Fused filament fabrication (FFF) is a material extrusion additive manufacturing (AM) process that works well with thermoplastic polymers and is notably inexpensive compared to other AM processes, leading to its increasing popularity for industrial applications. Finite element analysis (FEA) is used to simulate the thermal histories involved in FFF. In this paper, several simulation cases of increasing complexity are presented, and both a thermocouple and an infrared thermal imaging system are used to validate the simulation results. First, a steady-state case is conducted and simulated to corroborate the two validation tools and to calibrate the thermal emissivity value and conductivity coefficient of the thermoplastic used for testing, in this case, acrylonitrile butadiene styrene (ABS). Next, the thermal camera is tested for its response time by comparing its frame rate to the resulting thermal images. Lastly, MSC Digimat-AM is used to simulate the FFF printing process. It was concluded that infrared thermal imaging is suitable for in-process thermal data collection during FFF printing, but with several limitations, such as low resolution, thermal radiation from the print bed due to the nozzle, and reflections of surroundings off the print bed. Thermocouples can act as aids to calibrate the thermal imaging but affect the cooling rate of the surrounding filament.
{"title":"Validation of a Finite Element Model for Fused Filament Fabrication Additive Manufacturing","authors":"Sarah Clark, T. Yap, M. Tehrani","doi":"10.1115/imece2021-73803","DOIUrl":"https://doi.org/10.1115/imece2021-73803","url":null,"abstract":"\u0000 Fused filament fabrication (FFF) is a material extrusion additive manufacturing (AM) process that works well with thermoplastic polymers and is notably inexpensive compared to other AM processes, leading to its increasing popularity for industrial applications. Finite element analysis (FEA) is used to simulate the thermal histories involved in FFF. In this paper, several simulation cases of increasing complexity are presented, and both a thermocouple and an infrared thermal imaging system are used to validate the simulation results. First, a steady-state case is conducted and simulated to corroborate the two validation tools and to calibrate the thermal emissivity value and conductivity coefficient of the thermoplastic used for testing, in this case, acrylonitrile butadiene styrene (ABS). Next, the thermal camera is tested for its response time by comparing its frame rate to the resulting thermal images. Lastly, MSC Digimat-AM is used to simulate the FFF printing process. It was concluded that infrared thermal imaging is suitable for in-process thermal data collection during FFF printing, but with several limitations, such as low resolution, thermal radiation from the print bed due to the nozzle, and reflections of surroundings off the print bed. Thermocouples can act as aids to calibrate the thermal imaging but affect the cooling rate of the surrounding filament.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"39 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124867997","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}
A. Dubey, Harshal Y. Shahare, A. Pesin, D. Pustovoytov, Hailiang Yu, P. Tandon
Aerospace and automobile industries demand bend sheets with different radii of curvature and in some cases, even the sheets of continuously varying radius of curvature are also required by them. Forming of such parts require a flexible manufacturing process to closely control the radius of the curvature being formed. This work proposes a hybrid forming process that combines asymmetric rolling with incremental bending to form bend sheets with improved mechanical properties. In the proposed hybrid process, thin metal sheets are asymmetrically cold rolled and then bend by a punch placed after the rolling mill, in the direction of sheet flow. The work presents the numerical simulation of the hybrid process and explores the relation between the hammering amplitude and its frequency on the radius of curvature. Besides, the significance of different parameters on the bend sheet being formed is also investigated using analysis of variance (ANOVA). The results show that the velocity ratio and hammering amplitude are the paramount factors in the proposed hybrid process, and these parameters greatly influence the radius of the bend. Simulation results also indicate that the radius of bend can be augmented by decreasing velocity ratio, hammering frequency, and effective amplitude.
{"title":"Numerical Modeling of a Hybrid Asymmetric Rolling and Bending Process","authors":"A. Dubey, Harshal Y. Shahare, A. Pesin, D. Pustovoytov, Hailiang Yu, P. Tandon","doi":"10.1115/imece2021-69553","DOIUrl":"https://doi.org/10.1115/imece2021-69553","url":null,"abstract":"\u0000 Aerospace and automobile industries demand bend sheets with different radii of curvature and in some cases, even the sheets of continuously varying radius of curvature are also required by them. Forming of such parts require a flexible manufacturing process to closely control the radius of the curvature being formed. This work proposes a hybrid forming process that combines asymmetric rolling with incremental bending to form bend sheets with improved mechanical properties. In the proposed hybrid process, thin metal sheets are asymmetrically cold rolled and then bend by a punch placed after the rolling mill, in the direction of sheet flow. The work presents the numerical simulation of the hybrid process and explores the relation between the hammering amplitude and its frequency on the radius of curvature. Besides, the significance of different parameters on the bend sheet being formed is also investigated using analysis of variance (ANOVA). The results show that the velocity ratio and hammering amplitude are the paramount factors in the proposed hybrid process, and these parameters greatly influence the radius of the bend. Simulation results also indicate that the radius of bend can be augmented by decreasing velocity ratio, hammering frequency, and effective amplitude.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"92 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"126190828","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}
The skew rolling is a ideal metal forming technique for producing ball parts of various sizes. In order to analyze the forming mechanism ensuring the highest quality of copper ball during warm skew rolling, in this paper, a new modeling method was used for roller design based on the CREO platform. By using commercial FEM software Simufact 14.0, an FE simulation of warm skew rolling was established to predict the distribution of strain field, stress field, temperature field. meanwhile, the variation of rolling force and torque for copper balls during warm skew rolling were analyzed. Based on numerical simulation results, the deformation characteristics of copper ball during warm skew rolling is clarified. The simulation and experimental results Highly consistent and the copper balls have a high manufacturing quality confirm that the developed FE-simulation is reliable. This study was developed a new modeling method to overcome the difficulties and deficiencies in available finite element modeling process for complicated roller and lays a theoretical foundation for the high-quality copper balls manufacturing during warm skew rolling.
{"title":"Finite Element Analysis of Deformation Characteristics in Warm Skew Rolling of Copper Ball","authors":"J. Yuan, B. Sun, Xing Chen, X. Shu, Houliang Ma","doi":"10.1115/imece2021-70789","DOIUrl":"https://doi.org/10.1115/imece2021-70789","url":null,"abstract":"\u0000 The skew rolling is a ideal metal forming technique for producing ball parts of various sizes. In order to analyze the forming mechanism ensuring the highest quality of copper ball during warm skew rolling, in this paper, a new modeling method was used for roller design based on the CREO platform. By using commercial FEM software Simufact 14.0, an FE simulation of warm skew rolling was established to predict the distribution of strain field, stress field, temperature field. meanwhile, the variation of rolling force and torque for copper balls during warm skew rolling were analyzed. Based on numerical simulation results, the deformation characteristics of copper ball during warm skew rolling is clarified. The simulation and experimental results Highly consistent and the copper balls have a high manufacturing quality confirm that the developed FE-simulation is reliable. This study was developed a new modeling method to overcome the difficulties and deficiencies in available finite element modeling process for complicated roller and lays a theoretical foundation for the high-quality copper balls manufacturing during warm skew rolling.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"117087441","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}
W. J. Emblom, Ayotunde Olayinka, Jared Marcel, Joshua Ferrara, S. Depaula, Maria Fernanda Espinosa-Perez, Scott W. Wagner
Friction stir processing has become a popular method for welding, surface treatment, and more recently for producing extrusions such as tubing and cylinders. Currently, the extrusions produced usually have diameters from 6 to 19 millimeters because they are being produced in tooling that must be placed in conventional CNC mills located within university research settings and thus have limited available power as well as limited ability for plunge forces. The machine described here is purpose built for producing large diameter friction stirred cylinders and tubes that are up to 125mm long and 50mm in diameter. Unlike conventional CNC machines, this machine is designed to accommodate the temperatures generated by the probe rotating against the work piece as well as the higher plunge forces generated by the extrusion processes which can damage the bearings, motor shaft and motor in conventional CNC mills. The need to produce larger friction stir processed parts is important because friction stir processing results in material properties that may be advantageous in parts, may be part of an additive manufacturing process, or may be useful as a preprocessing stage for metal recycling operations which can reduce energy costs and product contamination. The current paper describes Phase 1 of the project. A-1100 aluminum will be the initial material tested and smaller diameters of harder alloys will be used at some future time. The current phase of the project is nearing completion and consists of the development of the machine frame, open-loop AC motor spindle speed controller, tooling and a method for plunging the probe into the work piece. Phase 2 will consist of implementing feedback control along with process monitoring. In this paper the design process will be summarized, including forces and temperatures expected during friction stir extrusion and back extrusion. The evolution of the design will be summarized with emphasis on the final design. The current status of the project is the machine has been designed and the major components have been purchased and have been assembled. The speed controller for the 10 HP AC (7.5 kW) motor, the rotating probe plunge system, tooling mounting system, and machine frame have also been incorporated into the machine. The basic functionality of the machine has been demonstrated but the variable frequency drive that controls the probe rotation failed in early tests and is being replaced.
摩擦搅拌加工已成为一种流行的方法焊接，表面处理，最近生产挤压，如管和气缸。目前，所生产的挤压件直径通常在6到19毫米之间，因为它们是在必须放置在大学研究机构内的传统数控铣床上的工具中生产的，因此可用功率有限，并且具有有限的插入力能力。这里描述的机器是专门为生产长125毫米，直径50毫米的大直径摩擦搅拌筒和管而建造的。与传统的数控机床不同，这台机器的设计是为了适应由探头旋转对工件产生的温度，以及由挤压过程产生的更高的冲击力，这可能会损坏传统数控铣床的轴承、电机轴和电机。生产更大的搅拌摩擦加工零件的需要是重要的，因为搅拌摩擦加工产生的材料性能可能对零件有利，可能是增材制造工艺的一部分，或者可能是金属回收操作的预处理阶段，可以减少能源成本和产品污染。本文描述了该项目的第一阶段。A-1100铝将是最初测试的材料，未来将使用直径较小的较硬合金。该项目的当前阶段已接近完成，包括机架、开环交流电机主轴转速控制器、工具和将探头插入工件的方法的开发。第二阶段将包括实现反馈控制和过程监控。本文将总结设计过程，包括搅拌摩擦挤压和反挤压时的受力和温度。将总结设计的演变，重点是最终的设计。项目目前的状态是机器已经设计完成，主要部件已经采购并组装完成。10 HP AC (7.5 kW)电机的速度控制器，旋转探头插入系统，工具安装系统和机器框架也被纳入机器中。该机器的基本功能已经得到证明，但控制探头旋转的变频驱动器在早期测试中失败，正在更换。
{"title":"The Development of a Machine for Macroscale Friction Stir Processing: A Work in Progress","authors":"W. J. Emblom, Ayotunde Olayinka, Jared Marcel, Joshua Ferrara, S. Depaula, Maria Fernanda Espinosa-Perez, Scott W. Wagner","doi":"10.1115/imece2021-69634","DOIUrl":"https://doi.org/10.1115/imece2021-69634","url":null,"abstract":"\u0000 Friction stir processing has become a popular method for welding, surface treatment, and more recently for producing extrusions such as tubing and cylinders. Currently, the extrusions produced usually have diameters from 6 to 19 millimeters because they are being produced in tooling that must be placed in conventional CNC mills located within university research settings and thus have limited available power as well as limited ability for plunge forces.\u0000 The machine described here is purpose built for producing large diameter friction stirred cylinders and tubes that are up to 125mm long and 50mm in diameter. Unlike conventional CNC machines, this machine is designed to accommodate the temperatures generated by the probe rotating against the work piece as well as the higher plunge forces generated by the extrusion processes which can damage the bearings, motor shaft and motor in conventional CNC mills. The need to produce larger friction stir processed parts is important because friction stir processing results in material properties that may be advantageous in parts, may be part of an additive manufacturing process, or may be useful as a preprocessing stage for metal recycling operations which can reduce energy costs and product contamination.\u0000 The current paper describes Phase 1 of the project. A-1100 aluminum will be the initial material tested and smaller diameters of harder alloys will be used at some future time. The current phase of the project is nearing completion and consists of the development of the machine frame, open-loop AC motor spindle speed controller, tooling and a method for plunging the probe into the work piece. Phase 2 will consist of implementing feedback control along with process monitoring.\u0000 In this paper the design process will be summarized, including forces and temperatures expected during friction stir extrusion and back extrusion. The evolution of the design will be summarized with emphasis on the final design. The current status of the project is the machine has been designed and the major components have been purchased and have been assembled. The speed controller for the 10 HP AC (7.5 kW) motor, the rotating probe plunge system, tooling mounting system, and machine frame have also been incorporated into the machine. The basic functionality of the machine has been demonstrated but the variable frequency drive that controls the probe rotation failed in early tests and is being replaced.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"118 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"127028129","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}
Single point incremental forming is a potential manufacturing process under sheet metal forming which promises various advantages over other manufacturing processes. Single point incremental forming is a die-less manufacturing process. In this process the sheet metal is clamped in the fixture and then a single point, incrementally form each point by sliding the material forward and downward. As at each point the single point is formed, the uniform deformation can be achieved in the whole part and due to which the part can show much higher formability as compared to the conventional forming. The process has these other advantages over conventional forming like complex shapes can be created, and higher flexibility in the process as it depends on the forming program. Enormous research on the subject are available in the literature on formability, process variation, process parameters and their influence, but limited research are available on residual formability on single point incrementally formed parts. The previously published paper in IMECE2019 by the author studied the residual formability of single point incrementally formed part with four cone angles. It was found that the 30 and 45° cone angle did not survive during single point incremental forming but 60 and 90° did. Further 60 and 90° cones were conventionally restrike with spherical dome punch to determine the residual formability, however the 60° cone failed without conforming the dome shape, but 90° deformed to full shape of dome and then fractured. In this paper the aim is to construct the whole section of forming limit point from uniaxial to equal-biaxial deformation mode restrike and measure the forming limits. These points will construct the whole residual forming limit curve of a single point incrementally formed part. For this, the successfully formed part by incremental forming were restrike with hemispherical tool in tensile, plane and biaxial deformation mode and limits were plotted. It was found that the maximum deformation is due to the single point incremental forming and less deformation are left in the part if it would be restrike by the conventional forming method.
{"title":"Residual Formability of Single Point Incrementally Formed Part","authors":"C. Nikhare","doi":"10.1115/imece2021-69895","DOIUrl":"https://doi.org/10.1115/imece2021-69895","url":null,"abstract":"\u0000 Single point incremental forming is a potential manufacturing process under sheet metal forming which promises various advantages over other manufacturing processes. Single point incremental forming is a die-less manufacturing process. In this process the sheet metal is clamped in the fixture and then a single point, incrementally form each point by sliding the material forward and downward. As at each point the single point is formed, the uniform deformation can be achieved in the whole part and due to which the part can show much higher formability as compared to the conventional forming. The process has these other advantages over conventional forming like complex shapes can be created, and higher flexibility in the process as it depends on the forming program. Enormous research on the subject are available in the literature on formability, process variation, process parameters and their influence, but limited research are available on residual formability on single point incrementally formed parts. The previously published paper in IMECE2019 by the author studied the residual formability of single point incrementally formed part with four cone angles. It was found that the 30 and 45° cone angle did not survive during single point incremental forming but 60 and 90° did. Further 60 and 90° cones were conventionally restrike with spherical dome punch to determine the residual formability, however the 60° cone failed without conforming the dome shape, but 90° deformed to full shape of dome and then fractured. In this paper the aim is to construct the whole section of forming limit point from uniaxial to equal-biaxial deformation mode restrike and measure the forming limits. These points will construct the whole residual forming limit curve of a single point incrementally formed part. For this, the successfully formed part by incremental forming were restrike with hemispherical tool in tensile, plane and biaxial deformation mode and limits were plotted. It was found that the maximum deformation is due to the single point incremental forming and less deformation are left in the part if it would be restrike by the conventional forming method.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"70 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124229647","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}
The feasibility of the applications of additively manufactured, i.e., electron beam melted (EBM), titanium parts requires acceptable tribological properties alongside acceptable mechanical and fatigue properties. Investigations on the tribological properties of EBM titanium are very limited. This paper aims to study the erosion behavior of as-built and machined EBM Ti6Al4V at two built orientations, i.e., XZ (0°) and YZ (90°). EBM fabricated Ti6Al4V specimens were subjected to silica particle impingement at 30°, 60°, and 90° angle of attacks. The mass removal was recorded, and volumetric removal was measured using an optical profiler. The erosion scars generated on as-built and machined Ti6Al4V plate were inspected through scanning electron microscopy to study the erosion mechanism at these two built orientations. Experimental results show that the erosion behavior of EBM Ti6Al4V is significantly influenced by built orientation. XZ (0°) plates show more erosion resistance due to better solidification. The erosion mechanism is discussed in detail.
{"title":"Solid Particle Erosion Behavior of Electron Beam Melted (EBM) Ti6Al4V at Different Built Orientation","authors":"Mohammad Sayem Bin Abdullah, A. Alajmi, M. Ramulu","doi":"10.1115/imece2021-71776","DOIUrl":"https://doi.org/10.1115/imece2021-71776","url":null,"abstract":"\u0000 The feasibility of the applications of additively manufactured, i.e., electron beam melted (EBM), titanium parts requires acceptable tribological properties alongside acceptable mechanical and fatigue properties. Investigations on the tribological properties of EBM titanium are very limited. This paper aims to study the erosion behavior of as-built and machined EBM Ti6Al4V at two built orientations, i.e., XZ (0°) and YZ (90°). EBM fabricated Ti6Al4V specimens were subjected to silica particle impingement at 30°, 60°, and 90° angle of attacks. The mass removal was recorded, and volumetric removal was measured using an optical profiler. The erosion scars generated on as-built and machined Ti6Al4V plate were inspected through scanning electron microscopy to study the erosion mechanism at these two built orientations. Experimental results show that the erosion behavior of EBM Ti6Al4V is significantly influenced by built orientation. XZ (0°) plates show more erosion resistance due to better solidification. The erosion mechanism is discussed in detail.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"39 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"127671374","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}
The different additive manufacturing (AM) technologies are showing a higher flexibility and process capabilities over the years, these technologies are not limited to produce a prototype only, but also to produce a valuable and cost-effective large near net parts. The Wire Arc Additive Manufacturing (WAAM) technique is regarded as one of the most important technologies for producing a metallic component. As it becomes one of the most interesting technology in the industrial sector, it can provide an unlimited printing size based on the used mechanism range. In this study, different microstructure deformation-based post processing methods have been discussed, some of them could be performed in-process (during) or even post-process (after) the WAAM technique. This study will focus more on the rolling deformation method comparing with the other post-processing techniques. Rolling process is observed as a good choice for post processing that can be used to improve the material microstructure features. Moreover, the parameters such as roller radius, applied load, the WAAM torch angle and the distance between the pressing side of the roller and the welding point show controlling influence on the internal grain features and on the surface waviness. surface roughness is termed as one of the main problems on the produce parts using WAAM technology. This study discussed different ways by which the internal residual stresses can be reduced, and mechanical properties of fabricated parts can be improved. Some studies revealed that hot forging can be used as a post processing technique after the WAAM process. Utilization of hot forging after the WAAM process shows an immediate positive effect on the produced sample by improving both of yield and ultimate strengths of the part. Furthermore, some other studies show that the forging significantly reduce the porosity due to the applied hot forging, as it is showing a higher effect with increasing the hammering force and vice versa. Also, some studies utilized rolling process as a post processing technique. So, the current study compared hot forging with the results extracted from the rolling deformation. This study aims to review the post processing techniques such as rolling process and hot forging process. The study provides understanding about the selection of the parameters to end up with a higher quality and tougher workpiece material. A comprehensive review on many rolling methods and directions during and after the WAAM process are discussed in detail. The main feature of this study is to provide a thorough understanding of the start-of-the-art involved in WAAM post processing. The study also revealed research gaps by comparing the existing literatures and adding a complete comparison and conclusions for each part which could be taken as potential in the future research topics for researchers in the same field. At the end, the manuscript has discussed the different post-processing design considerations t
{"title":"Reviewing Post-Processing Techniques to Enhance Mechanical Properties of Parts Fabricated Using WAAM","authors":"S. Abdallah, S. Pervaiz","doi":"10.1115/imece2021-73573","DOIUrl":"https://doi.org/10.1115/imece2021-73573","url":null,"abstract":"\u0000 The different additive manufacturing (AM) technologies are showing a higher flexibility and process capabilities over the years, these technologies are not limited to produce a prototype only, but also to produce a valuable and cost-effective large near net parts. The Wire Arc Additive Manufacturing (WAAM) technique is regarded as one of the most important technologies for producing a metallic component. As it becomes one of the most interesting technology in the industrial sector, it can provide an unlimited printing size based on the used mechanism range. In this study, different microstructure deformation-based post processing methods have been discussed, some of them could be performed in-process (during) or even post-process (after) the WAAM technique. This study will focus more on the rolling deformation method comparing with the other post-processing techniques. Rolling process is observed as a good choice for post processing that can be used to improve the material microstructure features. Moreover, the parameters such as roller radius, applied load, the WAAM torch angle and the distance between the pressing side of the roller and the welding point show controlling influence on the internal grain features and on the surface waviness. surface roughness is termed as one of the main problems on the produce parts using WAAM technology. This study discussed different ways by which the internal residual stresses can be reduced, and mechanical properties of fabricated parts can be improved. Some studies revealed that hot forging can be used as a post processing technique after the WAAM process. Utilization of hot forging after the WAAM process shows an immediate positive effect on the produced sample by improving both of yield and ultimate strengths of the part. Furthermore, some other studies show that the forging significantly reduce the porosity due to the applied hot forging, as it is showing a higher effect with increasing the hammering force and vice versa. Also, some studies utilized rolling process as a post processing technique. So, the current study compared hot forging with the results extracted from the rolling deformation.\u0000 This study aims to review the post processing techniques such as rolling process and hot forging process. The study provides understanding about the selection of the parameters to end up with a higher quality and tougher workpiece material. A comprehensive review on many rolling methods and directions during and after the WAAM process are discussed in detail. The main feature of this study is to provide a thorough understanding of the start-of-the-art involved in WAAM post processing. The study also revealed research gaps by comparing the existing literatures and adding a complete comparison and conclusions for each part which could be taken as potential in the future research topics for researchers in the same field. At the end, the manuscript has discussed the different post-processing design considerations t","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"9 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"130289881","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}
C. Nikhare, Tanya Buddi, N. Kotkunde, Swadesh Kumar Singh
Tube hydroforming is one of the successful manufacturing processes to create a variety of shapes using fluid pressure. The process fills the tube with fluid and pressurizes it to deform in various cross-sections. The method is categorized in three types: high pressure, pressure sequencing and low-pressure tube hydroforming. Tube hydroforming has gained popularity due to its many advantages such as part consolidation, uniform deformation, quality of the formed part and the possibility of unique shapes with indents or angles. Due to uniform thinning in the formed part, the parts can be lower weight and thus proven to be the technology to create light-weight parts for automotive and aerospace industries to increase the fuel economy. This paper focuses on low-pressure tube hydroforming. In low-pressure tube hydroforming, during the closing of the die the tube is marginally pressurized to a fixed volume. The previous study which was published in IMECE2019 and 2020 was focused on to investigate the effect of variation of thickness on deformation mechanics of the tube with variation in the process sequence during low-pressure tube hydroforming. In this part of the research, the study focused on how the velocity of the die effect the deformation mechanics with variation of the process sequence during low-pressure tube hydroforming. The circular tube was formed in a square shape. The four sides of die edges were considered as individual edges and the motion of these edges will be varied to achieve the final shape. The deformation mechanics in each condition was presented and analyzed. The die velocity effect on die filling, thickness and strain distribution were studied. It was found that the die velocity effects the tube deformation for the thinner tube and buckling could be eliminated using low pressure with tight die filling.
{"title":"Effect of Die Velocity on Tube Deformation Mechanics During Low Pressure Tube Hydroforming Process Sequence Variation","authors":"C. Nikhare, Tanya Buddi, N. Kotkunde, Swadesh Kumar Singh","doi":"10.1115/imece2021-70179","DOIUrl":"https://doi.org/10.1115/imece2021-70179","url":null,"abstract":"\u0000 Tube hydroforming is one of the successful manufacturing processes to create a variety of shapes using fluid pressure. The process fills the tube with fluid and pressurizes it to deform in various cross-sections. The method is categorized in three types: high pressure, pressure sequencing and low-pressure tube hydroforming. Tube hydroforming has gained popularity due to its many advantages such as part consolidation, uniform deformation, quality of the formed part and the possibility of unique shapes with indents or angles. Due to uniform thinning in the formed part, the parts can be lower weight and thus proven to be the technology to create light-weight parts for automotive and aerospace industries to increase the fuel economy. This paper focuses on low-pressure tube hydroforming. In low-pressure tube hydroforming, during the closing of the die the tube is marginally pressurized to a fixed volume. The previous study which was published in IMECE2019 and 2020 was focused on to investigate the effect of variation of thickness on deformation mechanics of the tube with variation in the process sequence during low-pressure tube hydroforming. In this part of the research, the study focused on how the velocity of the die effect the deformation mechanics with variation of the process sequence during low-pressure tube hydroforming. The circular tube was formed in a square shape. The four sides of die edges were considered as individual edges and the motion of these edges will be varied to achieve the final shape. The deformation mechanics in each condition was presented and analyzed. The die velocity effect on die filling, thickness and strain distribution were studied. It was found that the die velocity effects the tube deformation for the thinner tube and buckling could be eliminated using low pressure with tight die filling.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"10 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124125276","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}
Microstructure is one of the key factors determining the mechanical properties of an axle, which requires to obtain fine and uniform grain structure. This research work aims to explore the influence of different process parameters on the average grain size and distribution uniformity of the rolled piece during the closed-open cross wedge rolling (CWR) process, so as to improve the micro quality of the rolled piece by adjusting the process parameters. Firstly, an automobile oil pump axle made of 42Crmo is considered as a research object, and a 3D thermal-mechanical-microstructure coupled finite element model of closed-open CWR is established by adopting software DEFORM. Secondly, three points are uniformly selected along the central axis of the rolled piece as observation points, and the variation law of the average grain size at different positions with time is studied. Thirdly, the effects of the reduction of area, the diameter of the rolled piece, the forming angle of the wedge section and the stretching section on the average grain size of the rolled piece and the uniformity of the grain distribution are studied separately. Finally, combined with the closed-open CWR experiment, the influence of different billet diameter on the average grain size is consistent with the simulation results, which verifies the reliability of the model.
{"title":"Effect of Process Parameters on the Microstructure of Closed-Open Cross Wedge Rolling","authors":"X. Shu, Jitai Wang, Sutao Han, Yilun Wei","doi":"10.1115/imece2021-69787","DOIUrl":"https://doi.org/10.1115/imece2021-69787","url":null,"abstract":"\u0000 Microstructure is one of the key factors determining the mechanical properties of an axle, which requires to obtain fine and uniform grain structure. This research work aims to explore the influence of different process parameters on the average grain size and distribution uniformity of the rolled piece during the closed-open cross wedge rolling (CWR) process, so as to improve the micro quality of the rolled piece by adjusting the process parameters. Firstly, an automobile oil pump axle made of 42Crmo is considered as a research object, and a 3D thermal-mechanical-microstructure coupled finite element model of closed-open CWR is established by adopting software DEFORM. Secondly, three points are uniformly selected along the central axis of the rolled piece as observation points, and the variation law of the average grain size at different positions with time is studied. Thirdly, the effects of the reduction of area, the diameter of the rolled piece, the forming angle of the wedge section and the stretching section on the average grain size of the rolled piece and the uniformity of the grain distribution are studied separately. Finally, combined with the closed-open CWR experiment, the influence of different billet diameter on the average grain size is consistent with the simulation results, which verifies the reliability of the model.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"67 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"117303179","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}
There are two methods to 3D print a part using extrusion-based additive manufacturing technology namely filament-based and pellets/granules-based. Filament-based extrusion needed a wire form material called a filament, which is pushed by a motor and gear mechanism, into a heating zone. In the heating zone, it converts in semi-solid form and is extruded out of the nozzle to deposit in a layer-over-layer manner. This extrusion strategy needed a non-flexible filament, so it limits the variety of materials. Converting material into wire form also increases the cost of 3D printing. Pellet-based extrusion accepts the material in granules form. It is fed into the heating zone using an extrusion screw. This technology can accept a wide range of materials and eliminate the cost of producing filament. But pellet-based technology is still not being used on 3D printers, on the other hand, filament-based technology in the form of 3D printers is very popular in the market. So, in this study development of noble pellet and filament form integrated multi-material additive manufacturing co-extruder has been presented. The developed co-extruder is capable to accept material in filament form as well as pellet/granules form. This will help to 3D print a particular part with several materials. This hybrid form of the extruder is accommodating the features of both types of extrusion-based additive manufacturing. As per need, one can easily shift from filament extrusion to pellet/granules extrusion using this co-extruder.
{"title":"Development of a Pellet and Filament Form Integrated Multi-Material Additive Manufacturing Co-Extruder","authors":"Krishnanand, Mohammad Taufik","doi":"10.1115/imece2021-71044","DOIUrl":"https://doi.org/10.1115/imece2021-71044","url":null,"abstract":"\u0000 There are two methods to 3D print a part using extrusion-based additive manufacturing technology namely filament-based and pellets/granules-based. Filament-based extrusion needed a wire form material called a filament, which is pushed by a motor and gear mechanism, into a heating zone. In the heating zone, it converts in semi-solid form and is extruded out of the nozzle to deposit in a layer-over-layer manner. This extrusion strategy needed a non-flexible filament, so it limits the variety of materials. Converting material into wire form also increases the cost of 3D printing. Pellet-based extrusion accepts the material in granules form. It is fed into the heating zone using an extrusion screw. This technology can accept a wide range of materials and eliminate the cost of producing filament. But pellet-based technology is still not being used on 3D printers, on the other hand, filament-based technology in the form of 3D printers is very popular in the market. So, in this study development of noble pellet and filament form integrated multi-material additive manufacturing co-extruder has been presented. The developed co-extruder is capable to accept material in filament form as well as pellet/granules form. This will help to 3D print a particular part with several materials. This hybrid form of the extruder is accommodating the features of both types of extrusion-based additive manufacturing. As per need, one can easily shift from filament extrusion to pellet/granules extrusion using this co-extruder.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"114 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"123982125","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}
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