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Influence of the sheet thickness variability on the deep drawing of a cylindrical cup 板材厚度变化对圆柱形杯深冲的影响
Pub Date : 2024-05-15 DOI: 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.
摘要钣金成形工艺在工业中应用广泛。成形过程中不可避免的各种不确定因素会严重影响成形零件的质量。这项工作的目的是量化厚度变化对圆柱杯成形过程的影响。通过数值模拟,研究了在给定杯高的情况下,板材厚度变化对冲力与位移的演变、等效塑性应变分布、耳形轮廓和杯周围厚度的影响。研究了四种不同方差值和相同平均厚度值的厚度分布。得出的结论是,方差的增加会导致厚度分散(杯底和杯的弧度处)和杯沿等效应变分散的增加。杯耳轮廓也受到厚度变化的影响,但程度较小。另一方面,冲力的发展不受厚度变化的影响。
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引用次数: 0
An experimental investigation into tribological behaviour of additively manufactured biocompatible Ti-6Al-4V alloy 对添加式制造的生物相容性 Ti-6Al-4V 合金摩擦学行为的实验研究
Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-19
Marcin Madej
Abstract. Additive manufacturing techniques are increasingly being utilized in industrial-level applications due to their flexibility and ability to produce customized parts, such as various types of biomedical implants. However, the conditions during additive manufacturing fabrication and the nature of these processes can lead to implications on the properties of the produced parts, potentially requiring appropriate post-processing before real applications. The tribological behavior of printed parts not only affects their performance but also their service life, making it crucial to investigate their wear rate and friction coefficient under different lubricant environments. In this study, an experimental investigation was conducted on as-printed Ti-6Al-4V specimens to determine the effect of various lubricant environments on wear rate and friction coefficient. The results demonstrated that the reduction in wear rate in liquid environments can be significantly hindered by the accumulation of debris from the worn specimen. However, the development of a thin film of an appropriate lubricant was shown to be favorable regarding the friction behavior of printed parts.
摘要快速成型制造技术因其灵活性和生产定制部件(如各类生物医学植入物)的能力,正越来越多地应用于工业领域。然而,快速成型制造过程中的条件和这些工艺的性质会对所生产部件的性能产生影响,可能需要在实际应用前进行适当的后处理。打印部件的摩擦学行为不仅会影响其性能,还会影响其使用寿命,因此研究其在不同润滑剂环境下的磨损率和摩擦系数至关重要。在这项研究中,我们对经过印刷的 Ti-6Al-4V 试样进行了实验研究,以确定不同润滑剂环境对磨损率和摩擦系数的影响。结果表明,在液体环境中,磨损率的降低会受到磨损试样碎片堆积的严重阻碍。然而,适当润滑剂薄膜的形成则有利于印刷部件的摩擦行为。
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引用次数: 0
Machine learning application for optimization of laser directed energy deposition process for aerospace component rapid prototyping in additive manufacturing 将机器学习应用于优化增材制造中航空航天部件快速成型的激光定向能沉积工艺
Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-31
G. Ertugrul
Abstract. The paper proposes a methodology for determining the optimal L-DED parameters based on the minimum number planned of L-DED trials. A dataset compiled from planned L-DED experiments was used to train a machine learning model. The algorithm demonstrated a robust ability to predict the output metrics with notable accuracy and proposed a theoretical framework that modeled the complex relationships between the input variables and the resulting critical welding properties for AM. The application of the developed model and its comparison with conventional methods thus offers a methodical approach to determining the optimum process parameters in advance. This is a step towards the development and production of additively manufactured components for future digital twin application in the aerospace industry.
摘要本文提出了一种根据计划的 L-DED 试验的最少次数来确定最佳 L-DED 参数的方法。从计划的 L-DED 试验中汇编的数据集被用来训练一个机器学习模型。该算法表现出了强大的预测能力,能准确预测输出指标,并提出了一个理论框架,用于模拟 AM 输入变量和由此产生的关键焊接性能之间的复杂关系。因此,应用所开发的模型并将其与传统方法进行比较,为提前确定最佳工艺参数提供了一种有条不紊的方法。这是为未来航空航天工业数字孪生应用开发和生产增材制造部件迈出的一步。
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引用次数: 0
Effect of different oxide layer shares on the upsetting of titanium aluminide specimens 不同氧化层份额对铝钛试样镦粗的影响
Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-105
Sebastian Döring
Abstract. By ball milling in a low-oxygen atmosphere, it was possible to show that titanium aluminides (TiAl) can be processed into components by pressing and sintering in the same atmosphere. The properties (e.g. hardness and density) that can be realised with established processes such as field-assisted sintering (FAST) or hot isostatic pressing (HIP) were not achieved. Pores in the component are closed by forming processes, which improves the mechanical properties. In this work, powder-metallurgically processed TiAl was hot-formed in a low-oxygen atmosphere. The forging parameters and pre-consolidation were characterised with regard to their effect on the component properties. Force, hardness and porosity measurements as well as metallographic analyses were used to evaluate the process and the resulting specimens. It was found that a pre-consolidation and a higher degree of deformation lead to a lower porosity and a higher hardness.
摘要。通过在低氧气氛中进行球磨,可以证明钛铝化物(TiAl)可以在同一气氛中通过压制和烧结加工成部件。但在现场辅助烧结(FAST)或热等静压(HIP)等成熟工艺中无法实现这些特性(如硬度和密度)。组件中的孔隙通过成型工艺被封闭,从而提高了机械性能。在这项工作中,粉末冶金加工的钛铝在低氧环境下进行了热成形。根据锻造参数和预凝固对部件性能的影响,对锻造参数和预凝固进行了表征。力、硬度和孔隙率测量以及金相分析被用来评估锻造过程和由此产生的试样。结果发现,预凝固和较大的变形程度会导致较低的孔隙率和较高的硬度。
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引用次数: 0
Influence of cold rolled surface structures with undercuts for interlocking joints on bending processes 用于联锁接头的带暗槽冷轧表面结构对弯曲工艺的影响
Pub Date : 2024-05-15 DOI: 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.
摘要轻量化设计是交通领域减少二氧化碳排放和优化能源效率的方法之一。本研究的主要动机是通过使用汽车行业常用的钢和铝材料进行多材料设计来减轻重量。钢和铝的冶金结合存在形成脆性金属间相的风险。因此,新的连接技术(如通过成型或铸造连接)对这些多材料组件很有前景。在此之前,我们曾介绍过一种混合组件方法,即在改良冷轧工艺制造的钢板上使用带有凹槽的槽状表面结构。在随后的高压压铸过程中,槽道被铝熔体填充,在凝固过程中形成互锁连接。由于汽车部件的复杂性要求越来越高,因此对铸造前结构板材的弯曲进行了研究。本研究旨在分析表面结构如何影响弯曲过程。通过数值模拟和实验,研究了对最大弯曲力、产生的弯曲角度和回弹的影响。因此,弯曲角度、弯曲半径、弯曲两侧通道结构的横向或纵向方向等参数都被考虑在内。结果表明,横向和纵向方向对最大弯曲力有很大影响。此外,还发现弯曲半径对力和回弹的影响较小。
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引用次数: 0
Microstructure refinement by a novel friction-based processing on Mg-Zn-Ca alloy 通过新型摩擦加工细化镁锌钴合金的微观结构
Pub Date : 2024-05-15 DOI: 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.
摘要镁合金的机械性能不足和不可控制的降解率限制了其在生物植入材料中的广泛应用。微结构细化是提高镁合金机械性能和耐腐蚀性能的常用方法。为了有效地获得具有精细微结构的镁合金,使其在生物植入材料中得到潜在的应用,我们提出了一种新颖的约束摩擦加工(CFP)方法。在这项研究中,报告了通过优化加工参数的 CFP 工艺获得的 ZX10 合金的压缩性能。此外,还研究了 CFP 过程中的微观结构演变。结果表明,在 CFP 过程中,材料在搅拌区和热机械影响区之间的过渡区受到高剪切应变,导致再结晶,并产生强烈的局部基底纤维剪切纹理。随着肩部向下俯冲,再结晶晶粒的比例和晶粒尺寸都会增大。通过 CFP 获得的 ZX10 合金的抗压屈服强度提高了 300% 以上,极限抗压强度提高了 60%,这表明 CFP 在镁加工中的应用前景广阔。
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引用次数: 0
Experimental evidence on the twisting of incrementally formed polymer sheets by varying the toolpath strategy 通过改变刀具路径策略实现增量成形聚合物片材扭曲的实验证据
Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-262
A. Formisano
Abstract. In recent years, polymer sheets have been formed by a relatively innovative technology, born for metals and in line with the layered manufacturing principle of rapid prototyping, the incremental sheet forming. This process guarantees high customization and cost-effectiveness but, at the same time, activates some peculiar defects like the twisting phenomenon. To reduce the risk of twisting and the occurrence of failures, it is preferable to reduce the forming forces and one of the solutions is the choice of opportune toolpath strategies. Concerning this, the present experimental research is along the same lines as recent numerical works of the authors; thermoplastic sheets were worked by incremental forming by varying the toolpath strategy. Following the realization of cone frusta, the forming forces and the deformation of the sheets were monitored, to investigate a toolpath strategy capable of reducing the risk of failures and defects for incrementally formed polymer sheets.
摘要近年来,聚合物板材的成型采用了一种相对创新的技术--增量板材成型,这种技术诞生于金属领域,符合快速成型的分层制造原则。这种工艺保证了高度的定制性和成本效益,但同时也会产生一些特殊的缺陷,如扭曲现象。为降低扭曲风险和故障发生率,最好是减少成形力,而解决方案之一就是选择合适的刀具路径策略。在这方面,目前的实验研究与作者近期的数值研究思路相同;通过改变刀具路径策略,以增量成形的方式加工热塑性板材。在实现锥面成形后,对成形力和板材变形进行了监测,以研究一种能够降低增量成形聚合物板材失效和缺陷风险的刀具路径策略。
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引用次数: 0
Effect of micro-plasto-hydrodynamic lubrication on strip surface in steel cold rolling 钢材冷轧过程中微晶-流体动力润滑对带材表面的影响
Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-142
Cynthia Elhajj
Abstract. This study employs numerical calculations based on the micro-plasto-hydrodynamic lubrication (MPHDL) theory to analyze the evolution of oil pits during the stainless-steel cold rolling process. The model is enhanced by incorporating lubricant temperature variations caused by its contact with the heated roll and strip, as well as variations in pit slope. The findings show the significant impact and relevance of considering these additional parameters in assessing the performance of the MPHDL mechanism. Notably, the model demonstrates good agreement with experimental measurements conducted on a Stainless-Steel grade undergoing multiple passes.
摘要本研究采用基于微塑性流体动力润滑(MPHDL)理论的数值计算来分析不锈钢冷轧过程中的油坑演变。通过将润滑剂与加热轧辊和带钢接触时产生的温度变化以及凹坑坡度变化纳入模型,该模型得到了增强。研究结果表明,在评估 MPHDL 机制的性能时,考虑这些附加参数具有重大影响和意义。值得注意的是,该模型与在不锈钢牌号上进行的多道次实验测量结果非常吻合。
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引用次数: 0
Experimental investigation of heterogeneous mechanical tests 异质机械测试的实验研究
Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-193
M. Gonçalves
Abstract. The virtualization of sheet metal forming processes requires a precise numerical model with an accurate description of the material behavior that is classically obtained by carrying out quasi-homogeneous mechanical tests. However, several alternatives to this time-consuming task are under study. Heterogeneous tests can provide a large quantity of mechanical information in a single experiment and, therefore, their potential needs to be investigated. This work aims to present an advanced mechanical test designed by topology optimization under experimental investigation. A numerical design methodology is described, leading to a specimen geometry that is subjected experimentally to uniaxial tensile loading up to rupture. A dual-phase DP600 steel is used. During the test, the strain field is extracted from the specimen surface using a stereo digital image correlation system, and the richness of the mechanical information is further analyzed.
摘要金属板材成型过程的虚拟化需要一个精确的数值模型,该模型能准确描述材料行为,而材料行为通常是通过进行准均质机械测试获得的。然而,目前正在研究几种替代这一耗时任务的方法。异质试验可以在一次试验中提供大量的力学信息,因此需要对其潜力进行研究。这项工作旨在介绍一种通过拓扑优化设计的先进机械测试,并对其进行实验研究。通过描述数值设计方法,得出了试样的几何形状,并在实验中对其进行单轴拉伸加载直至断裂。使用的是双相 DP600 钢。在试验过程中,使用立体数字图像相关系统从试样表面提取应变场,并进一步分析丰富的力学信息。
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引用次数: 0
Recent advances in development, characterization and joining of new sustainable materials 新型可持续材料的开发、表征和连接方面的最新进展
Pub Date : 2024-05-15 DOI: 10.21741/9781644903131-59
Mariana DOINA BANEA
Abstract. Nowadays, in order to increase the transport efficiency and reduce fuel consumption and emissions of contaminants, a reduction in weight associated with improved safety performance of the materials in use must be achieved. On the other hand, environmental concern has generated interest in research about new materials aligned with the principles of sustainability. Thus, this need for better performing and ecological structures has resulted in the development of a new variety of materials. Among these materials, currently, are the composites produced from resources of renewable sources. Natural fiber composites have recently attracted a great deal of attention by the industry due to their many attractive benefits (e.g., high strength-to-weight ratio, sustainable characteristics and low cost). Welding is highly impractical to use in these situations (i.e., thermoset polymer composites) and rivets or screws exhibit stress concentrations and offer a low fatigue resistance. Adhesive bonding is usually the preferred method since it allows for greater flexibility in design and is more efficient in mechanical and energy aspects. In this work, recent advances in development, characterization and joining of new sustainable materials, critical challenges and future perspectives are presented. The application of sustainable green composites may further increase in many structural and non-structural applications if their joining behavior is well-known and established.
摘要如今,为了提高运输效率,减少燃料消耗和污染物排放,必须在减轻重量的同时提高所用材料的安全性能。另一方面,对环境的关注也激发了人们对符合可持续发展原则的新材料的研究兴趣。因此,对性能更好的生态结构的需求导致了各种新型材料的开发。目前,这些材料中包括利用可再生资源生产的复合材料。由于天然纤维复合材料具有许多吸引人的优点(如高强度重量比、可持续特性和低成本),因此最近引起了业界的极大关注。在这些情况下(如热固性聚合物复合材料),使用焊接是非常不切实际的,而铆钉或螺钉会产生应力集中,抗疲劳性能较低。粘合剂粘接通常是首选方法,因为它在设计上具有更大的灵活性,在机械和能源方面也更有效。本文介绍了新型可持续材料在开发、表征和连接方面的最新进展、面临的关键挑战和未来展望。如果可持续绿色复合材料的连接行为广为人知并得到认可,那么其在许多结构性和非结构性应用中的应用可能会进一步增加。
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引用次数: 0
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