This paper presents an experimental and numerical study on the mechanical quasi-static behavior of self-piercing rivet (SPR) connections with three stacked sheets made from an AA6016-T4 aluminum alloy. The goal was to study the effects of sheet thickness and stack up of the SPR connection under large deformation and failure. Several different types of tests were performed to investigate the initial load-bearing capacity as well as the remaining capacity after partial joint failure. Additionally, the performance of state-of-the-art constraint modeling techniques was evaluated. The parameters for large-scale connector models were found through inverse modeling of the experiments. The models were validated against an additional test configuration where the middle sheet was load-free.
{"title":"Behavior and large-scale modeling of multi-sheet aluminum connections with self-piercing rivets","authors":"V. André, M. Costas, M. Langseth, D. Morin","doi":"10.1115/1.4062859","DOIUrl":"https://doi.org/10.1115/1.4062859","url":null,"abstract":"\u0000 This paper presents an experimental and numerical study on the mechanical quasi-static behavior of self-piercing rivet (SPR) connections with three stacked sheets made from an AA6016-T4 aluminum alloy. The goal was to study the effects of sheet thickness and stack up of the SPR connection under large deformation and failure. Several different types of tests were performed to investigate the initial load-bearing capacity as well as the remaining capacity after partial joint failure. Additionally, the performance of state-of-the-art constraint modeling techniques was evaluated. The parameters for large-scale connector models were found through inverse modeling of the experiments. The models were validated against an additional test configuration where the middle sheet was load-free.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":" ","pages":""},"PeriodicalIF":4.0,"publicationDate":"2023-06-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42798781","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}
Salvador Gómez-Jiménez, T. Saucedo-Anaya, V. H. Baltazar Hernandez, Ada Rebeca Contreras-Rodriguez
The automotive industry is evolving by incorporating innovative tools to improve production processes. A proper manufacturing process influences the behavior of the door grommet during its lifetime. In this paper, molecular dynamics simulations are conducted to evaluate the chemical and physical crosslinking of the EPDM rubber over a range of temperatures using a COMPASS force field. Then, once the EPDM model was equilibrated and all possible crosslinks were formed, additional simulations were performed on the model to explore its mechanical behavior. Subsequently, using the superposition principle, viscosity and curing kinetics were evaluated using phenomenological models. To, validate the results of the simulations, three injection tests of the door grommet, were performed at different temperature conditions. The results indicate that the viscosity and elastic properties increase with increasing levels of crosslink density and that the critical gel point decreases with temperature. Molecular dynamics superposition results in phenomenological models are in reasonable agreement with the kinetic and viscoelastic behavior of EPDM during and after the injection process. The results presented in this paper provide novel molecular-level findings on the crosslinking mechanisms of amorphous polymers and their influence on viscoelastic behavior, which could facilitate the design of the injection process for door grommet applications
{"title":"Characterization of viscoelastic properties of EPDM molding compound for door grommet component using molecular dynamics and phenomenological modeling.","authors":"Salvador Gómez-Jiménez, T. Saucedo-Anaya, V. H. Baltazar Hernandez, Ada Rebeca Contreras-Rodriguez","doi":"10.1115/1.4062858","DOIUrl":"https://doi.org/10.1115/1.4062858","url":null,"abstract":"\u0000 The automotive industry is evolving by incorporating innovative tools to improve production processes. A proper manufacturing process influences the behavior of the door grommet during its lifetime. In this paper, molecular dynamics simulations are conducted to evaluate the chemical and physical crosslinking of the EPDM rubber over a range of temperatures using a COMPASS force field. Then, once the EPDM model was equilibrated and all possible crosslinks were formed, additional simulations were performed on the model to explore its mechanical behavior. Subsequently, using the superposition principle, viscosity and curing kinetics were evaluated using phenomenological models. To, validate the results of the simulations, three injection tests of the door grommet, were performed at different temperature conditions. The results indicate that the viscosity and elastic properties increase with increasing levels of crosslink density and that the critical gel point decreases with temperature. Molecular dynamics superposition results in phenomenological models are in reasonable agreement with the kinetic and viscoelastic behavior of EPDM during and after the injection process. The results presented in this paper provide novel molecular-level findings on the crosslinking mechanisms of amorphous polymers and their influence on viscoelastic behavior, which could facilitate the design of the injection process for door grommet applications","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":"329 ","pages":""},"PeriodicalIF":4.0,"publicationDate":"2023-06-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"41275738","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}
Freeform bending offers a wide range of possibilities in terms of component geometries, material grades and profile cross-sections. In the field of circular solid and hollow profiles, the design of the tool is determined by the circular shape of the profile used. When using rectangular profiles, the cross-section of the tool cannot be easily obtained by an offset of the profile cross-section. The large tolerance ranges of the profile standards require compromises with regard to the shape and tolerances of the tool. Tests have shown that the design of the tool has a great influence on the quality of the component. Furthermore, the trade-off in the tool design can lead to unsuitable tool shapes leading to defects and damages on the profile. These are mainly wrinkling, cross-sectional deformations and strongly deformed profile corners, which in some cases form cracks in the material. In this paper, the influences of the tool design on the bending result and the defects of the profiles are investigated. For this purpose, several tool designs with different variants and combinations of the movable die and the fixed die are compared with each other.
{"title":"Freeform bending tool design for rectangular profiles and its influence on the process","authors":"M. Werner, Lorenzo Scandola, D. Maier, W. Volk","doi":"10.1115/1.4062811","DOIUrl":"https://doi.org/10.1115/1.4062811","url":null,"abstract":"\u0000 Freeform bending offers a wide range of possibilities in terms of component geometries, material grades and profile cross-sections. In the field of circular solid and hollow profiles, the design of the tool is determined by the circular shape of the profile used. When using rectangular profiles, the cross-section of the tool cannot be easily obtained by an offset of the profile cross-section. The large tolerance ranges of the profile standards require compromises with regard to the shape and tolerances of the tool. Tests have shown that the design of the tool has a great influence on the quality of the component. Furthermore, the trade-off in the tool design can lead to unsuitable tool shapes leading to defects and damages on the profile. These are mainly wrinkling, cross-sectional deformations and strongly deformed profile corners, which in some cases form cracks in the material. In this paper, the influences of the tool design on the bending result and the defects of the profiles are investigated. For this purpose, several tool designs with different variants and combinations of the movable die and the fixed die are compared with each other.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":" ","pages":""},"PeriodicalIF":4.0,"publicationDate":"2023-06-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45941054","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}
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":" ","pages":""},"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":" ","pages":""},"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":" ","pages":""},"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":" ","pages":""},"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":" ","pages":""},"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":" ","pages":""},"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":" ","pages":""},"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}
京公网安备 11010802042870号
京ICP备2023020795号-1
扫码关注我们
求助内容：
应助结果提醒方式：