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}
引用次数: 0
Thermomechanical reverse flow forming of AISI 304L AISI 304L 的热机械反向流动成形
Materials Research Proceedings Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-151
B. Arian
{"title":"Thermomechanical reverse flow forming of AISI 304L","authors":"B. Arian","doi":"10.21741/9781644903131-151","DOIUrl":"https://doi.org/10.21741/9781644903131-151","url":null,"abstract":"Abstract. In manufacturing, property control ensures efficient part production. However, in reverse flow forming, current practices focus on geometry control rather than property control. To address the complexity of the process and tool machine interaction, process control is crucial for defined component properties. This study focuses on controlling local α’ martensite content in reverse flow forming of seamless AISI 304L steel tubes. Strategies and systems are presented to influence α’ martensite content, creating unique microstructure profiles for 1D and 2D Gradings, with tangible component outcomes.","PeriodicalId":515987,"journal":{"name":"Materials Research Proceedings","volume":"41 5","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140973398","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}
引用次数: 0
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