Pub Date : 2020-01-01DOI: 10.1051/mfreview/2020002
M. Condruz, G. Matache, A. Paraschiv
Additive manufacturing of high-quality materials by Selective Laser Melting depends not only on establishing appropriate process parameters, but also on the characteristics of the metal powders used and their stability over time or after recycling. The aim of the research was to characterize the IN 625 powder used over multiple manufacturing cycles with a Lasertec 30 SLM machine. In order to achieve the research's goal, virgin and recirculated powder's physical and technological characteristics were investigated. A decrease in all D-values (D10, D50, D90) of the powder size distribution was observed after multiple recirculation cycles showing a decrease of the powder dimensional range over time. Both virgin and recirculated powders are composed of mainly spherical particles, but elongated particles and satellite particles were observed as well. The dimensional evolution analysis showed a deviation from the powder ideal roundness, deviation that is more pronounced over multiple recirculation cycles. It was experimentally determined that the powders present a good flowability based on the flow rate value obtained for both virgin and recirculated powders, confirmed also by the Hausner ratio and angle of repose.
{"title":"Characterization of IN 625 recycled metal powder used for selective laser melting","authors":"M. Condruz, G. Matache, A. Paraschiv","doi":"10.1051/mfreview/2020002","DOIUrl":"https://doi.org/10.1051/mfreview/2020002","url":null,"abstract":"Additive manufacturing of high-quality materials by Selective Laser Melting depends not only on establishing appropriate process parameters, but also on the characteristics of the metal powders used and their stability over time or after recycling. The aim of the research was to characterize the IN 625 powder used over multiple manufacturing cycles with a Lasertec 30 SLM machine. In order to achieve the research's goal, virgin and recirculated powder's physical and technological characteristics were investigated. A decrease in all D-values (D10, D50, D90) of the powder size distribution was observed after multiple recirculation cycles showing a decrease of the powder dimensional range over time. Both virgin and recirculated powders are composed of mainly spherical particles, but elongated particles and satellite particles were observed as well. The dimensional evolution analysis showed a deviation from the powder ideal roundness, deviation that is more pronounced over multiple recirculation cycles. It was experimentally determined that the powders present a good flowability based on the flow rate value obtained for both virgin and recirculated powders, confirmed also by the Hausner ratio and angle of repose.","PeriodicalId":51873,"journal":{"name":"Manufacturing Review","volume":null,"pages":null},"PeriodicalIF":2.5,"publicationDate":"2020-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://sci-hub-pdf.com/10.1051/mfreview/2020002","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"57963740","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 : 2020-01-01DOI: 10.1051/mfreview/2020003
F. Pilz, J. Henneberg, M. Merklein
Increasing demands in modern production pose new challenges to established forming processes. One approach to meet these challenges is the combined use of established process classes such as sheet and bulk forming. This innovative process class, also called sheet-bulk metal forming (SBMF), facilitates the forming of minute functional elements such as lock toothing and gear toothing on sheet-metal bodies. High tool loads and a complex material flow that is hard to control are characteristic of SBMF. Due to these challenging process conditions, the forming of functional elements is often insufficient and necessitates rework. This negatively affects economic efficiency. In order to make use of SBMF in industrial contexts, it is necessary to develop measures for improving the forming of functional elements and thereby push existing forming boundaries. This paper describes the design and numerical replication of both a forward and a lateral extrusion process so as to create involute gearing in combination with carrier teeth. In a combined numerical-experimental approach, measures for extending the die filling in sheet-metal extrusion processes are identified and investigated. Here, the focus is on approaches such as process parameters, component design and locally adjusted tribological conditions; so-called ‘tailored surfaces’. Based on the findings, fundamental mechanisms of action are identified, and measures are assessed with regard to their potential for application. The examined approaches show their potential for improving the forming of functional elements and, consequently, the improvement of geometrical accuracies in functional areas of the workpieces.
{"title":"Extension of the forming limits of extrusion processes in sheet-bulk metal forming for production of minute functional elements","authors":"F. Pilz, J. Henneberg, M. Merklein","doi":"10.1051/mfreview/2020003","DOIUrl":"https://doi.org/10.1051/mfreview/2020003","url":null,"abstract":"Increasing demands in modern production pose new challenges to established forming processes. One approach to meet these challenges is the combined use of established process classes such as sheet and bulk forming. This innovative process class, also called sheet-bulk metal forming (SBMF), facilitates the forming of minute functional elements such as lock toothing and gear toothing on sheet-metal bodies. High tool loads and a complex material flow that is hard to control are characteristic of SBMF. Due to these challenging process conditions, the forming of functional elements is often insufficient and necessitates rework. This negatively affects economic efficiency. In order to make use of SBMF in industrial contexts, it is necessary to develop measures for improving the forming of functional elements and thereby push existing forming boundaries. This paper describes the design and numerical replication of both a forward and a lateral extrusion process so as to create involute gearing in combination with carrier teeth. In a combined numerical-experimental approach, measures for extending the die filling in sheet-metal extrusion processes are identified and investigated. Here, the focus is on approaches such as process parameters, component design and locally adjusted tribological conditions; so-called ‘tailored surfaces’. Based on the findings, fundamental mechanisms of action are identified, and measures are assessed with regard to their potential for application. The examined approaches show their potential for improving the forming of functional elements and, consequently, the improvement of geometrical accuracies in functional areas of the workpieces.","PeriodicalId":51873,"journal":{"name":"Manufacturing Review","volume":null,"pages":null},"PeriodicalIF":2.5,"publicationDate":"2020-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://sci-hub-pdf.com/10.1051/mfreview/2020003","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"57963763","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 : 2020-01-01DOI: 10.1051/mfreview/2020028
S. Oyinbo, T. Jen, S. A. Aasa, O. Abegunde, Yudan Zhu
The objective of this study is to create an ultra-thin palladium foil with a molecular dynamic (MD) simulation technique on a copper substrate surface. The layer formed onto the surface consists of a singular 3D palladium (Pd) nanoparticle structure which, by the cold gas dynamic spray (CGDS) technique, is especially incorporated into the low-cost copper substrate. Pd and Cu have been chosen for their possible hydrogen separation technology applications. The nanoparticles were deposited to the substrate surface with an initial velocity ranging from 500 to 1500 m/s. The particle radius was 1 to 4 nm and an angle of impact of 90° at room temperature of 300 K, in order to evaluate changes in the conduct of deformation caused by effects of size. The deformation mechanisms study revealed that the particle and substrate interface is subject to the interfacial jet formation and adiabatic softening resulting in a uniform layering. However, shear instabilities at high impact speeds were confirmed by the evolution of von Mises shear strain, temperature evolution and plastic strain. The results of this study can be used to further our existing knowledge in the complex spraying processes of cold gas dynamic spray technology.
{"title":"Development of palladium nanoparticles deposition on a copper substrate using a molecular dynamic (MD) simulation: a cold gas dynamic spray process","authors":"S. Oyinbo, T. Jen, S. A. Aasa, O. Abegunde, Yudan Zhu","doi":"10.1051/mfreview/2020028","DOIUrl":"https://doi.org/10.1051/mfreview/2020028","url":null,"abstract":"The objective of this study is to create an ultra-thin palladium foil with a molecular dynamic (MD) simulation technique on a copper substrate surface. The layer formed onto the surface consists of a singular 3D palladium (Pd) nanoparticle structure which, by the cold gas dynamic spray (CGDS) technique, is especially incorporated into the low-cost copper substrate. Pd and Cu have been chosen for their possible hydrogen separation technology applications. The nanoparticles were deposited to the substrate surface with an initial velocity ranging from 500 to 1500 m/s. The particle radius was 1 to 4 nm and an angle of impact of 90° at room temperature of 300 K, in order to evaluate changes in the conduct of deformation caused by effects of size. The deformation mechanisms study revealed that the particle and substrate interface is subject to the interfacial jet formation and adiabatic softening resulting in a uniform layering. However, shear instabilities at high impact speeds were confirmed by the evolution of von Mises shear strain, temperature evolution and plastic strain. The results of this study can be used to further our existing knowledge in the complex spraying processes of cold gas dynamic spray technology.","PeriodicalId":51873,"journal":{"name":"Manufacturing Review","volume":null,"pages":null},"PeriodicalIF":2.5,"publicationDate":"2020-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://sci-hub-pdf.com/10.1051/mfreview/2020028","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"57963799","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 : 2020-01-01DOI: 10.1051/mfreview/2020033
J. Henneberg, M. Merklein
The increasing demand for lightweight design requires functional integration. This poses challenges to conventional manufacturing processes due to the rising geometrical complexity of components. The application of bulk forming operations to sheet metal, named sheet-bulk metal forming (SBMF), is one approach to overcome these challenges. Currently, mainly pre-cut blanks are applied in research of SBMF. Production from coil, in contrast, would combine the advantages of SBMF with the advantages of manufacturing from a coil regarding high output quantity. To research SBMF from coil, a lateral and a backward extrusion process are set up. In addition to a reduced geometrical accuracy of the parts, which is known from SBMF of pre-cut blanks, an anisotropic material flow is identified as a coil-specific challenge. The aim of this research is to investigate measures that extend the forming limits by means of a material flow control. For this purpose, a combined numerical-experimental approach is applied in order to analyze and evaluate an adaption of the width of the coil, the feed width, and the local friction as measures for material flow control. Particularly local adaptation of friction by means of modified tool surfaces reduces the anisotropic material flow and improves the geometrical accuracy of the parts.
{"title":"Measures for controlling the material flow when extruding sheet-bulk metal forming parts from coil","authors":"J. Henneberg, M. Merklein","doi":"10.1051/mfreview/2020033","DOIUrl":"https://doi.org/10.1051/mfreview/2020033","url":null,"abstract":"The increasing demand for lightweight design requires functional integration. This poses challenges to conventional manufacturing processes due to the rising geometrical complexity of components. The application of bulk forming operations to sheet metal, named sheet-bulk metal forming (SBMF), is one approach to overcome these challenges. Currently, mainly pre-cut blanks are applied in research of SBMF. Production from coil, in contrast, would combine the advantages of SBMF with the advantages of manufacturing from a coil regarding high output quantity. To research SBMF from coil, a lateral and a backward extrusion process are set up. In addition to a reduced geometrical accuracy of the parts, which is known from SBMF of pre-cut blanks, an anisotropic material flow is identified as a coil-specific challenge. The aim of this research is to investigate measures that extend the forming limits by means of a material flow control. For this purpose, a combined numerical-experimental approach is applied in order to analyze and evaluate an adaption of the width of the coil, the feed width, and the local friction as measures for material flow control. Particularly local adaptation of friction by means of modified tool surfaces reduces the anisotropic material flow and improves the geometrical accuracy of the parts.","PeriodicalId":51873,"journal":{"name":"Manufacturing Review","volume":null,"pages":null},"PeriodicalIF":2.5,"publicationDate":"2020-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"57963883","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 : 2020-01-01DOI: 10.1051/mfreview/2020017
K. Alaneme, Ayoyemi Adebanji Fatokun, S. R. Oke, P. Olubambi
In this study, nanoindentation tests were used to evaluate the mechanical properties of spark plasma sintered Ti based composites containing 5, 10 and 15 wt.% Nb2O5, targeted for potential use as biomedical material. Nanoindentation tests were performed on the samples using indenter loads of 20 and 100 mN, while the microstructures were characterized using scanning electron microscopy. It was noted that with increasing Nb2O5 wt.%, there is transition from the lamellar structure of pure Ti to fully bimodal structures for the Ti-10 wt.% Nb2O5 and Ti-15 wt.% Nb2O5 composites. The hardness (6.0–40.67 GPa (20 mN) and 2.4–12.03 GPa (100 mN)) and reduced elastic modulus (115–266.91 GPa (20 mN) and (28.05–96.873 GPa (100 mN)) of the composites increases with increase in the Nb2O5 content, attributed to contributions of load transfer from the Ti matrix to the relatively harder Nb2O5 particles, particle and dispersion strengthening mechanisms. The elastic recovery index also improved with increase in Nb2O5 content, while the inverse was noted with respect to plasticity index. The elastic strain to failure and yield pressure both improved with increase in Nb2O5 content, which suggests that the antiwear properties and resistance to impact loading equally improves with Nb2O5 addition.
{"title":"Nanoindentation studies and analysis of the mechanical properties of Ti-Nb2O5 based composites","authors":"K. Alaneme, Ayoyemi Adebanji Fatokun, S. R. Oke, P. Olubambi","doi":"10.1051/mfreview/2020017","DOIUrl":"https://doi.org/10.1051/mfreview/2020017","url":null,"abstract":"In this study, nanoindentation tests were used to evaluate the mechanical properties of spark plasma sintered Ti based composites containing 5, 10 and 15 wt.% Nb2O5, targeted for potential use as biomedical material. Nanoindentation tests were performed on the samples using indenter loads of 20 and 100 mN, while the microstructures were characterized using scanning electron microscopy. It was noted that with increasing Nb2O5 wt.%, there is transition from the lamellar structure of pure Ti to fully bimodal structures for the Ti-10 wt.% Nb2O5 and Ti-15 wt.% Nb2O5 composites. The hardness (6.0–40.67 GPa (20 mN) and 2.4–12.03 GPa (100 mN)) and reduced elastic modulus (115–266.91 GPa (20 mN) and (28.05–96.873 GPa (100 mN)) of the composites increases with increase in the Nb2O5 content, attributed to contributions of load transfer from the Ti matrix to the relatively harder Nb2O5 particles, particle and dispersion strengthening mechanisms. The elastic recovery index also improved with increase in Nb2O5 content, while the inverse was noted with respect to plasticity index. The elastic strain to failure and yield pressure both improved with increase in Nb2O5 content, which suggests that the antiwear properties and resistance to impact loading equally improves with Nb2O5 addition.","PeriodicalId":51873,"journal":{"name":"Manufacturing Review","volume":null,"pages":null},"PeriodicalIF":2.5,"publicationDate":"2020-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://sci-hub-pdf.com/10.1051/mfreview/2020017","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"57964100","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 : 2020-01-01DOI: 10.1051/mfreview/2020001
Beata Skowrońska, T. Chmielewski, D. Golański, J. Szulc
The paper describes the microstructure of welded joints produced by the plasma+MAG (Metal Active Gas) method of S700MC high yield strength steel (700 MPa). Welded joints of thermomechanical steel have been made with different values of heat input. The results of metallographic research of welded joints, microstructure of the weld and heat affected zone, hardness distribution and impact toughness are presented. The heat affected zone consists of two sub-zones with different grain size and lowered hardness. The tensile test show that strength of welded joints was slightly reduced and the bending test revealed no crack formation in the weld. The impact toughness of measured welded samples with V-notch in HAZ (heat affected zone) reached high values that are higher comparing to samples with notch placed in the weld area. The investigation results show that the use of plasma concentrated heat source together with MAG welding arc does not significantly change the structure and deteriorate properties of welded S700MC thermomechanically treated high strength steel. The hybrid plasma+MAG welding method has a potential to become a beneficial alternative to other welding processes due to its high efficiency, reduced amount of weld metal content or limited requirements for a preparation of edges of welded joints.
{"title":"Weldability of S700MC steel welded with the hybrid plasma + MAG method","authors":"Beata Skowrońska, T. Chmielewski, D. Golański, J. Szulc","doi":"10.1051/mfreview/2020001","DOIUrl":"https://doi.org/10.1051/mfreview/2020001","url":null,"abstract":"The paper describes the microstructure of welded joints produced by the plasma+MAG (Metal Active Gas) method of S700MC high yield strength steel (700 MPa). Welded joints of thermomechanical steel have been made with different values of heat input. The results of metallographic research of welded joints, microstructure of the weld and heat affected zone, hardness distribution and impact toughness are presented. The heat affected zone consists of two sub-zones with different grain size and lowered hardness. The tensile test show that strength of welded joints was slightly reduced and the bending test revealed no crack formation in the weld. The impact toughness of measured welded samples with V-notch in HAZ (heat affected zone) reached high values that are higher comparing to samples with notch placed in the weld area. The investigation results show that the use of plasma concentrated heat source together with MAG welding arc does not significantly change the structure and deteriorate properties of welded S700MC thermomechanically treated high strength steel. The hybrid plasma+MAG welding method has a potential to become a beneficial alternative to other welding processes due to its high efficiency, reduced amount of weld metal content or limited requirements for a preparation of edges of welded joints.","PeriodicalId":51873,"journal":{"name":"Manufacturing Review","volume":null,"pages":null},"PeriodicalIF":2.5,"publicationDate":"2020-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://sci-hub-pdf.com/10.1051/mfreview/2020001","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"57963356","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 : 2020-01-01DOI: 10.1051/mfreview/2020010
C. Giosué, A. Mobili, B. Citterio, F. Biavasco, M. Ruello, F. Tittarelli
This paper reports a study on 8 unconventional hydraulic lime-based mortars able to improve indoor air quality by acting as passive systems. Mortars have been prepared with commercial sand or highly adsorbent materials as aggregates with/without TiO2 as photocatalytic agent, to test also the decomposition of airborne pollutants. Mechanical properties, hygrometric behavior, inhibition of growth of molds and depollution properties have been tested. Despite using porous materials (zeolite and activated carbon), in mortars with unconventional aggregates, compressive strength is higher than in sand-based ones, with a more than double higher water vapor permeability. Zeolite-based mortars have the highest moisture buffering capacity followed by silica gel- and activated carbon-based mortars (1.5–2 times higher than reference, respectively, because of the high porosity of unconventional aggregates). Sand-based mortars show optimum inhibitory capacity against fungal growth. Concerning unconventional aggregates, silica gel mortars have good inhibitory capacity, whereas zeolite and activated carbon give to mortars an optimum substrate for molds. Mortars with unconventional aggregates as silica gel remove more than 80% of tracer pollutant after 2 h of test, whereas zeolite-based mortars remove the 65% of it after 120 min. TiO2 enhances depollution properties as photocatalytic oxidation agent when the mortar is close to saturation.
{"title":"Innovative hydraulic lime-based finishes with unconventional aggregates and TiO2 for the improvement of indoor air quality","authors":"C. Giosué, A. Mobili, B. Citterio, F. Biavasco, M. Ruello, F. Tittarelli","doi":"10.1051/mfreview/2020010","DOIUrl":"https://doi.org/10.1051/mfreview/2020010","url":null,"abstract":"This paper reports a study on 8 unconventional hydraulic lime-based mortars able to improve indoor air quality by acting as passive systems. Mortars have been prepared with commercial sand or highly adsorbent materials as aggregates with/without TiO2 as photocatalytic agent, to test also the decomposition of airborne pollutants. Mechanical properties, hygrometric behavior, inhibition of growth of molds and depollution properties have been tested. Despite using porous materials (zeolite and activated carbon), in mortars with unconventional aggregates, compressive strength is higher than in sand-based ones, with a more than double higher water vapor permeability. Zeolite-based mortars have the highest moisture buffering capacity followed by silica gel- and activated carbon-based mortars (1.5–2 times higher than reference, respectively, because of the high porosity of unconventional aggregates). Sand-based mortars show optimum inhibitory capacity against fungal growth. Concerning unconventional aggregates, silica gel mortars have good inhibitory capacity, whereas zeolite and activated carbon give to mortars an optimum substrate for molds. Mortars with unconventional aggregates as silica gel remove more than 80% of tracer pollutant after 2 h of test, whereas zeolite-based mortars remove the 65% of it after 120 min. TiO2 enhances depollution properties as photocatalytic oxidation agent when the mortar is close to saturation.","PeriodicalId":51873,"journal":{"name":"Manufacturing Review","volume":null,"pages":null},"PeriodicalIF":2.5,"publicationDate":"2020-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://sci-hub-pdf.com/10.1051/mfreview/2020010","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"57963905","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 : 2020-01-01DOI: 10.1051/mfreview/2020034
V. Lakshmi, K. Subbaiah, Arun Vikram Kothapalli, K. Suresh
Sustainability in any production emphasizes green-manufacturing techniques, improvement in quality with energy-efficient techniques, and environment-friendly processes. Titanium machining productivity is greatly influenced by speed, as high cutting velocity raises the temperatures in the shear zone and heat, owing to its low thermal conductivity. Hence in this work, an attempt is made to increase productivity by exploring the efficacy at transition speed for titanium alloy machining. Water-soluble lubricant is mist-sprayed as aerosols at a near-zero temperature in minor quantity, to minimize the temperatures generated during the cutting process at increased speed. Besides, an optimal decision variable vector optimizes multi-goals of machining Titanium grade 5 alloys under Minimum quantity cooling lubrication explored in this study in transitional speed zones. The response goals are the optimization of “vibration, surface quality, tool wear rate, and Material removal rate.” Multi goal optimization achieved by hybrid Taguchi coupled with Data Envelopment Analysis based Ranking (DEAR). The tool wear is very rapid at velocities of 200 mm/min. DEAR technique uses computed Multi performance rank index (MPRI) to predict the best data set at: (velocity, feed, doc) at (120 mm/min, 0.2 mm/rev, 1.0 mm). In this setting, the responses are compared in dry, flood, and MQL environment. It is observed a 30%, 60%, 40% improvement in surface finish, tool life, and vibrations compared to a dry environment and 13% and 3% of roughness and tool wear rate compared to a flood environment. Thus MQCL can be adopted for Ti6Al4V at transitional speeds.
{"title":"Parametric optimization while turning Ti-6Al-4V alloy in Mist-MQCL (Green environment) using the DEAR method","authors":"V. Lakshmi, K. Subbaiah, Arun Vikram Kothapalli, K. Suresh","doi":"10.1051/mfreview/2020034","DOIUrl":"https://doi.org/10.1051/mfreview/2020034","url":null,"abstract":"Sustainability in any production emphasizes green-manufacturing techniques, improvement in quality with energy-efficient techniques, and environment-friendly processes. Titanium machining productivity is greatly influenced by speed, as high cutting velocity raises the temperatures in the shear zone and heat, owing to its low thermal conductivity. Hence in this work, an attempt is made to increase productivity by exploring the efficacy at transition speed for titanium alloy machining. Water-soluble lubricant is mist-sprayed as aerosols at a near-zero temperature in minor quantity, to minimize the temperatures generated during the cutting process at increased speed. Besides, an optimal decision variable vector optimizes multi-goals of machining Titanium grade 5 alloys under Minimum quantity cooling lubrication explored in this study in transitional speed zones. The response goals are the optimization of “vibration, surface quality, tool wear rate, and Material removal rate.” Multi goal optimization achieved by hybrid Taguchi coupled with Data Envelopment Analysis based Ranking (DEAR). The tool wear is very rapid at velocities of 200 mm/min. DEAR technique uses computed Multi performance rank index (MPRI) to predict the best data set at: (velocity, feed, doc) at (120 mm/min, 0.2 mm/rev, 1.0 mm). In this setting, the responses are compared in dry, flood, and MQL environment. It is observed a 30%, 60%, 40% improvement in surface finish, tool life, and vibrations compared to a dry environment and 13% and 3% of roughness and tool wear rate compared to a flood environment. Thus MQCL can be adopted for Ti6Al4V at transitional speeds.","PeriodicalId":51873,"journal":{"name":"Manufacturing Review","volume":null,"pages":null},"PeriodicalIF":2.5,"publicationDate":"2020-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://sci-hub-pdf.com/10.1051/mfreview/2020034","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"57963919","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 : 2020-01-01DOI: 10.1051/mfreview/2020015
Jian Zhang, Hong-wei Li, M. Zhan
The globularization of titanium alloy with lamellar colony during hot working is an important way to obtain fine and homogeneous microstructure which has excellent mechanical properties. Because of its great technological importance, globularization has captured wide attention and much research. This paper conducts a systematic study on state of art on globularization of titanium alloy, which mainly includes globularization mechanism, prediction model and the effects of hot-working parameters and microstructure parameters. Firstly, the shortcomings of the well-known globularization mechanisms (dynamic recrystallization, boundary splitting, shearing mechanism and termination migration) were summarized. Moreover, the comparison and analysis of prediction models were accomplished through tabular form. In addition, the effects of hot-working parameters (strain, strain rate, temperature) and microstructure parameters (alpha/beta interface, geometry necessary dislocation and high temperature parent beta phase) were systematically summarized and analyzed. Meanwhile, this study also explores those difficulties and challenges faced by precise control on globularization. Finally, an outlook and development tendency of globularization of titanium alloy are also provided, which includes microstructure evolution of three-dimensional lamellar alpha, the relationship between lamellar colony and mechanical properties and the effect of severe plastic deformation on globularization.
{"title":"Review on globularization of titanium alloy with lamellar colony","authors":"Jian Zhang, Hong-wei Li, M. Zhan","doi":"10.1051/mfreview/2020015","DOIUrl":"https://doi.org/10.1051/mfreview/2020015","url":null,"abstract":"The globularization of titanium alloy with lamellar colony during hot working is an important way to obtain fine and homogeneous microstructure which has excellent mechanical properties. Because of its great technological importance, globularization has captured wide attention and much research. This paper conducts a systematic study on state of art on globularization of titanium alloy, which mainly includes globularization mechanism, prediction model and the effects of hot-working parameters and microstructure parameters. Firstly, the shortcomings of the well-known globularization mechanisms (dynamic recrystallization, boundary splitting, shearing mechanism and termination migration) were summarized. Moreover, the comparison and analysis of prediction models were accomplished through tabular form. In addition, the effects of hot-working parameters (strain, strain rate, temperature) and microstructure parameters (alpha/beta interface, geometry necessary dislocation and high temperature parent beta phase) were systematically summarized and analyzed. Meanwhile, this study also explores those difficulties and challenges faced by precise control on globularization. Finally, an outlook and development tendency of globularization of titanium alloy are also provided, which includes microstructure evolution of three-dimensional lamellar alpha, the relationship between lamellar colony and mechanical properties and the effect of severe plastic deformation on globularization.","PeriodicalId":51873,"journal":{"name":"Manufacturing Review","volume":null,"pages":null},"PeriodicalIF":2.5,"publicationDate":"2020-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://sci-hub-pdf.com/10.1051/mfreview/2020015","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"57964029","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 : 2020-01-01DOI: 10.1051/mfreview/2020026
S. K. Pattnaik, M. Behera, S. Padhi, P. Dash, S. K. Sarangi
Enormous developmental work has been made in synthesis of metastable diamond by hot filament chemical vapor deposition (HFCVD) method. In this paper, micro-crystalline diamond (MCD) was deposited on WC–6 wt.% Co cutting tool inserts by HFCVD technique. The MCD coated tool was characterized by the scanning electron microscope (SEM), X-ray diffraction (XRD) and micro Raman spectroscopy (μ-RS). A comparison was made among the MCD tool, uncoated tungsten carbide (WC) tool and polycrystalline diamond (PCD) tool during the dry turning of rolled aluminum. The various major tests were conducted such as surface roughness, cutting force and tool wear, which were taken into consideration to establish a proper comparison among the advanced cutting tools. Surface roughness was measured during machining by Talysurf. The tool wear was studied by SEM after machining. The cutting forces were measured by Kistler 3D-dynamometer during the machining process. The test results indicate that, the CVD coated MCD tool and PCD tool produced almost similar results. But, the price of PCD tools are five times costlier than MCD tools. So, MCD tool would be a better alternative for machining of aluminium.
{"title":"Study of cutting force and tool wear during turning of aluminium with WC, PCD and HFCVD coated MCD tools","authors":"S. K. Pattnaik, M. Behera, S. Padhi, P. Dash, S. K. Sarangi","doi":"10.1051/mfreview/2020026","DOIUrl":"https://doi.org/10.1051/mfreview/2020026","url":null,"abstract":"Enormous developmental work has been made in synthesis of metastable diamond by hot filament chemical vapor deposition (HFCVD) method. In this paper, micro-crystalline diamond (MCD) was deposited on WC–6 wt.% Co cutting tool inserts by HFCVD technique. The MCD coated tool was characterized by the scanning electron microscope (SEM), X-ray diffraction (XRD) and micro Raman spectroscopy (μ-RS). A comparison was made among the MCD tool, uncoated tungsten carbide (WC) tool and polycrystalline diamond (PCD) tool during the dry turning of rolled aluminum. The various major tests were conducted such as surface roughness, cutting force and tool wear, which were taken into consideration to establish a proper comparison among the advanced cutting tools. Surface roughness was measured during machining by Talysurf. The tool wear was studied by SEM after machining. The cutting forces were measured by Kistler 3D-dynamometer during the machining process. The test results indicate that, the CVD coated MCD tool and PCD tool produced almost similar results. But, the price of PCD tools are five times costlier than MCD tools. So, MCD tool would be a better alternative for machining of aluminium.","PeriodicalId":51873,"journal":{"name":"Manufacturing Review","volume":null,"pages":null},"PeriodicalIF":2.5,"publicationDate":"2020-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://sci-hub-pdf.com/10.1051/mfreview/2020026","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"57963787","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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