Melih C. Yesilli, Max M. Chumley, Jisheng Chen, Firas A. Khasawneh, Yang Guo
Surface texture influences wear and tribological properties of manufactured parts, and it plays a critical role in end-user products. Therefore, quantifying the order or structure of a manufactured surface provides important information on the quality and life expectancy of the product. Although texture can be intentionally introduced to enhance aesthetics or to satisfy a design function, sometimes it is an inevitable byproduct of surface treatment processes such as Piezo Vibration Striking Treatment (PVST). Measures of order for surfaces have been characterized using statistical, spectral, and geometric approaches. For nearly hexagonal lattices, topological tools have also been used to measure the surface order. This paper explores utilizing tools from Topological Data Analysis for measuring surface texture. We compute measures of order based on optical digital microscope images of surfaces treated using PVST. These measures are applied to the grid obtained from estimating the centers of tool impacts, and they quantify the grid’s deviations from the nominal one. Our results show that TDA provides a convenient framework for characterization of pattern type that bypasses some limitations of existing tools such as difficult manual processing of the data and the need for an expert user to analyze and interpret the surface images.
{"title":"Exploring Surface Texture Quantification in Piezo Vibration Striking Treatment (PVST) Using Topological Measures","authors":"Melih C. Yesilli, Max M. Chumley, Jisheng Chen, Firas A. Khasawneh, Yang Guo","doi":"10.1115/msec2022-86659","DOIUrl":"https://doi.org/10.1115/msec2022-86659","url":null,"abstract":"\u0000 Surface texture influences wear and tribological properties of manufactured parts, and it plays a critical role in end-user products. Therefore, quantifying the order or structure of a manufactured surface provides important information on the quality and life expectancy of the product. Although texture can be intentionally introduced to enhance aesthetics or to satisfy a design function, sometimes it is an inevitable byproduct of surface treatment processes such as Piezo Vibration Striking Treatment (PVST). Measures of order for surfaces have been characterized using statistical, spectral, and geometric approaches. For nearly hexagonal lattices, topological tools have also been used to measure the surface order. This paper explores utilizing tools from Topological Data Analysis for measuring surface texture. We compute measures of order based on optical digital microscope images of surfaces treated using PVST. These measures are applied to the grid obtained from estimating the centers of tool impacts, and they quantify the grid’s deviations from the nominal one. Our results show that TDA provides a convenient framework for characterization of pattern type that bypasses some limitations of existing tools such as difficult manual processing of the data and the need for an expert user to analyze and interpret the surface images.","PeriodicalId":23676,"journal":{"name":"Volume 2: Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability","volume":"24 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"82950268","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}
Titanium (Ti) alloys are classified as difficult-to-machine materials due to low thermal conductivity, low modulus, and high chemical reactivity. In this paper, a Ti-6Al-4V alloy bar in a solution treated and aged (STA) microstructure is turned using uncoated carbide, two commercial multilayered coated carbides (Sandvik® MM1115 and MM11125), and several other advanced coated carbide tools with AlTiN, TiAlN, ZrN, BAM, and (AlCrSi/Ti)N coatings that were fabricated for this study. While coatings with increased hardness and chemical stability are expected to provide better protection against tool wear, coated inserts have not been successfully implemented in machining Ti alloys. A series of turning experiments was carried out while measuring the cutting forces using a dynamometer at three cutting speeds (61, 91, and 122 m/min), and the extent of tool wear on the inserts was assessed using Confocal Laser Scanning Microscopy (CLSM). Among the inserts tested, the (AlCrSi/Ti)N coated insert with a 7 μm coating thickness provided the best performance compared to other inserts, but only at the cutting speed of 61 m/min.
{"title":"A Machinability Study of Coated Inserts for Turning Ti-6Al-4V","authors":"Ryan M. Khawarizmi, Yang Guo, T. Bieler, P. Kwon","doi":"10.1115/msec2022-85632","DOIUrl":"https://doi.org/10.1115/msec2022-85632","url":null,"abstract":"\u0000 Titanium (Ti) alloys are classified as difficult-to-machine materials due to low thermal conductivity, low modulus, and high chemical reactivity. In this paper, a Ti-6Al-4V alloy bar in a solution treated and aged (STA) microstructure is turned using uncoated carbide, two commercial multilayered coated carbides (Sandvik® MM1115 and MM11125), and several other advanced coated carbide tools with AlTiN, TiAlN, ZrN, BAM, and (AlCrSi/Ti)N coatings that were fabricated for this study. While coatings with increased hardness and chemical stability are expected to provide better protection against tool wear, coated inserts have not been successfully implemented in machining Ti alloys. A series of turning experiments was carried out while measuring the cutting forces using a dynamometer at three cutting speeds (61, 91, and 122 m/min), and the extent of tool wear on the inserts was assessed using Confocal Laser Scanning Microscopy (CLSM). Among the inserts tested, the (AlCrSi/Ti)N coated insert with a 7 μm coating thickness provided the best performance compared to other inserts, but only at the cutting speed of 61 m/min.","PeriodicalId":23676,"journal":{"name":"Volume 2: Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability","volume":"94 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"89897711","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}
Magnesium alloys possess exceptionally good mechanical properties, primarily their excellent high strength to weight ratio, and have attracted many applications in the automobile and aerospace industries. However, their use is limited by the poor formability at room temperature when processed through conventional processes because the crystal lattice structure of magnesium is hexagonal closed packed (hcp), due to which there are limited sliding planes. At the elevated temperature ranges of 200–300 °C, more sliding planes get activated, which increases the ductility and decreases the flow stress. It leads to enhanced formability at a higher temperature for magnesium alloys. Therefore, several methods of heat-assisted single point incremental forming process (HA-SPIF) have been established by many researchers in order to improve the forming limits of such hard-to-deform materials. In this study, a new method of the heat-assisted single-point incremental forming process (HA-SPIF) is developed by using cartridge heaters to enhance the forming limits. The influence of higher temperature on fracture depth and thickness distribution of AZ31B magnesium alloy sheet is studied in detail. Experimental results indicate that the fracture depth and thickness distribution increases as the temperature increases. A coupled thermo-mechanical numerical simulation model using ABAQUS/EXPLICIT® is developed to predict forming limits; it was validated using the experimental results. The Johnson-Cook model was implemented as the constitutive model and also to define the fracture criterion. A reasonably good agreement between the results of the numerical simulation and those of the experiment is observed.
{"title":"Experimental and Numerical Investigation of Heat Assisted Incremental Sheet Forming Process of Magnesium Alloy","authors":"Narinder Kumar, Mohit Mahala, Anupam Agrawal","doi":"10.1115/msec2022-85205","DOIUrl":"https://doi.org/10.1115/msec2022-85205","url":null,"abstract":"\u0000 Magnesium alloys possess exceptionally good mechanical properties, primarily their excellent high strength to weight ratio, and have attracted many applications in the automobile and aerospace industries. However, their use is limited by the poor formability at room temperature when processed through conventional processes because the crystal lattice structure of magnesium is hexagonal closed packed (hcp), due to which there are limited sliding planes. At the elevated temperature ranges of 200–300 °C, more sliding planes get activated, which increases the ductility and decreases the flow stress. It leads to enhanced formability at a higher temperature for magnesium alloys. Therefore, several methods of heat-assisted single point incremental forming process (HA-SPIF) have been established by many researchers in order to improve the forming limits of such hard-to-deform materials. In this study, a new method of the heat-assisted single-point incremental forming process (HA-SPIF) is developed by using cartridge heaters to enhance the forming limits. The influence of higher temperature on fracture depth and thickness distribution of AZ31B magnesium alloy sheet is studied in detail. Experimental results indicate that the fracture depth and thickness distribution increases as the temperature increases. A coupled thermo-mechanical numerical simulation model using ABAQUS/EXPLICIT® is developed to predict forming limits; it was validated using the experimental results. The Johnson-Cook model was implemented as the constitutive model and also to define the fracture criterion. A reasonably good agreement between the results of the numerical simulation and those of the experiment is observed.","PeriodicalId":23676,"journal":{"name":"Volume 2: Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability","volume":"36 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"73172724","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}
Anisogrid cylindrical lattice (ACL) structures have been successfully used in space applications, demonstrating high mechanical performance and weight efficiency. However, the manufacturing process for the composite ACL structures is very complex and, traditionally, involves different technologies, including winding of filaments or prepregs and curing. Tacking the advantage of the fused deposition modeling (FDM) to manufacture completely integral composite parts with complex shape, in this paper, the FDM-3D printing of ACL structures using carbon fiber (CF) and glass fiber (GF) reinforced polyamide 12 (PA12) composites has been investigated. The mechanical behavior of 3D printed ACL structures has been analyzed in terms of the static stiffness, specific load, and failure mode through axial and transverse compression tests, as a function of the geometrical parameters of the lattice structure. It was observed that, under transverse compression, after the initial linear elastic response, the applied load changed its slope and continued to increase with increasing displacement up to a specified displacement (inner radius of the ACL structures) without visible fracture or delamination between layers, demonstrating that the 3D printed composite ACL structures are robust and highly efficient in the nodes. Under axial compression, the applied load increased with displacement up to a maximum load and then decreased until fracture, mainly, due to local buckling and material failure of the helical ribs. The 3D printed CF/PA12 ACL structures were found to be more efficient than either the GF/PA12 or PA12 ACL structures taking into account both the axial and transverse specific load and stiffness. The increase in the shell thickness, helical rib width or number of helical ribs resulted in a remarkable increase in the stiffness and load-bearing capacity of the 3D printed composite ACL structures. From the manufacturing perspective, it was shown that the FDM-3D printing technology holds promise for the development of mechanically robust composite ACL structures with excellent reliability.
{"title":"3D Printing and Mechanical Behavior of Anisogrid Composite Lattice Cylindrical Structures","authors":"F. Stan, I. Sandu, C. Fetecau","doi":"10.1115/msec2022-85532","DOIUrl":"https://doi.org/10.1115/msec2022-85532","url":null,"abstract":"\u0000 Anisogrid cylindrical lattice (ACL) structures have been successfully used in space applications, demonstrating high mechanical performance and weight efficiency. However, the manufacturing process for the composite ACL structures is very complex and, traditionally, involves different technologies, including winding of filaments or prepregs and curing. Tacking the advantage of the fused deposition modeling (FDM) to manufacture completely integral composite parts with complex shape, in this paper, the FDM-3D printing of ACL structures using carbon fiber (CF) and glass fiber (GF) reinforced polyamide 12 (PA12) composites has been investigated. The mechanical behavior of 3D printed ACL structures has been analyzed in terms of the static stiffness, specific load, and failure mode through axial and transverse compression tests, as a function of the geometrical parameters of the lattice structure.\u0000 It was observed that, under transverse compression, after the initial linear elastic response, the applied load changed its slope and continued to increase with increasing displacement up to a specified displacement (inner radius of the ACL structures) without visible fracture or delamination between layers, demonstrating that the 3D printed composite ACL structures are robust and highly efficient in the nodes. Under axial compression, the applied load increased with displacement up to a maximum load and then decreased until fracture, mainly, due to local buckling and material failure of the helical ribs. The 3D printed CF/PA12 ACL structures were found to be more efficient than either the GF/PA12 or PA12 ACL structures taking into account both the axial and transverse specific load and stiffness. The increase in the shell thickness, helical rib width or number of helical ribs resulted in a remarkable increase in the stiffness and load-bearing capacity of the 3D printed composite ACL structures. From the manufacturing perspective, it was shown that the FDM-3D printing technology holds promise for the development of mechanically robust composite ACL structures with excellent reliability.","PeriodicalId":23676,"journal":{"name":"Volume 2: Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability","volume":"64 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"76857183","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}
Intermetallic γ-TiAl based alloys have been developed for high-temperature lightweight applications in aerospace and automotive industries. However, their fabrication via selective laser melting (SLM) remains a great challenge due to the severe cracking issue and unsatisfied mechanical properties. In this study, we present a novel manufacturing strategy to significantly improve the printability of a Ti-48Al-2Cr-2Nb (Ti-4822, at.%) alloy for SLM by powder surface modification. Specially, graphene oxide (GO) sheets were decorated onto the metallic powder surface via the electrostatic adsorption process. Results indicated that crack-free samples could be fabricated by adding 0.1–0.5 wt.% GO during SLM experiments. The microstructure as affected by GO addition was characterized by backscatter electron imaging and electron backscatter diffraction, showing that the dual-phase (α2 + γ) cellular structure was refined at both grain and sub-grain scales. Further characterization by a three-dimensional focused ion beam-scanning electron microscopy tomography demonstrated the increased volume fraction of γ phase and the reduced porosity with GO addition. Finally, the surface strength of as-fabricated Ti-4822 was evaluated by microhardness test, demonstrating a maximal enhancement of 21.9% when modified using 0.3 wt.% GO. We envision that the proposed manufacturing strategy has provided new perspectives for the design and production of high-performance γ-TiAl based alloys via SLM.
{"title":"Selective Laser Melting of Crack-Free Ti-48Al-2Cr-2Nb Alloy: Improved Manufacturability by Powder Surface Modification Using Graphene Oxide","authors":"Xing Zhang, Dian Li, Yufeng Zheng, Y. Liao","doi":"10.1115/msec2022-84993","DOIUrl":"https://doi.org/10.1115/msec2022-84993","url":null,"abstract":"\u0000 Intermetallic γ-TiAl based alloys have been developed for high-temperature lightweight applications in aerospace and automotive industries. However, their fabrication via selective laser melting (SLM) remains a great challenge due to the severe cracking issue and unsatisfied mechanical properties. In this study, we present a novel manufacturing strategy to significantly improve the printability of a Ti-48Al-2Cr-2Nb (Ti-4822, at.%) alloy for SLM by powder surface modification. Specially, graphene oxide (GO) sheets were decorated onto the metallic powder surface via the electrostatic adsorption process. Results indicated that crack-free samples could be fabricated by adding 0.1–0.5 wt.% GO during SLM experiments. The microstructure as affected by GO addition was characterized by backscatter electron imaging and electron backscatter diffraction, showing that the dual-phase (α2 + γ) cellular structure was refined at both grain and sub-grain scales. Further characterization by a three-dimensional focused ion beam-scanning electron microscopy tomography demonstrated the increased volume fraction of γ phase and the reduced porosity with GO addition. Finally, the surface strength of as-fabricated Ti-4822 was evaluated by microhardness test, demonstrating a maximal enhancement of 21.9% when modified using 0.3 wt.% GO. We envision that the proposed manufacturing strategy has provided new perspectives for the design and production of high-performance γ-TiAl based alloys via SLM.","PeriodicalId":23676,"journal":{"name":"Volume 2: Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability","volume":"18 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"73857660","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}
Aiming at the problems of data redundancy and data abnormality of multi-source unstructured data such as video, picture, and text in the process of processing quality inspection and equipment status monitoring of discrete intelligent production line, a multi-source unstructured data cleaning method based on dynamic cloud Bayesian network is proposed. We analyze the characteristics of multi-source unstructured data in the processing operation of the discrete intelligent production line and construct a multi-source unstructured data description model. combine dynamic Bayesian network and cloud model theory to design a multi-source unstructured data cleaning framework and processing flow based on dynamic cloud Bayesian network. finally, the feasibility of the proposed method is demonstrated by simulation analysis of arithmetic cases.
{"title":"A Dynamic Cloud Bayes Network-Based Cleaning Method of Multi-Source Unstructured Data","authors":"Yin Chao, Liao Xinian, Liao Xiaobin","doi":"10.1115/msec2022-85769","DOIUrl":"https://doi.org/10.1115/msec2022-85769","url":null,"abstract":"\u0000 Aiming at the problems of data redundancy and data abnormality of multi-source unstructured data such as video, picture, and text in the process of processing quality inspection and equipment status monitoring of discrete intelligent production line, a multi-source unstructured data cleaning method based on dynamic cloud Bayesian network is proposed. We analyze the characteristics of multi-source unstructured data in the processing operation of the discrete intelligent production line and construct a multi-source unstructured data description model. combine dynamic Bayesian network and cloud model theory to design a multi-source unstructured data cleaning framework and processing flow based on dynamic cloud Bayesian network. finally, the feasibility of the proposed method is demonstrated by simulation analysis of arithmetic cases.","PeriodicalId":23676,"journal":{"name":"Volume 2: Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability","volume":"2 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"85619218","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}
In semiconductor manufacturing, clustering the fab-wide wafer map images is of critical importance for practitioners to understand the subclusters of wafer defects, recognize novel clusters or anomalies, and develop fast reactions to quality issues. However, due to the high-mix manufacturing of diversified wafer products of different sizes and technologies, it is difficult to cluster the wafer map images across the fab. This paper addresses this challenge by proposing a novel methodology for fab-wide wafer map data clustering. In the proposed methodology, a well-known deep learning technique, vision transformer with multi-head attention is first trained to convert binary wafer images of different sizes into condensed feature vectors for efficient clustering. Then, the Topological Data Analysis (TDA), which is widely used in biomedical applications, is employed to visualize the data clusters and identify the anomalies. The TDA yields a topological representation of high-dimensional big data as well as its local clusters by creating a graph that shows nodes corresponding to the clusters within the data. The effectiveness of the proposed methodology is demonstrated by clustering the public wafer map dataset WM-811k from the real application which has a total of 811,457 wafer map images. We further demonstrate the potential applicability of topology data analytics in the semiconductor area by visualization.
{"title":"A Novel Quality Clustering Methodology on Fab-Wide Wafer Map Images in Semiconductor Manufacturing","authors":"Yuan-Ming Hsu, Xiaodong Jia, Wenzhe Li, J. Lee","doi":"10.1115/msec2022-85670","DOIUrl":"https://doi.org/10.1115/msec2022-85670","url":null,"abstract":"\u0000 In semiconductor manufacturing, clustering the fab-wide wafer map images is of critical importance for practitioners to understand the subclusters of wafer defects, recognize novel clusters or anomalies, and develop fast reactions to quality issues. However, due to the high-mix manufacturing of diversified wafer products of different sizes and technologies, it is difficult to cluster the wafer map images across the fab. This paper addresses this challenge by proposing a novel methodology for fab-wide wafer map data clustering. In the proposed methodology, a well-known deep learning technique, vision transformer with multi-head attention is first trained to convert binary wafer images of different sizes into condensed feature vectors for efficient clustering. Then, the Topological Data Analysis (TDA), which is widely used in biomedical applications, is employed to visualize the data clusters and identify the anomalies. The TDA yields a topological representation of high-dimensional big data as well as its local clusters by creating a graph that shows nodes corresponding to the clusters within the data. The effectiveness of the proposed methodology is demonstrated by clustering the public wafer map dataset WM-811k from the real application which has a total of 811,457 wafer map images. We further demonstrate the potential applicability of topology data analytics in the semiconductor area by visualization.","PeriodicalId":23676,"journal":{"name":"Volume 2: Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability","volume":"57 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"84978490","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}
Laurent Heinrich, T. Feldhausen, K. Saleeby, C. Saldana, T. Kurfess
Metal additive manufacturing (AM) processing consists of numerous parameters which take time to optimize for various geometries. One aspect of the metal AM process that continues to be explored is the control of thermal energy accumulation during component manufacturing due to the melting and solidification of the feedstock. Excessive energy accumulation causes thermal failure of the component while minimal energy accumulation causes lack of fusion with the build plate or previous layer. The ability to simulate the thermal response of an AM component can increase research efficiency by reducing the time to optimize thermal energy accumulation. This paper presents an effective implementation of finite element analysis to determine the thermal response of a wire arc additive manufactured component with various build plate sizes and cooling methods including, integral build plate cooling, oversized build plates with passive cooling, and non-integral build plate cooling. The use of integral build plate cooling channels was shown to decrease the interpass temperature at the conclusion of the build process by 55% and build plate temperature by 96% compared to the conventionally deposited sample with 20 second dwell time. The use of a tall build plate with passive cooling was shown to reduce the interpass temperature by 32% as compared to the conventionally deposited sample with 20 second dwell time. Each cooling strategy evaluated decreased the interpass temperature within a range of 20–55% which enables higher deposition rates and decreased dwell times during depositions. The cooling strategies are designed to be implemented in a hybrid or retrofit AM platform to mitigate concerns of the thermal input from the additive process having detrimental effects on the precision of the machining process. This paper shows that accurate simulations of all strategies can be used to accurately predict the thermal response of the various strategies discussed. These cooling strategies will allow for increased deposition rates with comparable interpass temperature and decreased dwell time, increasing deposition efficiency. This model and these simulations are verified by experimental results. It is concluded that passive strategies, such as the over-sized tall build plate, can be used when liquid coolant in the AM environment could negatively affect the deposition process. Active cooling strategies, such as the integral build plate cooling could be used if low thermal conductivity materials are deposited or higher material deposition rates are desired. This paper discusses the use of active and passive cooling used during AM and shows how a simulation model can be used to make design choices for cooling strategies. The model also enables verification of select critical process parameters such as dwell times for a desired interpass temperature.
{"title":"Analysis of Conduction Cooling Strategies for Wire Arc Additive Manufacturing","authors":"Laurent Heinrich, T. Feldhausen, K. Saleeby, C. Saldana, T. Kurfess","doi":"10.1115/msec2022-81641","DOIUrl":"https://doi.org/10.1115/msec2022-81641","url":null,"abstract":"\u0000 Metal additive manufacturing (AM) processing consists of numerous parameters which take time to optimize for various geometries. One aspect of the metal AM process that continues to be explored is the control of thermal energy accumulation during component manufacturing due to the melting and solidification of the feedstock. Excessive energy accumulation causes thermal failure of the component while minimal energy accumulation causes lack of fusion with the build plate or previous layer. The ability to simulate the thermal response of an AM component can increase research efficiency by reducing the time to optimize thermal energy accumulation. This paper presents an effective implementation of finite element analysis to determine the thermal response of a wire arc additive manufactured component with various build plate sizes and cooling methods including, integral build plate cooling, oversized build plates with passive cooling, and non-integral build plate cooling. The use of integral build plate cooling channels was shown to decrease the interpass temperature at the conclusion of the build process by 55% and build plate temperature by 96% compared to the conventionally deposited sample with 20 second dwell time. The use of a tall build plate with passive cooling was shown to reduce the interpass temperature by 32% as compared to the conventionally deposited sample with 20 second dwell time. Each cooling strategy evaluated decreased the interpass temperature within a range of 20–55% which enables higher deposition rates and decreased dwell times during depositions. The cooling strategies are designed to be implemented in a hybrid or retrofit AM platform to mitigate concerns of the thermal input from the additive process having detrimental effects on the precision of the machining process. This paper shows that accurate simulations of all strategies can be used to accurately predict the thermal response of the various strategies discussed. These cooling strategies will allow for increased deposition rates with comparable interpass temperature and decreased dwell time, increasing deposition efficiency. This model and these simulations are verified by experimental results. It is concluded that passive strategies, such as the over-sized tall build plate, can be used when liquid coolant in the AM environment could negatively affect the deposition process. Active cooling strategies, such as the integral build plate cooling could be used if low thermal conductivity materials are deposited or higher material deposition rates are desired. This paper discusses the use of active and passive cooling used during AM and shows how a simulation model can be used to make design choices for cooling strategies. The model also enables verification of select critical process parameters such as dwell times for a desired interpass temperature.","PeriodicalId":23676,"journal":{"name":"Volume 2: Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability","volume":"46 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"74224185","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}
Recent experimental observations show that the frequency of stress and temperature fluctuations on the cutting tool’s rake face and the frequency of residual stress fluctuation at the finished surface of the workpiece are equal to the shear band formation’s frequency. In this article, new experimental observations of the shear band formation in cutting processes are presented. Then, the spacing between neighboring shear bands (which determines the shear band formation’s frequency) is obtained from different theoretical methods and compared with the experimental results. It is shown that the shear band spacing in cutting processes cannot be obtained from the theories developed in other dynamic deformation applications, including dynamic compression and torsion tests and ballistic impacts, due to the unique mechanics of cutting. In addition, we show that due to the intense plastic deformation in the primary deformation zone, the cooling rate of the shear band formed during cutting processes is considerably higher than the workshop cooling rates (6.85 × 108 K·s−1 for the cutting speed of 60 m·min−1 compared to 50 K·s−1 - 2 × 104 K·s−1 for workshop cooling rate of Ti-6Al-4V). The rapid cooling rate indicates the considerable amount of heat transferred into the cutting tool and explains the ductile to brittle transition in the fracture mechanism of shear band formation in cutting processes.
{"title":"Analysis of the Unique Mechanics of Shear Localization in Metal Cutting Processes","authors":"M. Fazlali, M. Ponga, Xiaoliang Jin","doi":"10.1115/msec2022-85645","DOIUrl":"https://doi.org/10.1115/msec2022-85645","url":null,"abstract":"\u0000 Recent experimental observations show that the frequency of stress and temperature fluctuations on the cutting tool’s rake face and the frequency of residual stress fluctuation at the finished surface of the workpiece are equal to the shear band formation’s frequency. In this article, new experimental observations of the shear band formation in cutting processes are presented. Then, the spacing between neighboring shear bands (which determines the shear band formation’s frequency) is obtained from different theoretical methods and compared with the experimental results. It is shown that the shear band spacing in cutting processes cannot be obtained from the theories developed in other dynamic deformation applications, including dynamic compression and torsion tests and ballistic impacts, due to the unique mechanics of cutting. In addition, we show that due to the intense plastic deformation in the primary deformation zone, the cooling rate of the shear band formed during cutting processes is considerably higher than the workshop cooling rates (6.85 × 108 K·s−1 for the cutting speed of 60 m·min−1 compared to 50 K·s−1 - 2 × 104 K·s−1 for workshop cooling rate of Ti-6Al-4V). The rapid cooling rate indicates the considerable amount of heat transferred into the cutting tool and explains the ductile to brittle transition in the fracture mechanism of shear band formation in cutting processes.","PeriodicalId":23676,"journal":{"name":"Volume 2: Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability","volume":"24 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"82138648","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}
With the development of Cyber-Physical Systems (CPS) technologies, many multi-disciplinary collaboration of complex systems that are difficult to solve in a single field can be addressed by simulation in the cyber world. Co-simulation is a typical solution to collaboration of distributed heterogeneous models for complex system. However, the problem of how to select proper simulation models with multi-resolution remains a technical gap for heterogeneous collaboration, which needs more intelligent simulation support provided in the cyber world. In this paper, an intelligent switching method of multi-resolution heterogeneous models oriented for co-simulation of complex systems is proposed. Timing advancing of models with more than one resolution level of simulation resources are incorporated in this architecture. Simulation resources in the form of plug-in-play function blocks can be scheduled by intelligent decision, which can extend the diversity of simulation tasks. After experiments of typical collaborative simulation of a robotic arm in an automatic cruise application scenario, analysis and results show that the proposed method can switch the multi-level simulation resources and trade off well between simulation efficiency and accuracy effectively.
{"title":"An Intelligent Switching Method of Multi-Resolution Models Oriented for Complex System Co-Simulation","authors":"Wenzheng Liu, Chun Zhao, Heming Zhang","doi":"10.1115/msec2022-85367","DOIUrl":"https://doi.org/10.1115/msec2022-85367","url":null,"abstract":"\u0000 With the development of Cyber-Physical Systems (CPS) technologies, many multi-disciplinary collaboration of complex systems that are difficult to solve in a single field can be addressed by simulation in the cyber world. Co-simulation is a typical solution to collaboration of distributed heterogeneous models for complex system. However, the problem of how to select proper simulation models with multi-resolution remains a technical gap for heterogeneous collaboration, which needs more intelligent simulation support provided in the cyber world. In this paper, an intelligent switching method of multi-resolution heterogeneous models oriented for co-simulation of complex systems is proposed. Timing advancing of models with more than one resolution level of simulation resources are incorporated in this architecture. Simulation resources in the form of plug-in-play function blocks can be scheduled by intelligent decision, which can extend the diversity of simulation tasks. After experiments of typical collaborative simulation of a robotic arm in an automatic cruise application scenario, analysis and results show that the proposed method can switch the multi-level simulation resources and trade off well between simulation efficiency and accuracy effectively.","PeriodicalId":23676,"journal":{"name":"Volume 2: Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability","volume":"86 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"77006818","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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