Advances in Industrial and Manufacturing Engineering最新文献

Manipulating martensitic transformation and residual stress development in stress superposed incremental forming of SS304

IF 3.9 Q2 ENGINEERING, INDUSTRIAL

Advances in Industrial and Manufacturing Engineering

Pub Date : 2025-03-18 DOI: 10.1016/j.aime.2025.100161

Elizabeth M. Mamros , Fabian Maaß , Thomas H. Gnäupel-Herold , A. Erman Tekkaya , Brad L. Kinsey , Jinjin Ha

Stress superposition is one of the strategies used in metal deformation processes to increase the material formability, decrease the required forming forces, and create highly customized components. To investigate the effects of tensile and compressive stresses superposed to the single point incremental forming (SPIF) process, experiments and numerical simulations were conducted for a stainless steel 304 (SS304) truncated square pyramid geometry. Tensile stresses were superposed in-plane on the specimen blank by a custom hydraulic frame, and compressive stresses were incorporated via a polyurethane die. Identified parameters for a martensitic transformation kinetics model for SS304 were used in a two-step finite element approach to predict the

α

’-martensite volume fraction. These results were compared to experimental results measured by a Feritscope at four locations along each pyramid wall and validated by electron backscatter diffraction. The residual stresses were measured using x-ray diffraction. The parts from each incremental forming process revealed differences in the residual stresses, which impacted the final geometries, and the

α

’-martensite volume fraction at the four measurement locations. The evolution of the stress state, defined by the stress triaxiality and Lode angle parameter, for each process contributed to the phase transformation variance. It was found that superposing both tensile and compressive stresses to SPIF resulted in the greatest phase transformation and lowest magnitude of residual stresses near the base and the greatest overall geometrical accuracy. Stress-superposed incremental forming can be implemented to manipulate final part properties, which is ideal for applications requiring highly customized parts, e.g., biomedical trauma fixation hardware.

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引用次数: 0

Deformation behavior of anisotropic TA18 titanium alloy tube in hydroforming process at room temperature

IF 3.9 Q2 ENGINEERING, INDUSTRIAL

Advances in Industrial and Manufacturing Engineering

Pub Date : 2025-03-15 DOI: 10.1016/j.aime.2025.100159

Xiao-Lei Cui , Yuanyang Zhao , Shijie Yin , Jiuqiang He

While hydroforming of titanium alloy at room temperature is difficult due to its high strength, low hardening capacity, and significant springback, it is typically deformed into desired shape under high-temperature conditions exceeding 500°C, which increases the complexity of the process and raises costs. In this paper, the hydroforming method was used to manufacture TA18 titanium alloy variable-diameter tubular components at room temperature based on an innovative idea of useful wrinkles. The results show that the TA18 titanium alloy tube blank has a strong normal anisotropy of

\overline{r}

= 5.2, which is conducive to developing wrinkles while preventing excessive thinning. When the pressure increases from 0.4 p_s (p_s is initial yield internal pressure) to 0.8 p_s, the number of wrinkles produced on the tube blanks gradually decreases from three to two, and their width increases. When the pressure exceeds p_s, wrinkles cannot be formed on the tube blanks, which will undergo bulging deformation. In the simulation, the wrinkling behavior of the tube blanks does not match the experiment when the Mises yield criterion was used. While using the anisotropic Hill48 yield criterion, the wrinkling trend and development of wrinkles can be well predicted. Furthermore, the wrinkled tubes can be completely flattened under 70 MPa during calibration, and their wall thickness distributions are consistent with the simulation results, with the maximum thinning ratio of the formed components at 6.2%. All of these results provide basic support for manufacturing titanium alloy tubular components with large cross-sectional differences at room temperature using the hydroforming process.

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引用次数: 0

Hybrid investment casting of Al-Cu-Sc alloy-based lattice structures: Material and process characterization

IF 3.9 Q2 ENGINEERING, INDUSTRIAL

Advances in Industrial and Manufacturing Engineering

Pub Date : 2025-03-14 DOI: 10.1016/j.aime.2025.100160

Yifan Li , José Marcelino Dias Filho , Shirin Dehgahi , Sajid Ullah Butt , Hani Henein , Ahmed Jawad Qureshi

This paper characterizes the development and optimization of a hybrid investment casting approach tailored for accurately crafting lattice structures with Al-4.5 wt pct Cu-0.4 wt pct Sc alloy, emphasizing precision in mold making, complex surface detailing, and porosity reduction. The core of the research is the description of the manufacturing procedure and the dimensional optimization strategies associated with this hybrid cast lattice geometries. After exploring the lattice shape produced through this advanced casting method, this research explores the microstructural properties and the solidification cooling rate of this hybrid investment casting. Furthermore, this work also addresses the complexity of the manufacturing protocol and the dimensional refinement method.

引用次数: 0

3D-printed motorcycle seats: Replicating polymer foam performance for rapid prototyping and rider comfort

IF 3.9 Q2 ENGINEERING, INDUSTRIAL

Advances in Industrial and Manufacturing Engineering

Pub Date : 2025-02-20 DOI: 10.1016/j.aime.2025.100158

Andrea Montalti, Patrich Ferretti, Fiammetta Spano, Alfredo Liverani

The development of prototypes prior to the market launch of final products requires adapting production components to reduce costs and increase flexibility for potential modifications. While the manufacturing of rigid or structural components is well-established and widely practiced, the production of expanded materials presents significantly greater challenges due to the final product's reliance on the specific process employed. Changing the process to lower costs necessitates reproducing the same mechanical behaviour and appearance to ensure validation in terms of both style and function. This study focuses on replicating the behaviour of expanded polyurethane foam, commonly used in motorcycle seat padding, using thermoplastic polyurethane (TPU). The aim is to create a prototype or a customised version of the foam. The internal stochastic closed-cell structure is designed using slicing software, and test specimens are subsequently fabricated through Material Extrusion (MEX) additive manufacturing and subjected to compression testing. The results emphasise the critical influence of material hardness and infill density on the force-displacement curves. An experimental map, derived from three parameters (material hardness, elastic modulus, and foam density) illustrates the behaviour of the specimens, with iso-lines representing constant density. This map serves as a valuable tool for accurately replicating desired foam properties, providing guidance on material selection based on force-displacement characteristics.

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引用次数: 0

Manufacturing of irregular shapes through force control in incremental sheet forming with active medium

IF 3.9 Q2 ENGINEERING, INDUSTRIAL

Advances in Industrial and Manufacturing Engineering

Pub Date : 2025-02-11 DOI: 10.1016/j.aime.2025.100157

Sebastian Thiery , Mazhar Zein El Abdine , Jens Heger , Noomane Ben Khalifa

Convex shapes can be created in incremental sheet forming by supporting the workpiece with the pressure of an active medium. In this paper, a method is presented for creating irregular convex shapes by adjusting the pressure to control the forming forces. At first, the general characteristics of the forming forces in incremental sheet forming with active medium (IFAM) are investigated based on a truncated pyramid and a truncated cone. The findings show that the pressure has to be adapted for each contour of the toolpath to achieve a specific wall angle. However, this strategy cannot be applied for an irregular shape consisting of half a truncated pyramid and half a truncated cone since the forming forces fluctuate over one contour. To enhance the control approach, a data set is subsequently generated by recording the forming forces under the influence of the wall angle. The data analysis reveals a strong correlation between the height difference per contour and the tangential force. Finally, a control concept is proposed to adjust the tangential force and is subsequently validated on the irregular-shaped part. The results prove that irregular shapes require a sophisticated control of the forming forces to increase the geometrical accuracy.

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引用次数: 0

Analytical criterion to prevent thermal overshoot during dynamic curing of thick composite laminates

IF 3.9 Q2 ENGINEERING, INDUSTRIAL

Advances in Industrial and Manufacturing Engineering

Pub Date : 2024-12-24 DOI: 10.1016/j.aime.2024.100156

Jordi Farjas , José Antonio González , Daniel Sánchez-Rodríguez , Norbert Blanco , Marc Gascons , Josep Costa

Local overheating during curing of thermosetting resins is likely to occur for thick laminates or during fast curing. Overheating may lead to heterogeneous mechanical properties along the laminate thickness or even to an uncontrolled reaction. To avoid overheating, most thermoset resin manufacturers recommend a “safe” cure cycle. However, these cure cycles can be improved to shorten cure times in thin laminates and may not be good enough to avoid overheating in thick laminates. In this paper, we propose a new analytical model to determine the critical thickness above which thermal runaway occurs when the laminate is heated at a constant rate up to a constant temperature. The model considers different thermal boundaries between the mould and the laminate, i.e., from a perfect thermal contact to a contact of infinite resistance. The analytical model was corroborated through the numerical integration of the equations governing it and experimental data from the curing process of a thick laminate composed of the commercial VTC401 epoxy resin and M55J carbon fiber system. Model predictions indicate that, under the manufacturer's recommended cure cycle, which includes an initial heating rate of 2 K/min, thermal runaway occurs in laminates thicker than 12.4 mm, aligning with experimental observations. A 20-mm-thick laminate, exceeding this threshold, was cured using a reduced heating rate of 0.3 K/min based on our criteria, successfully preventing overheating. The maximum temperature gradient recorded experimentally remained below 1 °C, confirming the model's prediction of uniform thermalization.

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引用次数: 0

Experimental investigation on micro-EDM hybrid drilling process 微型-EDM 混合钻孔工艺的实验研究

IF 3.9 Q2 ENGINEERING, INDUSTRIAL

Advances in Industrial and Manufacturing Engineering

Pub Date : 2024-11-20 DOI: 10.1016/j.aime.2024.100155

C. Ravasio, G. Pellegrini

Micro-EDM drilling is highly appreciated to produce micro-holes on any type of conductive material. Several industrial fields use this technology thanks to its capability to realize very accurate machining. A greater use of micro-EDM drilling process is limited by its poor performance in terms of machining time. To overcome this limit, hybrid solutions are being tested. The idea consists of benefitting from the advantages of at least two technologies trying to overcome the limitation of each one of them. Typically, EDM is used as secondary operation and the process consists of executing the micro-hole on a pre-hole realized by another process like laser. In this way, both the process performance and the quality aspects are guaranteed. Aim of this work is the investigation of the behaviour of the micro-EDM drilling on a pre-hole. In fact, the presence of a pre-hole changes deeply the machining conditions especially in terms of the dielectric flushing. In order to understand how the pre-hole changes the performance of the EDM drilling process, several aspects were investigated: the effects of the diameter of the pre-hole, the behaviour of the type of electrode, the influence of the accuracy of centring operation on the pre-hole and the hole depth. Titanium alloy sheets were used to execute final hole using electrode diameter of 0.3 mm. The process was evaluated considering both the process performance and the accuracy of the machining. The study of the law of electrode motion along its Z axis was also used to gather process information. In general, working with pre-holes yields much better performances than traditional EDM drilling thanks to different level of debris contamination in the machining zone. It was found that increasing the dimension of the pre-hole, the Material Removal Rate undergoes little changes. The electrode type (cylinder or tubular) on the pre-hole does not have evident effects on the process performance but only on the geometrical characteristics. The misalignment of the final hole on the pre-hole can improve the debris flow making the process more efficient but only when a part of the pre-hole lays outside the final hole. Within the limit of this experiments, the hole depth does not affect the presented results.

微电火花钻孔技术可在任何类型的导电材料上钻出微孔，因此备受青睐。由于该技术能够实现非常精确的加工，一些工业领域都在使用这种技术。但由于其在加工时间方面的性能较差，微电火花钻孔工艺的更广泛应用受到了限制。为了克服这一限制，目前正在测试混合解决方案。混合方案的理念是利用至少两种技术的优势，克服每种技术的局限性。通常情况下，电火花加工（EDM）被用作辅助操作，加工过程包括在激光等其他工艺实现的预孔上加工微孔。这样，工艺性能和质量都能得到保证。这项工作的目的是研究在预孔上进行微电火花钻孔的行为。事实上，预孔的存在极大地改变了加工条件，尤其是在电介质冲洗方面。为了了解预孔如何改变放电加工钻孔过程的性能，我们从几个方面进行了研究：预孔直径的影响、电极类型的作用、定心操作精度对预孔和孔深的影响。使用直径为 0.3 毫米的电极对钛合金板进行最终孔加工。对该工艺进行了工艺性能和加工精度评估。对电极沿 Z 轴运动规律的研究也用于收集工艺信息。总的来说，由于加工区的碎片污染程度不同，使用预孔加工比传统电火花钻孔加工的性能要好得多。研究发现，增加预孔的尺寸，材料去除率变化不大。预孔上的电极类型（圆柱形或管状）对加工性能没有明显影响，只是对几何特征有影响。最终孔与预孔的错位可以改善碎片流，提高工艺效率，但仅限于预孔的一部分位于最终孔之外的情况。在本实验范围内，孔的深度不会影响实验结果。

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引用次数: 0

Impact of graphene nanoparticles on DLP-printed parts' mechanical behavior 石墨烯纳米颗粒对 DLP 印刷部件机械性能的影响

IF 3.9 Q2 ENGINEERING, INDUSTRIAL

Advances in Industrial and Manufacturing Engineering

Pub Date : 2024-11-04 DOI: 10.1016/j.aime.2024.100153

Md Imran Hossain , Ola L.A. Harrysson , Mohammad Asaduzzaman Chowdhury , Nayem Hossain

Digital Light Processing (DLP) is one of the most promising techniques among the additive manufacturing (AM) technologies for polymer resin. The polymer parts produced through this technique demonstrate a diverse range of characteristics that can be specifically designed for various fields of application. Specific attributes can be attained by utilizing polymer composites composed of multiple materials in numerous ratios. This research delves into evaluating and comparing different properties, including microstructure, surface texture, and mechanical behavior, of resin-based polymer composites fabricated using the DLP 3D printing technology. To achieve this, specimens have been printed using photopolymer resin as the base material, with varying percentages of graphene nanoparticles added to the resin. Tensile tests and particle analysis based on optical microscope images validate that optimizing parameters, especially the energy setting of the printer, significantly impact the printed samples' strength, surface texture, layering, and microstructure. The findings indicate that at a specific percentage of graphene, such as 0.5%, there is an increase in tensile strength by 38.1%, Young's modulus by 54.7%, and Yield strength by 11.2%, accompanied by an improved surface roughness. A graphene concentration of 0.75% results in diminished tensile strength, yield strength, and Young's modulus. The significance of fine-tuning printing parameters to achieve desired properties in resin-based polymer composites manufactured via 3D printing is highlighted.

数字光处理（DLP）是聚合物树脂增材制造（AM）技术中最有前途的技术之一。通过这种技术生产出的聚合物部件具有多种特性，可针对不同的应用领域进行专门设计。利用由多种材料按不同比例组成的聚合物复合材料可以获得特定的属性。本研究旨在评估和比较使用 DLP 3D 打印技术制造的树脂基聚合物复合材料的不同特性，包括微观结构、表面纹理和机械性能。为此，我们使用感光树脂作为基础材料，在树脂中添加不同比例的石墨烯纳米颗粒，打印出试样。拉伸试验和基于光学显微镜图像的颗粒分析证实，优化参数，尤其是打印机的能量设置，会对打印样品的强度、表面纹理、分层和微观结构产生显著影响。研究结果表明，在特定的石墨烯比例（如 0.5%）下，拉伸强度提高了 38.1%，杨氏模量提高了 54.7%，屈服强度提高了 11.2%，同时表面粗糙度也有所改善。石墨烯浓度为 0.75% 会导致拉伸强度、屈服强度和杨氏模量降低。微调打印参数对通过三维打印技术制造的树脂基聚合物复合材料实现理想性能的重要意义由此凸显。

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引用次数: 0

Erratum to “Influence of changing loading directions on damage in sheet metal forming” [Adv. Ind. Manuf. Eng. 8 (2024) 100139] 对 "改变加载方向对金属板材成型中损坏的影响 "的勘误 [Adv. Ind. Manuf. Eng. 8 (2024) 100139]

IF 3.9 Q2 ENGINEERING, INDUSTRIAL

Advances in Industrial and Manufacturing Engineering

Pub Date : 2024-11-01 DOI: 10.1016/j.aime.2024.100147

Philipp Lennemann, Joshua Grodotzki, Yannis P. Korkolis, A. Erman Tekkaya

引用次数: 0

Modeling of equivalent strain in 2D cross-sections of open die forged components using neural networks 利用神经网络建立开模锻造部件二维截面等效应变模型

IF 3.9 Q2 ENGINEERING, INDUSTRIAL

Advances in Industrial and Manufacturing Engineering

Pub Date : 2024-10-16 DOI: 10.1016/j.aime.2024.100152

Nikhil Vijay Jagtap , Niklas Reinisch , Rasul Abdusalamov , David Bailly , Mikhail Itskov

Open die forging is one of the oldest manufacturing methods known to remove defects in the ingot resulting from the casting process. The improved properties of the final component are highly dependent on the strain distribution. Although sinusoidal equations and empirical formulations have been already used to estimate the strain, they have been applied only to the core of the workpiece. In this work, a novel approach is presented to model the equivalent strain distribution in 2D cross-sections, in the direction of the press, of open die forged components using neural networks. The proposed method efficiently combines a parametric sinusoidal function with a neural network to learn the complex relationships between the process parameters and the resulting local strain. The neural network is trained on a dataset of finite element (FE) simulations of rectangular geometries that cover a wide range of aspect ratios, bite ratios, and height reductions. The presented methodology with near real-time prediction capabilities shows good agreement with FE results. Moreover, the parametric function captures the characteristic pattern of the strain distribution and reveals certain physical relationships affecting the deformation of the material. These patterns are later examined by analyzing the parameters identified in the parametric sinusoidal function.

开模锻造是已知的最古老的制造方法之一，用于消除铸造过程中产生的钢锭缺陷。最终部件性能的改善在很大程度上取决于应变分布。虽然正弦方程和经验公式已被用于估算应变，但它们只适用于工件的核心部分。在这项工作中，提出了一种新方法，利用神经网络对开模锻造部件的二维横截面在冲压方向上的等效应变分布进行建模。所提出的方法将参数正弦函数与神经网络有效地结合起来，以学习工艺参数与所产生的局部应变之间的复杂关系。神经网络是在矩形几何形状的有限元（FE）模拟数据集上进行训练的，该数据集涵盖了宽广的长宽比、咬合比和高度缩减范围。所提出的方法具有近乎实时的预测能力，与 FE 结果显示出良好的一致性。此外，参数函数捕捉到了应变分布的特征模式，并揭示了影响材料变形的某些物理关系。随后，通过分析正弦参数函数中确定的参数，对这些模式进行了研究。

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引用次数: 0