Although it is an old technique, research on the hot rolling process maintains its importance because of its widespread usage in steel production and its requirement for a vast amount of resources, especially energy. The roll pass design of the hot rolling process considerably affects many operational parameters such as energy requirement, wear of the rolls, working forces, and torques. Furthermore, due to the sequential nature of the rolling process, a design of any number of passes is strictly interrelated with all other passes in the process. This makes it very involved to find optimum design solutions that allow for the compromise between conflicting goals and restrictions. In this paper, a new optimized solution search strategy based on a desirability function is offered to deal with the sequential characteristics of the roll pass design. A novel optimization method utilizing response surfaces and the proposed solution search strategy is presented to reduce the shaping energy of the overall process while minimizing turning moments and radial forces on rolls during the rough rolling process. The method and solution search strategy developed are illustrated and validated via a case study. Comparing the case study's findings to three distinct pass designs used in industrial power plants, it was discovered that significant energy savings, low turning moments, and reduced radial forces had been made compared to the reference designs.
{"title":"A Desirability-Based Solution Search Method for Sequential Optimization of the Hot Rolling Process","authors":"F. Çavdar, E. Kanca","doi":"10.1115/1.4062787","DOIUrl":"https://doi.org/10.1115/1.4062787","url":null,"abstract":"\u0000 Although it is an old technique, research on the hot rolling process maintains its importance because of its widespread usage in steel production and its requirement for a vast amount of resources, especially energy. The roll pass design of the hot rolling process considerably affects many operational parameters such as energy requirement, wear of the rolls, working forces, and torques. Furthermore, due to the sequential nature of the rolling process, a design of any number of passes is strictly interrelated with all other passes in the process. This makes it very involved to find optimum design solutions that allow for the compromise between conflicting goals and restrictions. In this paper, a new optimized solution search strategy based on a desirability function is offered to deal with the sequential characteristics of the roll pass design. A novel optimization method utilizing response surfaces and the proposed solution search strategy is presented to reduce the shaping energy of the overall process while minimizing turning moments and radial forces on rolls during the rough rolling process. The method and solution search strategy developed are illustrated and validated via a case study. Comparing the case study's findings to three distinct pass designs used in industrial power plants, it was discovered that significant energy savings, low turning moments, and reduced radial forces had been made compared to the reference designs.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":null,"pages":null},"PeriodicalIF":4.0,"publicationDate":"2023-06-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42507900","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Zoe Alexander, T. Feldhausen, K. Saleeby, Thomas Kurfess, Katherine Fu, Christopher Saldaña
In additive manufacturing, choosing process parameters to prevent over and under deposition is a time and resource intensive trial-and-error process. Due to the uniqueness of each part geometry, further development of real-time process monitoring and control is needed for reliable part dimensional accuracy. This research shows that support vector regression (SVR) and convolutional neural network (CNN) models offer a promising solution for real-time process control due to the models' abilities to recognize complex, nonlinear patterns with high accuracy. A novel experiment was designed to compare the performance of SVR and CNN models to indirectly detect bead height from a coaxial image of a melt pool from a single layer, single bead build. The study showed that both SVR and CNN models trained on melt pool data collected from a coaxial optical camera can accurately predict the bead height with a mean absolute percentage error of 3.67% and 3.68%, respectively.
{"title":"Data-Driven Approaches for Bead Geometry Prediction via Melt Pool Monitoring","authors":"Zoe Alexander, T. Feldhausen, K. Saleeby, Thomas Kurfess, Katherine Fu, Christopher Saldaña","doi":"10.1115/1.4062800","DOIUrl":"https://doi.org/10.1115/1.4062800","url":null,"abstract":"\u0000 In additive manufacturing, choosing process parameters to prevent over and under deposition is a time and resource intensive trial-and-error process. Due to the uniqueness of each part geometry, further development of real-time process monitoring and control is needed for reliable part dimensional accuracy. This research shows that support vector regression (SVR) and convolutional neural network (CNN) models offer a promising solution for real-time process control due to the models' abilities to recognize complex, nonlinear patterns with high accuracy. A novel experiment was designed to compare the performance of SVR and CNN models to indirectly detect bead height from a coaxial image of a melt pool from a single layer, single bead build. The study showed that both SVR and CNN models trained on melt pool data collected from a coaxial optical camera can accurately predict the bead height with a mean absolute percentage error of 3.67% and 3.68%, respectively.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":null,"pages":null},"PeriodicalIF":4.0,"publicationDate":"2023-06-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42842089","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
A. Adriaensen, Margherita Bernabei, F. Costantino, Andrea Falegnami, Sara Stabile, R. Patriarca
The increasing usage of cobot applications reshapes work environments and working conditions, requiring specific advancements in organizational practices for health and safety. Enterprises should shift from a technocentric risk management approach to considering cobots application as socio-technical systems, where resilience engineering is beneficial. This study presents an instantiation of the Resilience Analysis Grid (RAG) in cobot applications with the aim of measuring resilience potentials in terms of the four cornerstones of resilience engineering (respond, learn, monitor, anticipate). The assessment has been provided via a questionnaire to fifteen companies that make use of cobot applications. Results revealed that companies mainly focus on the risk assessment of cobot applications with a traditional view of machine-centric safety, paying less attention to assessing contexts and process variables. This observation seems to arise mainly due to the lack of formally available safety methods or limited guidance from technical standards. Additionally, traditional industrial approaches to risk management lack monitoring of several risks that are essential for managing resilience, defined as the adaptive capacity of people, organizations, and human-machine systems. In addition, companies strongly rely on data from the cobot manufacturer for their safety assessment. The Resilience Analysis Grid was confirmed as a valuable assessment tool for the participating companies to identify improvement areas and assess health and safety from a resilience engineering perspective.
{"title":"Resilience potentials for health and safety management in cobot applications using the Resilience Analysis Grid","authors":"A. Adriaensen, Margherita Bernabei, F. Costantino, Andrea Falegnami, Sara Stabile, R. Patriarca","doi":"10.1115/1.4062786","DOIUrl":"https://doi.org/10.1115/1.4062786","url":null,"abstract":"\u0000 The increasing usage of cobot applications reshapes work environments and working conditions, requiring specific advancements in organizational practices for health and safety. Enterprises should shift from a technocentric risk management approach to considering cobots application as socio-technical systems, where resilience engineering is beneficial. This study presents an instantiation of the Resilience Analysis Grid (RAG) in cobot applications with the aim of measuring resilience potentials in terms of the four cornerstones of resilience engineering (respond, learn, monitor, anticipate). The assessment has been provided via a questionnaire to fifteen companies that make use of cobot applications. Results revealed that companies mainly focus on the risk assessment of cobot applications with a traditional view of machine-centric safety, paying less attention to assessing contexts and process variables. This observation seems to arise mainly due to the lack of formally available safety methods or limited guidance from technical standards. Additionally, traditional industrial approaches to risk management lack monitoring of several risks that are essential for managing resilience, defined as the adaptive capacity of people, organizations, and human-machine systems. In addition, companies strongly rely on data from the cobot manufacturer for their safety assessment. The Resilience Analysis Grid was confirmed as a valuable assessment tool for the participating companies to identify improvement areas and assess health and safety from a resilience engineering perspective.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":null,"pages":null},"PeriodicalIF":4.0,"publicationDate":"2023-06-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"47092696","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Shear localization is the dominant chip formation mechanism in machining of high performance metallic components, such as those made of titanium and nickel-based alloys. This paper presents an analytical thermo-mechanical model considering a new tool-chip contact mechanism due to shear localization. First, it is experimentally shown that the sticking and sliding contact lengths fluctuate with the frequency of shear localization. Second, a cutting mechanics model is developed considering the shear band formation, its rolling on the tool’s rake face, and the time-varying tool-chip contact length with experimental validation. Finally, the transient temperature at the tool-chip interface is predicted by taking the rolling phenomenon and the time-varying heat sources at the tool-chip interface into account. The proposed model shows that at the beginning of each segmentation cycle, the entire tool-chip contact length is dominated by sliding condition with negligible sticking length. When the tool advances, new workpiece material piles up in its front with an increase in the sticking length. Meanwhile, the sliding length decreases due to the drop in the load-bearing capacity of the shear band. When enough material piles up in front of the tool, a new shear band forms, and the entire contact length returns to the sliding condition. This process repeats each time a shear band occurs, causing the cyclic formation of shear bands and time-varying nature of the tool-chip contact length, therefore influencing the temperature and stress evolution at the tool-chip interface.
{"title":"Time-Varying Tool-Chip Contact in the Cutting Mechanics of Shear Localization","authors":"M. Fazlali, Xiaoliang Jin","doi":"10.1115/1.4062749","DOIUrl":"https://doi.org/10.1115/1.4062749","url":null,"abstract":"\u0000 Shear localization is the dominant chip formation mechanism in machining of high performance metallic components, such as those made of titanium and nickel-based alloys. This paper presents an analytical thermo-mechanical model considering a new tool-chip contact mechanism due to shear localization. First, it is experimentally shown that the sticking and sliding contact lengths fluctuate with the frequency of shear localization. Second, a cutting mechanics model is developed considering the shear band formation, its rolling on the tool’s rake face, and the time-varying tool-chip contact length with experimental validation. Finally, the transient temperature at the tool-chip interface is predicted by taking the rolling phenomenon and the time-varying heat sources at the tool-chip interface into account. The proposed model shows that at the beginning of each segmentation cycle, the entire tool-chip contact length is dominated by sliding condition with negligible sticking length. When the tool advances, new workpiece material piles up in its front with an increase in the sticking length. Meanwhile, the sliding length decreases due to the drop in the load-bearing capacity of the shear band. When enough material piles up in front of the tool, a new shear band forms, and the entire contact length returns to the sliding condition. This process repeats each time a shear band occurs, causing the cyclic formation of shear bands and time-varying nature of the tool-chip contact length, therefore influencing the temperature and stress evolution at the tool-chip interface.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":null,"pages":null},"PeriodicalIF":4.0,"publicationDate":"2023-06-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"47287384","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
This paper is aimed at studying the acoustic emission signatures of dominant failure mechanisms encountered during fracture cutting of bovine cortical bone. This is achieved through an orthogonal cutting study performed in a sensor-rich environment comprising of a cutting force sensor, acoustic emission sensor and a high-speed camera. The synchronization of these three sensing modalities allows for the visual identification of the dominant failure modes, while also mapping them to their corresponding acoustic and cutting force metrics. Given their distinctly different underlying microstructures, the haversian and plexiform components of the bovine cortical bone are investigated separately. A total of six dominant failure mechanisms have been confirmed across the haversian and plexiform bone types. Osteon fracture and trans-lamellar fracture have been identified as the mechanisms expending the maximum energy during the fracture cutting of haversian and plexiform bone, respectively. Overall, the acoustic emission and the cutting force metrics are seen to be complementary in characterizing the six failure mechanisms. The findings of this work have implications for tool-mounted sensing modalities that could be used to detect ‘in-process’ failure mechanisms during bone surgical procedures.
{"title":"THE MICROSTRUCTURAL ORIGINS OF ACOUSTIC EMISSION SIGNATURES ENCOUNTERED DURING FRACTURE CUTTING OF BOVINE CORTICAL BONE","authors":"Roshan Mishra, Michael Conward, J. Samuel","doi":"10.1115/1.4062728","DOIUrl":"https://doi.org/10.1115/1.4062728","url":null,"abstract":"\u0000 This paper is aimed at studying the acoustic emission signatures of dominant failure mechanisms encountered during fracture cutting of bovine cortical bone. This is achieved through an orthogonal cutting study performed in a sensor-rich environment comprising of a cutting force sensor, acoustic emission sensor and a high-speed camera. The synchronization of these three sensing modalities allows for the visual identification of the dominant failure modes, while also mapping them to their corresponding acoustic and cutting force metrics. Given their distinctly different underlying microstructures, the haversian and plexiform components of the bovine cortical bone are investigated separately. A total of six dominant failure mechanisms have been confirmed across the haversian and plexiform bone types. Osteon fracture and trans-lamellar fracture have been identified as the mechanisms expending the maximum energy during the fracture cutting of haversian and plexiform bone, respectively. Overall, the acoustic emission and the cutting force metrics are seen to be complementary in characterizing the six failure mechanisms. The findings of this work have implications for tool-mounted sensing modalities that could be used to detect ‘in-process’ failure mechanisms during bone surgical procedures.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":null,"pages":null},"PeriodicalIF":4.0,"publicationDate":"2023-06-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"43001209","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
U. Kizhakkinan, S. Seetharaman, N. Raghavan, David W. Rosen
Laser powder bed fusion (L-PBF) is a popular metal additive manufacturing (AM) process used to manufacture complex metallic 3D components. Maraging steel is one of the metals used in AM and it belongs to the class of ultra-high-strength steels used in aerospace and tooling industries. In the L-PBF process, a laser beam is used to melt and fuse the metal powder particles. This creates a high thermal gradient and rapid cooling of the melt pool results in columnar grains. The microstructure of AM part is entirely different from the conventionally manufactured case and this necessitates post-AM heat treatments. The current paper reviews the effects of printing parameters and heat treatment on microstructure and mechanical properties of L-PBF produced maraging steel 300 alloy. Tensile, impact, fracture, and fatigue properties of as-built and heat-treated L-PBF parts are discussed in detail.
{"title":"Laser powder bed fusion additive manufacturing of maraging steel: A review","authors":"U. Kizhakkinan, S. Seetharaman, N. Raghavan, David W. Rosen","doi":"10.1115/1.4062727","DOIUrl":"https://doi.org/10.1115/1.4062727","url":null,"abstract":"\u0000 Laser powder bed fusion (L-PBF) is a popular metal additive manufacturing (AM) process used to manufacture complex metallic 3D components. Maraging steel is one of the metals used in AM and it belongs to the class of ultra-high-strength steels used in aerospace and tooling industries. In the L-PBF process, a laser beam is used to melt and fuse the metal powder particles. This creates a high thermal gradient and rapid cooling of the melt pool results in columnar grains. The microstructure of AM part is entirely different from the conventionally manufactured case and this necessitates post-AM heat treatments. The current paper reviews the effects of printing parameters and heat treatment on microstructure and mechanical properties of L-PBF produced maraging steel 300 alloy. Tensile, impact, fracture, and fatigue properties of as-built and heat-treated L-PBF parts are discussed in detail.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":null,"pages":null},"PeriodicalIF":4.0,"publicationDate":"2023-06-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46205651","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Shu Wang, Xueqin Zheng, Cunfu Wang, Huageng Luo, Shi-Kai Jing
The paper presents formulations for hybrid casting and additive manufacturing(AM) in density-based topology optimization. A location-based Heaviside function is introduced to represent the parting surface. The optimized part on two sides of the parting surface can be fabricated with casting, additive manufacturing or both. Through the location-based Heaviside function and density gradient, two global constraints are formulated to remove undercuts and strong overhangs for casting and AM, respectively, inside the design domain. Since density gradient does not exist on the design domain boundary, two extra density-based global constraints are developed to control the strong overhangs and undercuts outside the design domain. Due to the smoothed parameterization of the parting surface, the proposed approach enables us to optimize the part and partition surface(including location and parting direction) simultaneously for hybrid casting and additive manufacturing. Both 2D and 3D numerical examples are presented to demonstrate the validity and efficiency of the proposed formulations for hybrid manufacturing processes. The proposed approach further enlarges the design space with manufacturing constraints, and has the potential to be used in the design for hybrid and multi-component manufacturing.
{"title":"Simultaneous optimization of part and parting surface for hybrid casting and additive manufacturing","authors":"Shu Wang, Xueqin Zheng, Cunfu Wang, Huageng Luo, Shi-Kai Jing","doi":"10.1115/1.4062662","DOIUrl":"https://doi.org/10.1115/1.4062662","url":null,"abstract":"\u0000 The paper presents formulations for hybrid casting and additive manufacturing(AM) in density-based topology optimization. A location-based Heaviside function is introduced to represent the parting surface. The optimized part on two sides of the parting surface can be fabricated with casting, additive manufacturing or both. Through the location-based Heaviside function and density gradient, two global constraints are formulated to remove undercuts and strong overhangs for casting and AM, respectively, inside the design domain. Since density gradient does not exist on the design domain boundary, two extra density-based global constraints are developed to control the strong overhangs and undercuts outside the design domain. Due to the smoothed parameterization of the parting surface, the proposed approach enables us to optimize the part and partition surface(including location and parting direction) simultaneously for hybrid casting and additive manufacturing. Both 2D and 3D numerical examples are presented to demonstrate the validity and efficiency of the proposed formulations for hybrid manufacturing processes. The proposed approach further enlarges the design space with manufacturing constraints, and has the potential to be used in the design for hybrid and multi-component manufacturing.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":null,"pages":null},"PeriodicalIF":4.0,"publicationDate":"2023-06-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42465853","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Nils Potthoff, Ankit Agarwal, F. Wöste, P. Wiederkehr, L. Mears
Tool wear plays a decisive role in achieving the required surface quality and dimensional accuracy during the machining of Inconel 718-based products. The highly stochastic phenomenon of tool wear, particularly in later stages, results in difficulty in predicting the failure point of the tool. The present research work aims to study this late-stage wear of the tool by generating consistent wear conditions and thereby decoupling the late-stage wear from the wear history. To do so, a multi-axis grinding operation is employed to create artificial tool wear that replicates the topology of natural wear occurring in the process. In order to evaluate the imitating ability of the proposed methodology, microscopic images in different wear states of naturally and contrived worn tools were analyzed. The methodology was validated by comparing the resulting process forces measured during end milling with the natural and contrived worn tool for different path strategies. Finally, a qualitative FE-analysis was conducted, and specific force coefficients for worn tool segments were determined through simulation.
{"title":"Evaluation of Contrived Wear Methodology in End Milling of Inconel 718","authors":"Nils Potthoff, Ankit Agarwal, F. Wöste, P. Wiederkehr, L. Mears","doi":"10.1115/1.4062603","DOIUrl":"https://doi.org/10.1115/1.4062603","url":null,"abstract":"\u0000 Tool wear plays a decisive role in achieving the required surface quality and dimensional accuracy during the machining of Inconel 718-based products. The highly stochastic phenomenon of tool wear, particularly in later stages, results in difficulty in predicting the failure point of the tool. The present research work aims to study this late-stage wear of the tool by generating consistent wear conditions and thereby decoupling the late-stage wear from the wear history. To do so, a multi-axis grinding operation is employed to create artificial tool wear that replicates the topology of natural wear occurring in the process. In order to evaluate the imitating ability of the proposed methodology, microscopic images in different wear states of naturally and contrived worn tools were analyzed. The methodology was validated by comparing the resulting process forces measured during end milling with the natural and contrived worn tool for different path strategies. Finally, a qualitative FE-analysis was conducted, and specific force coefficients for worn tool segments were determined through simulation.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":null,"pages":null},"PeriodicalIF":4.0,"publicationDate":"2023-05-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"48824156","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
High-entropy alloys (HEAs) are highly anticipated due to their excellent properties (e.g. high strength, high hardness, excellent wear resistance). However, compared with numerous studies on the design and properties of HEAs, the research on the machinability of HEAs is extremely rare, which limits the application of HEAs. In this work, grinding experiments of (FeCoNi)86Al7Ti7 dual-phase HEA workpieces were carried out, and the results are analysed from general machinability perspective (the effect of machining parameters on grinding force and surface roughness value) to a more in-depth perspective, including grinding induced changes in morphology and microstructure on ground surface and subsurface. With SEM and EBSD information of subsurface, the deformation mechanisms have been studied, including the role of the second phase (Ni2AlTi) in the grinding process, the material removal modes of the different phases and the morphology of the nanoprecipitates in the matrix, based on the completely opposite properties of different phases in HEA. It is noticed that the hard and brittle property of the second phase brings support to the material, reduces the plastic deformation, and also makes its own removal brittle, while the plastic matrix experiences shear deformation in grinding, which makes the nanoprecipitates in it assume different morphologies. These detailed findings could be of help to understand the effect of grinding on material properties so as to improve the machining quality of this material.
{"title":"Surface Integrity Analysis in Grinding of Dual-phase High Entropy Alloy","authors":"Xing Wang, Shu Zan, Qin Xu, Z. Liao","doi":"10.1115/1.4062604","DOIUrl":"https://doi.org/10.1115/1.4062604","url":null,"abstract":"\u0000 High-entropy alloys (HEAs) are highly anticipated due to their excellent properties (e.g. high strength, high hardness, excellent wear resistance). However, compared with numerous studies on the design and properties of HEAs, the research on the machinability of HEAs is extremely rare, which limits the application of HEAs. In this work, grinding experiments of (FeCoNi)86Al7Ti7 dual-phase HEA workpieces were carried out, and the results are analysed from general machinability perspective (the effect of machining parameters on grinding force and surface roughness value) to a more in-depth perspective, including grinding induced changes in morphology and microstructure on ground surface and subsurface. With SEM and EBSD information of subsurface, the deformation mechanisms have been studied, including the role of the second phase (Ni2AlTi) in the grinding process, the material removal modes of the different phases and the morphology of the nanoprecipitates in the matrix, based on the completely opposite properties of different phases in HEA. It is noticed that the hard and brittle property of the second phase brings support to the material, reduces the plastic deformation, and also makes its own removal brittle, while the plastic matrix experiences shear deformation in grinding, which makes the nanoprecipitates in it assume different morphologies. These detailed findings could be of help to understand the effect of grinding on material properties so as to improve the machining quality of this material.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":null,"pages":null},"PeriodicalIF":4.0,"publicationDate":"2023-05-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45584087","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
E. Gongadze, Chris Dighton, Gregory Nash, Martin Moss, Brett Hemingway, J. Belnoue, S. Hallett
Composite materials and especially those made from pre-impregnated (prepreg) material are widely used in the aerospace industry. To achieve the tight assembly dimensional tolerances required, manufacturers rely on additional manufacturing steps like shimming or machining, which generate extra waste, are time-consuming and expensive. Prepreg sheets come naturally with fibre and resin volume content variability that leads manufacturers to guarantee cured ply thicknesses within a typical +/-5% margin of their nominal values. For thick laminates, this can equate to a thickness variability of as much as a few mm. To solve the issue, it is proposed to twin in-situ laser measurements of the uncured prepreg thickness with numerical simulations of the laminate autoclave consolidation and cure process and to adjust the number of additional sacrificial plies in the laminate based on the model predictions. Data for IM7/8552 and IM7/977-3 is presented to demonstrate the potential of the method to reach an almost exact target thickness for flat panels.
{"title":"Thickness control of autoclave-moulded composite laminates","authors":"E. Gongadze, Chris Dighton, Gregory Nash, Martin Moss, Brett Hemingway, J. Belnoue, S. Hallett","doi":"10.1115/1.4062581","DOIUrl":"https://doi.org/10.1115/1.4062581","url":null,"abstract":"\u0000 Composite materials and especially those made from pre-impregnated (prepreg) material are widely used in the aerospace industry. To achieve the tight assembly dimensional tolerances required, manufacturers rely on additional manufacturing steps like shimming or machining, which generate extra waste, are time-consuming and expensive. Prepreg sheets come naturally with fibre and resin volume content variability that leads manufacturers to guarantee cured ply thicknesses within a typical +/-5% margin of their nominal values. For thick laminates, this can equate to a thickness variability of as much as a few mm. To solve the issue, it is proposed to twin in-situ laser measurements of the uncured prepreg thickness with numerical simulations of the laminate autoclave consolidation and cure process and to adjust the number of additional sacrificial plies in the laminate based on the model predictions. Data for IM7/8552 and IM7/977-3 is presented to demonstrate the potential of the method to reach an almost exact target thickness for flat panels.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":null,"pages":null},"PeriodicalIF":4.0,"publicationDate":"2023-05-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"48626059","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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