Pub Date : 2024-05-15DOI: 10.21741/9781644903131-243
Xavier Lemoine
Abstract. ArcelorMittal is constantly developing new steel grades to enable the automotive industry to offer safer, lighter, and more environmentally friendly vehicles. These new grades include advanced high-strength steels (AHSS) and Ultra High Strength steels (UHSS) having for some of them lower uniform elongation (UE) than conventional drawing steels. This particularity needs to be considered for an accurate formability prediction in sheet forming numerical simulations. One of these difficulties is the effect of the relatively low uniform elongation on the identification of the parameters of the isotropic hardening model. Various experimental tests can be used to reach the large plastic deformation (hydraulic bulge test, stack compression test, shear test, torsion test or plane strain compression test). The identification protocol of ArcelorMittal for hardening models is based solely on stress-strain curves determined in uniaxial tension. The Exp_S hardening law (TU experimental values before UE%, Swift extension above) was validated by comparison with the stress-strain curves obtained from measurements of experimental tests reaching large strains.
摘要安赛乐米塔尔正在不断开发新的钢种，以使汽车行业能够提供更安全、更轻便、更环保的汽车。这些新钢种包括高级高强度钢（AHSS）和超高强度钢（UHSS），其中一些钢种的均匀伸长率（UE）低于传统的拉拔钢。要在板材成型数值模拟中准确预测可成形性，就必须考虑这种特殊性。其中一个困难是相对较低的均匀伸长率对确定各向同性硬化模型参数的影响。为达到大塑性变形，可采用各种实验测试（液压鼓包测试、堆叠压缩测试、剪切测试、扭转测试或平面应变压缩测试）。安赛乐米塔尔公司对硬化模型的识别规程完全基于单轴拉伸中测定的应力-应变曲线。Exp_S 硬化定律（UE% 前的 TU 实验值，上述 Swift 扩展）通过与达到大应变的实验测试测量所获得的应力-应变曲线进行比较而得到验证。
{"title":"A robust identification protocol of flow curve adjusting parameters using uniaxial tensile curve","authors":"Xavier Lemoine","doi":"10.21741/9781644903131-243","DOIUrl":"https://doi.org/10.21741/9781644903131-243","url":null,"abstract":"Abstract. ArcelorMittal is constantly developing new steel grades to enable the automotive industry to offer safer, lighter, and more environmentally friendly vehicles. These new grades include advanced high-strength steels (AHSS) and Ultra High Strength steels (UHSS) having for some of them lower uniform elongation (UE) than conventional drawing steels. This particularity needs to be considered for an accurate formability prediction in sheet forming numerical simulations. One of these difficulties is the effect of the relatively low uniform elongation on the identification of the parameters of the isotropic hardening model. Various experimental tests can be used to reach the large plastic deformation (hydraulic bulge test, stack compression test, shear test, torsion test or plane strain compression test). The identification protocol of ArcelorMittal for hardening models is based solely on stress-strain curves determined in uniaxial tension. The Exp_S hardening law (TU experimental values before UE%, Swift extension above) was validated by comparison with the stress-strain curves obtained from measurements of experimental tests reaching large strains.","PeriodicalId":515987,"journal":{"name":"Materials Research Proceedings","volume":"19 9","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140971668","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}
Pub Date : 2024-05-15DOI: 10.21741/9781644903131-82
S. Di Donato
Abstract. In the cold wire drawing process, the stress acting on the wire depends on process parameters, as well as on the material flow stress, including the strain-hardening that occurs step by step. It is essential to ensure that the stress applied to the wire at the exit of the die remains below the material's yield stress, to prevent wire necking and fracture. Industrially, the process is carried out continuously using multi-step-multi-wires machines that deform the material to high strain at elevated strain rate values. The application of analytical models for evaluating the stresses acting on the wire assumes simplified boundary conditions, such as an average distribution of strain and strain rate within the die. Further studies are necessary, considering the entire multi-pass industrial case and involving finite element simulation, which is today the main tool for optimizing industrial processes. In this work, the drawing process applied to ETP Pure Copper (99.9% in weight) is analyzed experimentally, analytically, and numerically. The material was characterized by torsion tests and experimental drawing tests were carried out on four steps of the process. Through the analysis of the different analytical methods, it was shown that a careful evaluation of the friction coefficient values is necessary to reduce errors in estimating the drawing forces. The aim is to provide a reliable numerical model for predicting the stress acting on the wire during the multi-pass drawing process, through an appropriate characterization of the material flow stress and an evaluation of the friction model.
{"title":"Experimental, analytical, and numerical analysis of the copper wire multi-pass drawing process","authors":"S. Di Donato","doi":"10.21741/9781644903131-82","DOIUrl":"https://doi.org/10.21741/9781644903131-82","url":null,"abstract":"Abstract. In the cold wire drawing process, the stress acting on the wire depends on process parameters, as well as on the material flow stress, including the strain-hardening that occurs step by step. It is essential to ensure that the stress applied to the wire at the exit of the die remains below the material's yield stress, to prevent wire necking and fracture. Industrially, the process is carried out continuously using multi-step-multi-wires machines that deform the material to high strain at elevated strain rate values. The application of analytical models for evaluating the stresses acting on the wire assumes simplified boundary conditions, such as an average distribution of strain and strain rate within the die. Further studies are necessary, considering the entire multi-pass industrial case and involving finite element simulation, which is today the main tool for optimizing industrial processes. In this work, the drawing process applied to ETP Pure Copper (99.9% in weight) is analyzed experimentally, analytically, and numerically. The material was characterized by torsion tests and experimental drawing tests were carried out on four steps of the process. Through the analysis of the different analytical methods, it was shown that a careful evaluation of the friction coefficient values is necessary to reduce errors in estimating the drawing forces. The aim is to provide a reliable numerical model for predicting the stress acting on the wire during the multi-pass drawing process, through an appropriate characterization of the material flow stress and an evaluation of the friction model.","PeriodicalId":515987,"journal":{"name":"Materials Research Proceedings","volume":"88 8","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140973190","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}
Pub Date : 2024-05-15DOI: 10.21741/9781644903131-166
M. Vanhulst
Abstract. This study focuses on finding a toolpath strategy for accurately forming geometric details on a preshaped sheet metal part by incremental forming in multiple steps. The final thickness distributions and geometrical accuracy are analyzed for spiraling and dedicated feature toolpath strategies. The results are compared to forming the full part (base shape with details) in a conventional single stage manner. Forming the part in multiple steps did improve the accuracy of the part, by decreasing the underforming of the base shape compared to single stage forming. The observed overforming was highly influenced by the location of the detail. In terms of thickness distributions, the toolpath strategy highly influenced the location of the minimal thickness inside each detail. Here, the dedicated feature toolpath proved to be effective for achieving a more uniform thickness distribution.
{"title":"Influence of toolpath strategies on the final accuracy and thickness distributions in multi-stage incremental forming","authors":"M. Vanhulst","doi":"10.21741/9781644903131-166","DOIUrl":"https://doi.org/10.21741/9781644903131-166","url":null,"abstract":"Abstract. This study focuses on finding a toolpath strategy for accurately forming geometric details on a preshaped sheet metal part by incremental forming in multiple steps. The final thickness distributions and geometrical accuracy are analyzed for spiraling and dedicated feature toolpath strategies. The results are compared to forming the full part (base shape with details) in a conventional single stage manner. Forming the part in multiple steps did improve the accuracy of the part, by decreasing the underforming of the base shape compared to single stage forming. The observed overforming was highly influenced by the location of the detail. In terms of thickness distributions, the toolpath strategy highly influenced the location of the minimal thickness inside each detail. Here, the dedicated feature toolpath proved to be effective for achieving a more uniform thickness distribution.","PeriodicalId":515987,"journal":{"name":"Materials Research Proceedings","volume":"29 4","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140973415","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}
Pub Date : 2024-05-15DOI: 10.21741/9781644903131-153
V. Psyk
Abstract. Joining by electromagnetic forming can provide high-strength connections of tubes and connector parts from different materials. In order to qualify this technology for manufacturing components made of high-strength aluminum alloys typically used in aircraft manufacturing a parameter study was performed on form fit joining of tubes (outer diameter: 70 mm, wall thickness: 1.6 mm) and mandrels (diameter: 66.6 mm) both made of EN AW-2024 (T351). Since some aircraft applications, e. g. the so-called z-struts, which support the passenger floor of the airplane, are related to high axial compressive loads and medium axial tensile loads, this load scenario was considered. In order to increase especially the compressive load-bearing capacity, joint configurations featuring direct support of the tube end via a step or a shoulder of the joining partner were designed and investigated. The axial support can increase the transferable compressive load, while the tensile load remains largely unaffected. Attention must be paid to the gap between tube end and axial support, which cannot be fully avoided due to axial material flow during the electromagnetic joining process. Bending the tube end into a groove providing axial support of the tube end enables compressive load-bearing capacities, which can approximate the strength of the tube material. Here, increasing bending angles improve the load-bearing capacity under tensile force, but reduce the transferable compressive load. Multiple groove configurations can provide acceptable load bearing capacity considering tensile and compressive load. Numerical simulation can predict the general behavior of components joined by electromagnetic forming, help to understand the damage mechanisms of the joint and allow identifying trends for joint design.
摘要通过电磁成形连接可实现不同材料管材和连接件的高强度连接。为了验证该技术是否适用于飞机制造中常用的高强度铝合金部件，对 EN AW-2024 (T351) 管（外径：70 毫米，壁厚：1.6 毫米）和心轴（直径：66.6 毫米）的成型连接进行了参数研究。由于某些飞机应用（例如支撑飞机乘客地板的所谓 Z 形支柱）需要承受高轴向压缩载荷和中等轴向拉伸载荷，因此考虑了这种载荷情况。为了特别提高压缩承载能力，设计并研究了通过连接件的台阶或肩部直接支撑管端的连接构造。轴向支撑可以增加可传递的压缩载荷，而拉伸载荷基本不受影响。必须注意管端与轴向支撑之间的间隙，在电磁连接过程中，由于材料的轴向流动，无法完全避免这种间隙。将管端弯曲到凹槽中，为管端提供轴向支撑，可实现压缩承载能力，这可以接近管材料的强度。在这种情况下，增加弯曲角度可提高拉伸力下的承载能力，但会降低可传递的压缩载荷。考虑到拉伸和压缩载荷，多种沟槽配置可提供可接受的承载能力。数值模拟可以预测通过电磁成形连接的部件的一般行为，有助于了解连接的损坏机制，并确定连接设计的趋势。
{"title":"Numerical and experimental analysis of struts joined by electromagnetic forming for aircraft applications","authors":"V. Psyk","doi":"10.21741/9781644903131-153","DOIUrl":"https://doi.org/10.21741/9781644903131-153","url":null,"abstract":"Abstract. Joining by electromagnetic forming can provide high-strength connections of tubes and connector parts from different materials. In order to qualify this technology for manufacturing components made of high-strength aluminum alloys typically used in aircraft manufacturing a parameter study was performed on form fit joining of tubes (outer diameter: 70 mm, wall thickness: 1.6 mm) and mandrels (diameter: 66.6 mm) both made of EN AW-2024 (T351). Since some aircraft applications, e. g. the so-called z-struts, which support the passenger floor of the airplane, are related to high axial compressive loads and medium axial tensile loads, this load scenario was considered. In order to increase especially the compressive load-bearing capacity, joint configurations featuring direct support of the tube end via a step or a shoulder of the joining partner were designed and investigated. The axial support can increase the transferable compressive load, while the tensile load remains largely unaffected. Attention must be paid to the gap between tube end and axial support, which cannot be fully avoided due to axial material flow during the electromagnetic joining process. Bending the tube end into a groove providing axial support of the tube end enables compressive load-bearing capacities, which can approximate the strength of the tube material. Here, increasing bending angles improve the load-bearing capacity under tensile force, but reduce the transferable compressive load. Multiple groove configurations can provide acceptable load bearing capacity considering tensile and compressive load. Numerical simulation can predict the general behavior of components joined by electromagnetic forming, help to understand the damage mechanisms of the joint and allow identifying trends for joint design.","PeriodicalId":515987,"journal":{"name":"Materials Research Proceedings","volume":"89 6","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140973181","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}
Pub Date : 2024-05-15DOI: 10.21741/9781644903131-181
Marc Crescenti
Abstract. The combination of different materials enables to achieve highly efficient structures in terms of lightweight and mechanical performance, as well as in terms of manufacturing costs. However, the weakest points of these structures use to be the joints. For this reason, in the last years, many studies have dealt with joining technologies for dissimilar materials. The Reinforce3D’s Continuous Fibre Injection Process (CFIP) technology delivers a unique method to join dissimilar materials. CFIP is based on injecting continuous fibers, such as carbon fibers, simultaneously with liquid resin into tubular cavities within the part. Then the resin is cured and the final composite part is obtained. This work focuses on the characterization of the mechanical properties of CFIP-made specimens and describes the potential lightweight benefits of the technology. Mechanical tests were performed under tensile and bending conditions following standardized methods. The lightweight potential is addressed by developing a representative case study by implementing finite element and topology optimization methods. The results of this case study were finally compared with a monomaterial equivalent component (aluminium) demonstrating the improvement that CFIP provides in terms of lightweight while keeping the strength.
{"title":"The continuous fibre injection process (CFIP): A novel approach to lightweight design of multi-material structural components","authors":"Marc Crescenti","doi":"10.21741/9781644903131-181","DOIUrl":"https://doi.org/10.21741/9781644903131-181","url":null,"abstract":"Abstract. The combination of different materials enables to achieve highly efficient structures in terms of lightweight and mechanical performance, as well as in terms of manufacturing costs. However, the weakest points of these structures use to be the joints. For this reason, in the last years, many studies have dealt with joining technologies for dissimilar materials. The Reinforce3D’s Continuous Fibre Injection Process (CFIP) technology delivers a unique method to join dissimilar materials. CFIP is based on injecting continuous fibers, such as carbon fibers, simultaneously with liquid resin into tubular cavities within the part. Then the resin is cured and the final composite part is obtained. This work focuses on the characterization of the mechanical properties of CFIP-made specimens and describes the potential lightweight benefits of the technology. Mechanical tests were performed under tensile and bending conditions following standardized methods. The lightweight potential is addressed by developing a representative case study by implementing finite element and topology optimization methods. The results of this case study were finally compared with a monomaterial equivalent component (aluminium) demonstrating the improvement that CFIP provides in terms of lightweight while keeping the strength.","PeriodicalId":515987,"journal":{"name":"Materials Research Proceedings","volume":"72 6","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140973715","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}
Pub Date : 2024-05-15DOI: 10.21741/9781644903131-70
Connie Qian
Abstract. Composites manufacturing using prepreg general a large proportion of waste from ply cutting, which usually ends up in landfill. A novel reuse route for prepreg manufacturing waste is proposed by combining chip-SMC reprocessed from the waste material and the virgin continuous fibre prepreg to create hybrid architecture composites. Experimental studies are performed to investigate the flow behaviour of prepreg chip-SMC under typical compression moulding conditions and benchmark it against a conventional SMC. Process characterisation is also performed for hybrid architecture composites to understand the critical deformation mechanisms of chip-SMC and prepreg, and the interaction between the two materials. Compression moulding trials are performed to further study the material behaviour and process characterises under realistic manufacturing conditions.
{"title":"Experimental characterisation for compression moulding of hybrid architecture composites using reclaimed prepreg manufacturing waste","authors":"Connie Qian","doi":"10.21741/9781644903131-70","DOIUrl":"https://doi.org/10.21741/9781644903131-70","url":null,"abstract":"Abstract. Composites manufacturing using prepreg general a large proportion of waste from ply cutting, which usually ends up in landfill. A novel reuse route for prepreg manufacturing waste is proposed by combining chip-SMC reprocessed from the waste material and the virgin continuous fibre prepreg to create hybrid architecture composites. Experimental studies are performed to investigate the flow behaviour of prepreg chip-SMC under typical compression moulding conditions and benchmark it against a conventional SMC. Process characterisation is also performed for hybrid architecture composites to understand the critical deformation mechanisms of chip-SMC and prepreg, and the interaction between the two materials. Compression moulding trials are performed to further study the material behaviour and process characterises under realistic manufacturing conditions.","PeriodicalId":515987,"journal":{"name":"Materials Research Proceedings","volume":"31 2","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140974219","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}
Pub Date : 2024-05-15DOI: 10.21741/9781644903131-202
A.F.G. Pereira
Abstract. Sheet metal forming processes are widely used in industry. The quality of formed parts can be significantly affected by various sources of uncertainty inevitably associated with the forming process. The objective of this work is to quantify the influence of thickness variability on the forming process of a cylindrical cup. Using numerical simulation, the influence of the sheet thickness variance on the evolution of the punch force versus displacement, the equivalent plastic strain distribution, the earing profile and the thickness around the cup is studied for a given cup height. Four thickness distributions with different variance values and the same average thickness value were studied. It was concluded that an increase in variance leads to an increase in thickness dispersion (at the base and curvature of the cup) and an increase in equivalent strain dispersion along the cup. The earing profile of the cup is also affected by the thickness variability, but to a lesser extent. On the other hand, the development of the punch force is not affected by the thickness variability.
{"title":"Influence of the sheet thickness variability on the deep drawing of a cylindrical cup","authors":"A.F.G. Pereira","doi":"10.21741/9781644903131-202","DOIUrl":"https://doi.org/10.21741/9781644903131-202","url":null,"abstract":"Abstract. Sheet metal forming processes are widely used in industry. The quality of formed parts can be significantly affected by various sources of uncertainty inevitably associated with the forming process. The objective of this work is to quantify the influence of thickness variability on the forming process of a cylindrical cup. Using numerical simulation, the influence of the sheet thickness variance on the evolution of the punch force versus displacement, the equivalent plastic strain distribution, the earing profile and the thickness around the cup is studied for a given cup height. Four thickness distributions with different variance values and the same average thickness value were studied. It was concluded that an increase in variance leads to an increase in thickness dispersion (at the base and curvature of the cup) and an increase in equivalent strain dispersion along the cup. The earing profile of the cup is also affected by the thickness variability, but to a lesser extent. On the other hand, the development of the punch force is not affected by the thickness variability.","PeriodicalId":515987,"journal":{"name":"Materials Research Proceedings","volume":"6 12","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140974441","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}
Pub Date : 2024-05-15DOI: 10.21741/9781644903131-64
N. Siddig
Abstract. The ZEBRA project aims to advance the circular economy by creating wind turbine blades that can be completely recycled. Currently, Wind turbine blades are fabricated through Vacuum-Assisted Resin Infusion (VARI) using thermoset resins. In this endeavor, the recyclable thermoplastic resin Elium® from Arkema is utilized as a sustainable alternative to traditional thermoset resins. The production of thick and sizable components using reactive resins presents various intertwined physical aspects and difficulties, notably concerning potential overheating during the Elium® radical polymerization process. The optimization of this process necessitates the use of simulation to save the expensive time and effort caused by the experiments. However, to be reliable, these numerical methods must be validated to allow accurate predictions for potential defects with thick and complex parts. The challenge lies in flow front detection in the through-thickness direction. In this work, infusion tests were conducted for thick parts in a testing bench instrumented with a robust monitoring system. QRS sensors are placed through the part thickness to detect the front arrival instantaneously. The simulations are compared and validated to the signals of the QRS sensors for validation. Then the model was used to predict the flow behavior for more complex parts. A 3D flow is observed by the differences in permeability between the flow medium and the fabric, which induces a high difference in resin arrival times to the sensors depending on the position of sensors through the part thickness. The flow simulations showed a good approximation of the experimental results. However, deviations are observed in the flow front position, caused by the disturbance induced by the presence of the sensors.
{"title":"Simulation and monitoring of the infusion of thick composites with thermoplastic acrylic resin","authors":"N. Siddig","doi":"10.21741/9781644903131-64","DOIUrl":"https://doi.org/10.21741/9781644903131-64","url":null,"abstract":"Abstract. The ZEBRA project aims to advance the circular economy by creating wind turbine blades that can be completely recycled. Currently, Wind turbine blades are fabricated through Vacuum-Assisted Resin Infusion (VARI) using thermoset resins. In this endeavor, the recyclable thermoplastic resin Elium® from Arkema is utilized as a sustainable alternative to traditional thermoset resins. The production of thick and sizable components using reactive resins presents various intertwined physical aspects and difficulties, notably concerning potential overheating during the Elium® radical polymerization process. The optimization of this process necessitates the use of simulation to save the expensive time and effort caused by the experiments. However, to be reliable, these numerical methods must be validated to allow accurate predictions for potential defects with thick and complex parts. The challenge lies in flow front detection in the through-thickness direction. In this work, infusion tests were conducted for thick parts in a testing bench instrumented with a robust monitoring system. QRS sensors are placed through the part thickness to detect the front arrival instantaneously. The simulations are compared and validated to the signals of the QRS sensors for validation. Then the model was used to predict the flow behavior for more complex parts. A 3D flow is observed by the differences in permeability between the flow medium and the fabric, which induces a high difference in resin arrival times to the sensors depending on the position of sensors through the part thickness. The flow simulations showed a good approximation of the experimental results. However, deviations are observed in the flow front position, caused by the disturbance induced by the presence of the sensors.","PeriodicalId":515987,"journal":{"name":"Materials Research Proceedings","volume":"36 4","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140972672","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}
Pub Date : 2024-05-15DOI: 10.21741/9781644903131-186
A. Ringel
Abstract. Lightweight design is one of the methods to reduce CO2 emissions and optimize energy efficiency in the transportation sector. The main motivation of this study arise from weight reduction through multi-material design with the materials commonly used in the automotive industry, steel and aluminum. Metallurgical bonding of steel and aluminum carries the risk of forming brittle intermetallic phases. Hence, new joining techniques such as joining by forming or casting are promising for these multi-material components. Previously, a hybrid component method was presented using channel-like surface structures with undercuts on a steel sheet created in a modified cold rolling process. In a subsequent high-pressure die casting, the channels were filled with aluminum melt, forming an interlocking connection as it solidified. As automotive components demand increased complexity, the bending of the structured sheet before casting was investigated. This study aims to analyze how the surface structure affects the bending process. Numerical simulations and experiments were used to investigate the effect on the maximum bending force, the resulting bending angle and springback. Therefore, the parameters bending angle, bending radius, and the lateral or longitudinal orientations of the channel structure on either sides of the bend were taken into account. The results showed a strong influence of the lateral and longitudinal orientation on the maximum bending force. Furthermore, a minor effect of the bending radius on the force and springback was found.
{"title":"Influence of cold rolled surface structures with undercuts for interlocking joints on bending processes","authors":"A. Ringel","doi":"10.21741/9781644903131-186","DOIUrl":"https://doi.org/10.21741/9781644903131-186","url":null,"abstract":"Abstract. Lightweight design is one of the methods to reduce CO2 emissions and optimize energy efficiency in the transportation sector. The main motivation of this study arise from weight reduction through multi-material design with the materials commonly used in the automotive industry, steel and aluminum. Metallurgical bonding of steel and aluminum carries the risk of forming brittle intermetallic phases. Hence, new joining techniques such as joining by forming or casting are promising for these multi-material components. Previously, a hybrid component method was presented using channel-like surface structures with undercuts on a steel sheet created in a modified cold rolling process. In a subsequent high-pressure die casting, the channels were filled with aluminum melt, forming an interlocking connection as it solidified. As automotive components demand increased complexity, the bending of the structured sheet before casting was investigated. This study aims to analyze how the surface structure affects the bending process. Numerical simulations and experiments were used to investigate the effect on the maximum bending force, the resulting bending angle and springback. Therefore, the parameters bending angle, bending radius, and the lateral or longitudinal orientations of the channel structure on either sides of the bend were taken into account. The results showed a strong influence of the lateral and longitudinal orientation on the maximum bending force. Furthermore, a minor effect of the bending radius on the force and springback was found.","PeriodicalId":515987,"journal":{"name":"Materials Research Proceedings","volume":"38 2","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140975867","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}
Pub Date : 2024-05-15DOI: 10.21741/9781644903131-224
Ting Chen
Abstract. Insufficient mechanical properties and uncontrollable degradation rates limit the wide application of Mg alloys in bioimplant materials. Microstructure refinement is a common method to improve both the mechanical properties and the corrosion resistance of Mg alloys. In order to efficiently obtain Mg alloys with fine microstructures for potential applications in bioimplant materials, a novel constrained friction processing (CFP) was proposed. In this work, the resulting compression properties of ZX10 alloy obtained by CFP with optimized processing parameter are reported. Additionally, the microstructure evolution during CFP was studied. The results show that during CFP, materials are subjected to high shear strain at the transition zone between the stir zone and thermo-mechanical affected zone, leading to recrystallization with strong local basal fiber shear texture. As the shoulder plunges down, the fraction of recrystallized grain and grain size increase. ZX10 alloy obtained by CFP exhibited higher compressive yield strength by more than 300% and ultimate compressive strength improves by 60%, which indicates the bright prospect of CFP for Mg processing.
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