Editorial Board Vol. 14 No. 2 February 2015 Technical Papers FEB... · 2015-03-30 · Vol. 14 No. 2...

Vol. 14 No. 2 February 2015

Contents

Technical Papers

• Anexperimental investigationongrindabilityofTitaniumgrade 1 under different environmental conditionsbyManabDas,BijoyMandalandSantanuDas 3

• Developmentofempiricalrelationshipstopredictstrengthof P/M Sintered pure Copper and pure Nickel diffusionbondedbimetallicjointsbyMuruganA,SenthilvelanTandBalasubramanianV 11

• The effect of defocused machining during Laser Micro-Turning process of Aluminium Oxide (Al2O3) CeramicsbyKibriaG,DoloiB,BhattacharyyaB 20

Calendar of Events 28

Photo Gallery: Vintage Machine: CombinedUniversalMillingMachineandWheelandPinionCutterStark,USA,Late1800s 31

Manufacturing Technology Abstracts 32

Bibliography:High Speed Grinding 50

Patent Abstracts: High Speed Grinding 51

IPR News: Centre seeks expert feedback on IPR draft 58

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Editorial Board

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Editorial Advisory CommitteeProf.SMohanPJMohanRamVKSubramanya

ChairmanSSatishKumar

Technical Paper Review PanelSUshaNBalashanmugamDr.CKSrinivasaKKRajagopalBRMohanraj

EditorMallikarjunG

Editorial Assistants

ShashiRekhaNMalaRC

Events

Manufacturing Technology Today, February 201528

INDIA 01 Mar 2015IRAJ-Intl Conf On Electrical, Electronics, Computer Science & Mechanical Engg (ICEECSME)10,CVRamanRoad,SriramColony,Alwarpet,Chennai,TamilNaduContact: IRAJ, Tel:+918598978459E-mail:[email protected]:http://iraj.in/Conference/2015

01 Mar 2015IRAJ - Intl Conf on Computer Science and Mechanical Engineering (ICCSME)Hotel Madhav International, 6A, RamabaiAmbedkarRoad,BeforeHotelLe-Meridien,BehindPuneRailwayStation,PuneContact: IRAJ, Tel:+918598978459E-mail:[email protected]:http://iraj.in/Conference/2015

01 Mar 2015IRAJ - Intl Conf on Computer Science and Mechanical Engineering (ICCSME)HotelGrandplaza,(AUnitofM/S.M.S.GuestLineServices), 5-9-88/A/1, Beside Haj House, Opp.PublicGarden,Nampally,HyderabadContact: IRAJ, Tel:+918598978459E-mail:[email protected]:http://iraj.in/Conference/2015/Hyderabad

01 Mar 2015IRAJ - Intl Conf on Research in Mechanical and Production Engineering (ICRMPE)LaPlaceSarovarPortico,GeneralManager-RanjanK.Das,6,ShahnajafRoad,LucknowContact: IRAJ, Tel:+91-7855922996 E-mail:[email protected]:http://iraj.in/Conference/2015

08 Mar 2015IRAJ-Intl Conf on Electrical, Electronics ,Computer Science and Mechanical Engineering (ICEECSME)HotelPresidency,KCMMatherRd,AyyappankavuErnakulam,KLContact: IRAJTel:+918598978459 E-mail:[email protected]:http://iraj.in/Conference/2015/COCHIN

08 Mar 2015IRAJ - Intl Research Conference on Computer Science & Mechanical Engineering (IRCCSME)HOTELTRINITYISLE,#139,SubedarChatramRoad,SwastikCircle,Sheshadripuram,BangaloreContact: IRAJ, Tel:+91773523412 E-mail:[email protected]:http://iraj.in/Conference/2015/Bangalore

08 Mar 2015IRAJ-Intl Conf on Civil, Mechanical, Biological and Medical Engineering (ICMBME - 2015)HotelRainbow,10,CVRamanRoad,SriramColony,Alwarpet,Chennai,TamilNaduContact: IRAJ, Tel:+918598978459E-mail:[email protected]:http://iraj.in/Conference/2015/Chennai

08 Mar 2015IRAJ-Intl Conf on Mechanical & Production Engineering (ICMPE)Hotel Madhav International, 6A, RamabaiAmbedkarRoad,BeforeHotelLe-Meridien,BehindPuneRailwayStation,PuneContact: IRAJ, Tel:+918598978459 E-mail:[email protected]:http://iraj.in/Conference/2015/Pune

14 Mar 2015National Conference on Energy and Manufacturing scenario - 2015Thanjavur,TamilnaduContact: Department of Mechanical Engineering, KingsCollegeofEngineering,Punalkulam,ThanjavurTel:04362-282474,282397,282400 E-mail:[email protected]:http://www.kingsindia.net

15 Mar 2015IRAJ - Intl Conf on Electrical, Electronics, Robotics & Mechanical Engineering (ICEERME)The Royal Plaza, Upper Syari, Gangtok - 737102,SikkimContact: ITRESEARCH, Tel:+91-8339923308 E-mail:[email protected]:http://iraj.in/Conference/2015/Gangtok

15 Mar 2015IRAJ- Intl Conf on Recent Development in Mechanical & Industrial Engineering

Events

Manufacturing Technology Today, February 2015 29

INTERNATIONALHotelSunstarGrand,KarolBagh,NewDelhiContact: ITRESEARCH, Tel:+917205807246 E-mail:[email protected]:http://www.iraj.in/Conference/2015/Delhi

20 - 21 Mar 2015Intl Conf On “Innovative Trends in Mechanical, Material, Manufacturing, Automobile and Aeronautical Engineering” (ITMAAE-2015)BapatlaEngineeringCollege,Bapatla,Guntur(Dt),AndhraPradeshContact: Dr.GovindChandraMishra,Organizing Secretary,ContactNo:+91-8527006560Dept.ofMechEngg,BapatlaEngineeringCollege&“KrishiSanskriti”,NewDelhiE-mail:[email protected]:http://krishisanskriti.org/itmaae.html

22 Mar 2015IRAJ - Intl Conf on Computer Science and Mechanical Engineering (ICCSME-2015)Hotel Madhav International, Ramabai AmbedkarRoad,BehindPuneRailwayStation,PuneContact: ITRESEARCH,InstituteofResearchandJournalsPlotNo.161,DharmaVihar,Bhubaneswar,OdishaTel:+91-7735082562E-mail:[email protected]:http://iraj.in/Conference/2015/Pune

22 Mar 2015IRAJ-Intl Conf on Computer Science and Mechanical Engineering (ICCSME)Hotel Narain Niwas Palace, Kanota Bagh, NarainSinghRoad,Jaipur,RajasthanContact: ITRESEARCH,InstituteofResearchandJournalsPlotNo.161,DharmaVihar,Bhubaneswar,OdishaTel:+917735234124 E-mail:[email protected]:http://iraj.in/Conference/2015/Jaipur

22 Mar 2015IRAJ-International Conference on Computer Science and Mechanical Engineering (ICCSME)Hotel Crown Palace, South Tukoganj, Opp., JainMandir,GetaBhawan,IndoreContact: ITRESEARCH,InstituteofResearchandJournalsPlot No. 161 (Ground Floor), Dharma Vihar,Jagmara,Bhubaneswar,751030,OdishaTel:+917205807246E-mail:[email protected]:http://iraj.in/Conference/2015/Indore

03 - 08 Mar 2015International Machine Tool ShowTWTC-TaipeiWorldTradeCenterNo.6,Sung-ShouRd.,11568Taipei,Taipei,TaiwanContact: TaiwanExternalTradeDevelopmentCouncil5-7Fl.,333KeelungRd.,Section111012Taipei,TaiwanTel:+886(0)227255200Fax:+886(0)227576245E-mail:[email protected]:http://www.tradefairdates.com

05 - 08 Mar 2015International metal working, mould and automation technologies fairInternational Izmir Fair Center, KültürparkMimarSinanMh,35220Izmir,Izmir,TurkeyContact: YagmurFuarcilik,MecidiyeCd.Cüre IshaniNo:16Kat:2,Istanbul,TurkeyTel:+90(2)122724560Fax:+90(2)122724559E-mail:[email protected]:http://www.tradefairdates.com

06 - 08 Mar 2015Trade fair for automation, robotics and mechatronicsIECInterExpoCenter,147,Tsarigradskoshoseblvd.1787Sofia,Sofia-City,BulgariaContact: ICM International d.o.o, Ismeta MujezinovicaBelgrade,SerbiaTel:+381(0)606688611E-mail:[email protected]:http://www.tradefairdates.com

08 - 12 Mar 2015Trade fair on smart materials and nondestructive evaluationTownandCountryResort&ConventionCenter500HotelCircleNorth,SanDiego,California,USAContact: SPIE,100020thSt,WA98227Bellingham,USATel:+1(3)606763290, Fax:+1(3)606471445E-mail:[email protected]:http://www.tradefairdates.com

10 - 11 Mar 2015Trade Fair for Measurement and SensorsSI-Erlebnis-Centrum,PlieningerStr.10070567Stuttgart,Baden-Wurttemberg,GermanyContact:

Events


D&HPremiumEventsGmbHJosef-Jägerhuber-Str.682319Starnberg,GermanyTel:+49(0)8151746482Fax:+49(0)8151746483E-mail:[email protected]:http://www.tradefairdates.com

10 - 12 Mar 2015Trade fair for industrial measuring technologyTargiKielceExhibition&CongressCentreZakladowa1,Kielce,Œwiêtokrzyskie,PolandContact: KielceTradeFairsLtd.,Zakladowa1,Kielce,PolandTel:+48(0)413651222Fax:+48(0)413456261E-mail:[email protected]:http://www.tradefairdates.com

10 - 12 Mar 2015Trade fair for metalworkingTargi Kielce Exhibition & Congress Centre,Zakladowa1,Kielce,Œwiêtokrzyskie,PolandContact: KielceTradeFairsLtd.,Zakladowa1,Kielce,PolandTel:+48(0)413651222Fax:+48(0)413456261E-mail:[email protected]:http://www.tradefairdates.com

10 - 13 Mar 2015Fair for nanosciences and nanotechnologiesBECBilbaoExhibitionCenter,RondadeAzkue148902Barakaldo,Bizcay,SpainContact: Phantoms Foundation, C/ Alfonso Gomez 17 /Planta2-Loft16,28037Madrid,SpainTel:+34(0)911402144 E-mail:[email protected]:http://www.tradefairdates.com

11 - 12 Mar 2015Smart Systems Integration Copenhagen: Intl Conf and Exhibition on Integration Issues of Miniaturized Systems - MEMS, NEMS, ICs and Electronic ComponentsCrowne Plaza Copenhagen Towers, OerestadsBoulevard114–118,Copenhagen,Capital,DenmarkContact: MesagoMesse Frankfurt GmbH, Rotebühlstr. 83-85,70178Stuttgart,GermanyTel:+49(0)711619460Fax:+49(0)7116194691E-mail:[email protected]:http://www.tradefairdates.com

17 - 19 Mar 2015Trade fair for Metallurgy and metal processing machineryUECUzexpocentre, AmirTemur street,Tashkent,

Tashkent,UzbekistanContact: IEGUzbekistan,107B,A.Temurastr.,Office4C-021000084Tashkent,UzbekistanTel:+998(0)712385988Fax:+998(0)712385982E-mail:[email protected]:http://www.tradefairdates.com

18 - 20 Mar 2015Intl trade fair for distribution, material and information flowNanjingInternationalExpoCenter,YanshanRoadNanjing,Jiangsu,ChinaContact: Euroexpo Messe- und Kongress-GmbH, Joseph-Dollinger-Bogen7,Munich,GermanyTel:+49(0)8932391253Fax:+49(0)8932391246E-mail:[email protected]:http://www.tradefairdates.com

18 - 20 Mar 2015Intl Trade Fair of Analytical, Measurment and Control TechnologyMT Polska Trade Fair and Congress Centre, 56cMarsaStreet,04-242Warsaw,Mazovia,PolandContact: MTTargi,ul.Makowska95,Warsaw,PolandTel:+48(0)225293900Fax:+48(0)225293930E-mail:[email protected]:http://www.tradefairdates.com

19 - 22 Mar 2015Materials Handling Eurasia Istanbul: Trade fair for materials handling and logisticsTüyap Fair Convention & Congress Center, E-5KarayoluÜzeri,Gürpinar Kavsagi, 34500 Istanbul,Istanbul,TurkeyContact: Hannover-MesseInternationalIstanbulLtd.BüyükdereCad.SarliIsMerkeziNo:103BBlokKat:5-6,34394Istanbul,TurkeyTel:+90(2)123346900Fax:+90(2)123346934E-mail:[email protected]:http://www.tradefairdates.com

30 Mar 02 Apr 2015Intl Machinery Manufacturing ExhibitionConvention&ExhibitionCenter,3.FuhuaRoad518048Shenzhen,Guangdong,ChinaContact: Shenzhen XieGuang Machinery Co. Ltd., R1204,TowerA,HailrunComplex,Shenzhen,ChinaTel:+86(7)5583458909Fax:+86(7)5583458708E-mail:[email protected]:http://www.tradefairdates.com◘

Abstracts


MANUFACTURING TECHNOLOGY ABSTRACTS

CASTING & FOUNDRY PRACTICE 33

COATING & FINISHING 35

FORMING 36

HYDRO FORMING 38

WARM FORMING 38

SHEET METAL WORKING 38

INDUSTRIAL ENGINEERING 39

JOINING & ASSEMBLY 40

LASERS 42

MACHINE ELEMENTS & MECHANISMS 43

MACHINING 43

NON TRADITIONAL MACHINING 44

LASER MACHINING 45

LASER WELDING 46

MANUFACTURING SYSTEMS 47

MATERIALS & TREATMENT 48

Abstracts


MANUFACTURING TECHNOLOGY ABSTRACTS

CASTING & FOUNDRY PRACTICE

110081 Determination of local properties of plastic anisotropy in thick plate by small-cube compression test for precise simulation of plate forgingKitamura, K; Terano, M [CIRP Annals, v 63, n 1, 2014, Starting Page 293, Pages 4] A small-cubecompression test is proposed to experimentallydetermine local properties of plastic anisotropy.Smallcubespecimensarecutoutofathickplatein various positions. After the test the shape ofa compressed plane on the specimen changesfrom a square into a rectangle due to plasticanisotropy. The six anisotropic constants in Hill’syield criterion are calculated from the ratiosof width-to-length strains on the compressedrectangular plane. The deformed shapes of acylinderandablockafterupsettingcanbepreciselysimulated by considering the local properties ofplasticanisotropy.(8refs,9figs,1table)(AA)

110082 Friction control for accurate cold forged partsGroche,Peter;Heß,Benjamin[CIRP Annals, v 63, n 1, 2014, Starting Page 285, Pages 4] Anoscillatingrammovementcanbeusedtoreducefrictionandtherebyformingforces incoldforging.Thiseffectis attributed to the rebuilding of the lubricatingfilm during back stroke. A correspondingmotioncontrol also affects the final part’s geometryand enables a reaction to uncertainties like theactual semi-finished product properties. Basedonnumericalandexperimental investigationsthepaperdiscussesthepotentialsandprerequisitesofthiskindofclosed-loopcontrolof thefinalpart’sgeometry.(12refs,8figs)(AA)

110083 3D finite element modeling and analysis of radial forging processesFan, Lixia Wang, ; Zhigang; Wang, He [J of Manufacturing Processes, v 16, n 2, Apr 2014, Starting Page 329, Pages 6] This paper presentsa novel 3D finite element model for the radialforgingprocesswithconsiderationofmandrel.Asdifferent with the previous works, the proposedmodel captures more accurately the featuresof the radial forging process. The proposedmodel is validated.With the proposed model, acomprehensiveanalysisofthedeformationforthetubeispresented.Thecontributionsofthepresent

workare:(1)afull3Dfiniteelementmodelwhichcapturesmorefeaturesoftheradialforgingprocessthanthemodelsinliterature,(2)aproofthatafull3Dfiniteelementmodelisneeded,(3)aproofoftheeffectivenessofthespringbarinstabilizingthecontactbetweenthehammerdieandwork-piece,and(4)thespindlespeedhaslittleeffectonforgingload. Finally, thismodel canbewellused for theanalysis and comprehensive understanding oftheradialforgingprocessandoptimizationoftheprocessinfuture.(12refs,16figs,3tables)(AA)

110084 Electrically assisted blanking using the electroplasticity of ultra-high strength metal alloysKim, Woong; Yeom, Kyeong-Ho; Thien, NguyenTrung;Hong,Sung-Tae;Min,Byung-Kwon;Oh,SooIk,Moon-JoKim,Han,HeungNam;Lee,Hyun-Woo[CIRP Annals, v 63, n 1, 2014, Starting Page 273, Pages 4] The electroplastic tensile behavior ofultra-highstrengthsteels(UHSS)subjecttoasinglepulseofelectriccurrentisbrieflyintroduced,andelectrically-assisted (EA) blanking, which utilizesthis electroplastic characteristic, is suggested.The experimental result shows that the blankingload of EA blanking is clearly lower than that ofblanking with local resistance heating, which islower than that of cold blanking. No significantchange inmaterial propertieswas observed in theEAblanked parts at the electric energy densitiesselected in the present study. EA blanking ortrimmingisexpectedtominimizeoreveneliminatetheneedforexpensiveandtime-consuminglasertrimminginthemanufactureofautomotivepartsusingUHSS.(13refs,8figs,2tables)(AA)

110085 Gas-assisted compression moulding of recycled GMT: Effect of gas injection parametersGoodship, V; Brzeski, I; Wood, BM; Cherrington,R; Makenji, K; Reynolds, N; Gibbons, GJ [J of Materials Processing Technology, v 214, n 3, Mar 2014, Starting Page 515, Pages 9] Gas assistedcompression moulding (or GasComp) is a novelprocess based on the injection of nitrogen gasduring a conventional compression mouldingcycle, a technique originally introduced in theinjection moulding industry. The gas is injectedinto the molten material at a preset gas inletpoint, hollowing out the part and thus assistingthe compressive force of the press in generatingmaterial flow. This paper presents gas injection

Abstracts


parameter studies on polypropylene basedrecycledglassmat-reinforcedthermoplastic(GMT).The parameters investigated are gas ramp rate,gas injection delay time, and peak pressure. Thesizeofcavitywasfoundtobeinverselyproportionaltogasinjectiondelaytime.Rheologicalinstabilitiesat the polymer–gas interface were observed;a phenomenon previously noted during thedevelopment of gas assisted injection moulding.(9refs,14figs,2tables)(AA)

110086 Investigating the technological limits of micro-injection molding in replicating high aspect ratio micro-structured surfacesLucchetta,G; Sorgato,M;Carmignato, S; Savio, E[CIRP Annals, v 63, n 1, 2014, Starting Page 521, Pages 4] Microinjectionmoldingisakeytechnologyformass-productionofmicro-structuredsurfaces,suchasopticalandmicrofluidicdevices.However,thecompletereplicationofhighaspectratiomicrofeatures is challenging even using state-of-the-arthigh-speed injectionsystems,rapidheatcyclemolding and vacuummold venting. In this workthetechnologicallimitsofmicro-injectionmoldingin replicating high aspect ratio micro-structuredsurfacesareexperimentallyinvestigated,usingthemoldingofabio-MEMSforerythrocytesdepletionas a case study. The obtained results show howthese limits are inherently related to an unevendistributionofcavitypressureduringmoldfilling.(12refs,6figs,5tables)(AA)

110087 Development of efficient production routes based on strip casting for advanced high strength steels for crash-relevant partsDaamen, M; Guvenc, O; Bambach, M; Hirt, G[CIRP Annals, v 63, n 1, 2014, Starting Page 265, Pages 4] Twinrollstripcastingcanbeaneffectivealternative to produce high manganese TWIPsteel, which provides extraordinary mechanicalproperties. In the work presented, 1.5–3 mmthin hot strips with up to 30 wt% manganesewereproduceddirectlyfromthemeltandfurtherprocessed to cold strip. An adapted thermo-mechanical treatment, consisting of cold rollingwith or without subsequent annealing, enablesto adjust different material states, such asrecrystallised or strengthened state, and thus totailorthemechanicalproperties.Asanexampleforthe superior crash behaviour of highmanganeseTWIPsteels,dynamiccrashtestswerecarriedoutusingcold rolledFe–29Mn–0.3Csteel indifferentmaterialstates.(14refs,6figs,1table)(AA)

110088 Hot extrusion process modeling using a coupled upper bound-finite element method

Hosseinabadi, H Goodarzi; Serajzadeh, S [J of Manufacturing Processes, v 16, n 2, Apr 2014, Starting Page 233, Pages 8] Athermo-mechanicalmodel has been developed for modeling of hotextrusion processes. Accordingly, an admissiblevelocity field was first proposed by means ofstream function method and then, extrusionpressureaswellastemperaturevariationswithinthemetalandthediewerepredictedemployingacombinedupperboundandPetrov–Galerkinfiniteelement analysis. Inorder toevaluate themodelpredictions, hot extrusion of AA6061-10%SiCpwas considered under both isothermal and non-isothermal conditions and the predicted force–displacement diagrams under various extrusionconditionswerecomparedwiththeexperimentalones and reasonable consistency was foundbetweenthetwosetsofresults. (21refs,12figs,2tables)(AA)

110089 Control of thermal contraction of aluminum alloy for precision cold forgingIshikawa, T; Ishiguro, T; Yukawa,N;Goto, T [CIRP Annals, v 63, n 1, 2014, Starting Page 289, Pages 4] Thermal contraction affects the finalgeometry of a cold forged product. Control ofthe thermal geometry changes of aluminumalloys is essential because aluminum alloyshave higher thermal conductivity than othermetals. Finite element analysis revealed thatinhomogeneous temperature distributions causelocal heat shrinkage, which lowers the accuracyof the final geometry. An optimal slide motionwas proposed to ensure uniform temperaturedistribution. Simulation results indicated thatoscillatory slidemotion is superior at ensuring auniform temperature distribution, and this wasconfirmed by experiments. Our study showedthat process design with consideration fortemperaturedistributionisadvantageous.(7refs,11figs,1table)(AA)

110090 Effect of homogenization temperature on the corrosion resistance of extruded 7050 Al-alloy barsHou, Wenrong; Ji, Weibin; Zhang, Zhihao; Xie,Jianxin; Cheng, Xiaole [J of Materials Processing Technology, v 214, n 3, Mar 2014, Starting Page 635, Pages 6] The homogenization time is decreasedfrom 28 h to 6 h by using high-temperaturehomogenization heat treatment. With increasingof the holding time, the content of intergranularphase decreases quickly at first. When theholding time is more than 6 h, the content ofintergranular phase keeps unchanged, and thearea fraction of residual intergranular phase

Abstracts


is 0.5%, lower than that (0.64%) of the two-step homogenization process. The mechanicalpropertiesoftheextrudedbarsheat-treatedbythehigh-temperature homogenization and the two-stephomogenizationheattreatmentarealmostthesame. In the accelerated corrosion experiments,the maximum intergranular corrosion depth inthedirectionofperpendicularandparallel tothebar axis heat-treated by the high-temperaturehomogenizationheattreatmentaredecreasedby43% and 60%, respectively, compared with thatheat-treated by the two-step homogenizationheattreatment.(15refs,8figs,1table)(AA)

110091 Compressive properties and energy absorption of aluminum foams with modified cellular geometryPinto, P; Peixinho, N; Silva, F; Soares, D [J of Materials Processing Technology, v 214, n 3, Mar 2014, Starting Page 571, Pages 7] This studypresents experimental results on the behaviorof aluminum alloy metal foams with controlledpore morphology in compression. Two types ofmetal foams were analyzed, having uniform cellstructure and with a dual-size cell arrangementseeking optimized mechanical properties. Thestructures were manufactured by lost-waxcastingusing3Dprinted components for internalstructure definition. Results for stiffness andenergy absorption were obtained and comparedonweightefficiencybasis.Theresultsareindicativeof higher efficiency of the dual-size structuresthat may be considered for use in componentssubjected to impact or compression loading.(10refs,11figs,4tables)(AA)

110092 Reduction of friction of steel covered with oxide scale in hot forgingMatsumoto, Ryo; Osumi, Yuta; Utsunomiya,Hiroshi [J of Materials Processing Technology, v 214, n 3, Mar 2014, Starting Page 651, Pages 9] The hot ring compression test of chrome steelcoveredwithanoxidescalefilm iscarriedout toexaminetheeffectsoftheoxidescalefilmonthehotforgingcharacteristicsthroughexperimentandfinite element analysis. The nominal coefficientof shear friction of the scale is estimated fromthe plastic deformation behavior of the chromesteelcoveredwithoxidescalefilm.Theestimatedcoefficient of shear friction of the oxide scaleis found to be lower than that of the chromesteel. The plastic deformations and temperaturechanges of the chrome steel workpiece and theoxidescalelayerarecalculatedusingfiniteelementanalysis method to investigate the mechanismunderlyingthereductioninthefrictionduringthe

hotforgingofchromesteelcoveredwithanoxidescale film. Low friction and thermal conductivityvaluesoftheoxidescale leadto lowforging loadinthehotforgingofchromesteelcoveredwithanoxidescalefilm.(27refs,18figs,2tables)(AA)

110093 Improvement in formability by control of temperature in hot stamping of ultra-high strength steel partsMaeno, Tomoyoshi; Mori, Ken-ichiro; Nagai,Takaaki [CIRP Annals, v 63, n 1, 2014, Starting Page 301, Pages 4] Theformabilityinhotstampingofanultra-highstrengthsteelpartwas improvedby preventing a temperature drop of the flangeincreasingresistancetodrawing.Thetemperaturedrop was reduced by high speed forming usinga servopress andby less contactwith a die andblankholderusingspacers thickerthanthesheet.Inaddition,hardeningoftheflangewaspreventedby slow cooling for the less contact using thespacers to facilitate trimmingof thehot-stampedpart. From a hot deep drawing experiment witha hemispherical punch, the effectiveness of thepresent approaches of temperature control wasdemonstrated.(11refs,17figs)(AA)

COATING & FINISHING

110094 Brittleness and fatigue effect of mono- and multi-layer PVD films on the cutting performance of coated cemented carbide insertsSkordaris, G; Bouzakis, KD; Charalampous, P;Bouzakis,E;Paraskevopoulou,R;Lemmer,O;Bolz,S[CIRP Annals, v 63, n 1, 2014, Starting Page 93, Pages 4] The effect of brittleness and fatigue ofmono- andmulti-layerPVDfilmson coated toolscutting performance is introduced. Cementedcarbide inserts were coated to the same overallfilmthickness with various numbers of layers.Nanoindentationswereconductedtoevaluatethehardness of the diverse coating structures. Thefilmbrittlenessandfatiguewerecharacterizedbynano- and macro-impact tests respectively. Thecoated inserts’ wear behaviour was investigatedin milling hardened steel. The attained resultsrevealed the coatings’ brittleness and fatigueendurance enhancement by increasing thenumber of film’s layers. This increase leadssimultaneouslytothecoatedtoollifeimprovement.(14refs,7figs)(AA)

110095 Mechanisms of surface response to overlapped abrasive grits of controlled shapes and positions: An analysis of ductile and brittle materialsButler-Smith, Paul; Axinte, Dragos; Daine, Mark;

Abstracts


Kong,Ming Chu [CIRP Annals, v 63, n 1, 2014, Starting Page 321, Pages 4] Abrasivesurfacescannowadays be produced incorporating precisioncuttingfeaturesofcontrolledshape,size,protrusionandlocation.Thisstudyinvestigatestheinfluenceof defined abrasive shapes (square/ triangular/conic pyramidal frusta) of designed groups ofoverlapped abrasives on the successive removalof ductile (Cu) and brittle (Al2O3) materials.Scanning electron microscopy studies combinedwith detailed micro-topographical evaluationsof scratches/adjacent material have revealedthe progressive actions of material removal/displacement of copper and the fracture andbrittle/plastic transitions of sapphire for thedifferent abrasive shapes, aiding a fundamentalunderstanding of the influenceof definedmicro-geometrieson thegrindingprocessand resultingmaterialsurfacetopography.(13refs,7figs)(AA)

110096 Determining work-brush interface temperature in magnetic abrasive finishing processMishra, Vivek; Goel, Harsha; Mulik, Rahul S;Pandey, PM [J of Manufacturing Processes, v 16, n 2, Apr 2014, Starting Page 248, Pages 9] Magneticabrasivefinishing (MAF) is aprocess inwhichtheworksurfaceisfinishedbyremovingthematerial in the form ofmicro chips bymagneticabrasive particles (MAPs) in the presence ofmagnetic field in the finishing zone. During theMAF process, the frictional heat is generatedat the workpiece surface due to the rubbingaction of magnetic abrasive particles with thework surface. The order of temperature rise isimportant to study, as finishing mechanism andsurface integrity of workmaterials depend uponit. Themeasurement of temperature distributionduring MAF operation at the interface of workpieceandflexiblemagneticabrasivebrush(FMAB)interface is difficult. In the present analysis,finite element based ANSYS software has beenused to model and simulate magnetic fielddistribution, magnetic pressure and temperaturedistribution at work-brush interface during theprocess. In this work the maximum magneticflux density has been simulated of the order of0.223 T at 0.91 A of current in electromagnetcoil. Magnetic pressure on MAPs due tomagnetic field of electromagnetic coil hasbeen calculated to evaluate the frictional heatflux generated at the work-brush interface.Transient thermal analysis of workpiece domainhas been performed to predict the temperaturerise due to frictional heat flux. The predictedtemperature on work-brush interface was

found in the range of 34–51 °C. The developedsimulation results based on FEA have beenvalidated with experimental findings. (14 refs,13figs,5tables)(AA)

FORMING

110097 Evaluation of localization and failure of boron alloyed steels with different microstructure compositionsÖstlund,R;Oldenburg,M;Häggblad,HÅ;Berglund,D [J of Materials Processing Technology, v 214, n 3, Mar 2014, Starting Page 592, Pages 7] Within the press hardening technology, wherehotsheetblanksaresimultaneouslyformedfixedand quenched, new methods with differentialthermaltreatmentcometo light.Withcontrolledtool temperature variation, components withtailoredproperties canbeproduced.Automotivecomponents combining high energy absorptionand intrusion protection in a crash situation arefeasible. In the present work the mechanicalproperties of three different material qualities,beginning with the same base sheet metalsubjected to different thermal histories, areinvestigated.Astrategyformodellingpost-neckingresponseandcrackinitiationusingshellelementslargerthenthetypicalbandwidthofthelocalizedneck is used. Themodel relies on a sequence offullfieldmeasurementsthroughoutatensiletest;i.e. digital speckle photography (DSP). The fullfield experimental method allows for evaluationof mechanical and failure properties at differentanalysislengths,providingparametersforamodelwhichaccountsforshellelementsize.Additionallythemodel contains a strain based failure criteriaasafunctionofstresstriaxiality.Goodcorrelationsbetweenasimulatedtensiletestandexperimentalresults were found. A detailed metallographicstudy of the three grades was performed and ispresented.(17refs,7figs,2tables)(AA)

110098 Bending force prediction for dynamic roll-bending during 3-roller conical bending processChudasama, MK; Raval, HK [J of Manufacturing Processes, v 16, n 2, Apr 2014, Starting Page 284, Pages 12] Cylindricalaswellasconicalcross-sectionstructuralpartsarewidelyusedinindustrialapplicationsworldwide. Such parts are producedfrom metal plates using many manufacturingmethods. 3-roller conical bending process is onesuchprocess.Inthisprocessfirstthemetalplatesinspecifiedblankshapesaregivenstaticbendingintherollers.Thentherollersaredrivenusingmotorsforbendingoftheblanksunderdynamiccondition.

Abstracts


During bending reaction forces will be there ontherollers.Forcesactingontherollersduringtheprocess are transmitted to themachine frameattherollersupports.Inthepaperananalyticalmodelisdevelopedforthepredictionofforceduringthestage of dynamic bending. The model consistsof various parameters like material parametersand geometrical parameters. Experimentation iscarriedoutandthedevelopedmodel isvalidatedwith the experimental results. Effects of variousmaterial and geometrical parameters are studiedin the present paper. The present work can giveinsight in the process and can be helpful to thedesignersaswellastotheresearchersworkingintheareaofmetalforming.(19refs,11figs)(AA)

110099 Characterization of precision of a handling system in high performance transfer press for micro formingMahshid, Rasoul; Hansen, Hans Nørgaard;Arentoft,Mogens [CIRP Annals, v 63, n 1, 2014, Starting Page 497, Pages 4] Multi-stepmicrobulkforming is characterized by complex processesandhighprecisionrequirements.Inparticularthedemands regarding handling accuracy betweendifferent forming steps areof theorderof a fewmm. The paper introduces a methodology forthe analysis and characterization of this transfersystem on component level and system level.Laser interferometry is used in combinationwith analyticalmodels to predict the positioningabilityoftheactuatorinastaticaswellasdynamicmode. In combination with an analysis of thegrippers,afulldescriptionofthetransferprecisioninsidetheformingpressisobtained.(13refs,8figs,4tables)(AA)

110100 Hybrid hierarchical fabrication of three-dimensional scaffoldsWei, Chuang; Dong, Jingyan [J of Manufacturing Processes, v 16, n 2, Apr 2014, Starting Page 257, Pages 7] Three-dimensional (3D) porousstructures facilitating cell attachment, growth,and proliferation is critical to tissue engineeringapplications.Traditionalsolidfreeformfabrication(SFF) methods have limited capabilities in thefabricationofhighresolutionmicro-scalefeaturesto implement advanced biomedical functions. Inthiswork,wepresentahybridscaffoldfabricationapproach by integrating electrohydrodynamic(EHD) printing technology with extrusiondeposition together to fabricate hierarchical3D scaffolds with well controlled structures atboth macro and micro scale. We developeda hybrid fabrication platform and a robustfabrication process to achieve 3D hierarchical

structures. The melting extrusion by pneumaticpressurewas used to fabricate 3D scaffoldswithfilaments dimension of hundreds of micronsusing thermoplasticbiopolymerpolycaprolactone(PCL). An electrohydrodynamic (EHD) melt jetplottingprocesswasdevelopedtofabricatemicro-scale features on the scaffolds with sub-10 μmresolution,whichhasgreatpotential inadvancedbiomedicalapplications,suchascellalignmentandcellguidance.(26refs,7figs)(AA)

110101 Investigation of enhanced formability in AA5182-O Al during high-rate free-forming at room-temperature: Quantification of deformation historyRohatgi, Aashish; Soulami, Ayoub; Stephens,Elizabeth V; Davies, RichardW; Smith,Mark T [J of Materials Processing Technology, v 214, n 3, Mar 2014, Starting Page 722, Pages 11] Thegoalof this work is to improve our understandingof formability enhancement in aluminum (Al)sheet alloys that has generally been observedduring high-strain-rate forming. In the workpresented here, experiments and numericalmodeling were used to investigate the room-temperature formability of AA5182-O Al alloysheet (1 mm thick) at high strain-rates usingthe electro-hydraulic forming (EHF) technique.A finite element model, using Johnson–Cookconstitutiveequation,wasdeveloped to simulatethe high-rate forming behavior of Al under EHFandtestsamplesweredesignedtoobtaindifferentstrain paths at the apex of the EHF domes. Thedeformation history of Al sheets, under free-forming conditions and inside a conical die, wasexperimentally determined and compared tothe model predictions. Experimental data showsthat the high-rate formability of AA5182-O Alat minor strains of ~−0.1 and ~0.05, relative toits corresponding quasi-static formability, wasenhanced locally by~2.5× and~6.5× under free-formingandwhenforming insidetheconicaldie,respectively.Thein-planepeakengineeringstrain-rate associated with the enhanced formabilityduring free-formingwasmeasuredtobe~3900/swhilethepre-impactstrain-rateduringconical-dieformingwasestimatedtobe~4230/s.Thestrain-path associated with enhanced formability wasexperimentally determined under a free-formingcaseandwasfoundtobeingoodagreementwiththat predicted by the numerical model. To theauthors’ knowledge, these results are thefirst toexperimentally quantify the deformation historyassociated with enhanced formability that hasoften been reported in the literature. (21 refs,9figs,1table)(AA)

Abstracts


HYDRO FORMING

110102 Development of a microscale strain measurement system applied to sheet bulge hydroformingEmblom,WilliamJ;Jones,RichardJ;Aithal,Mitra;Md.FarhanS Ibne Islam, Glass,GaryA;Wagner,Scott W [J of Manufacturing Processes, v 16, n 2, Apr 2014, Starting Page 320, Pages 9] Thepresent paper describes the development ofa method for creating microscale grids andmeasuring strains on microscale parts ormicroscale locationson largerparts. Themethoddevelopedwasabletomeasuretruestrainsupto0.618forsquaregridsthatare127μmmeasuredfromcenter-to-center.Microscalestrainsresultingfrom sheet bulge hydroforming experimentsusing11mm,5mm,and1mmdiameterdieswereevaluated and material properties of the sheetmetal were estimated based upon the strainsmeasured in conjunction with FEA simulationsand compared to analytical solutions andmicroscale tension tests. Thematerial propertiesdetermined using the strains and FEM approachwereconsistentwiththeothermethods.(17refs,21figs,7tables)(GM)

WARM FORMING

110103 Warm forming die design, Part II: Parting surface temperature response characterization of a novel thermal finite element modeling codeHarrison, NR; Friedman, PA [J of Manufacturing Processes, v 16, n 2, Apr 2014, Starting Page 312, Pages 8] The majority of the research activitiesin the area of warm forming are concentratedon demonstrating or simulating the improvedformability associated with forming lightweightmaterials such as aluminum alloys at elevatedtemperatures. However, the ability to designthe proper thermal management system withinthe forming tool is a critical aspect to deliveringthis technology as a viable, stable productionalternative to traditional stamping. This workbegins to address the thermal stability issues ofthis process by examining the impact of processcycle time on the parting surface temperatureresponse.Cycletimesof10,15,30,and300swereevaluatedusingareciprocatingsurfaceandaself-heated experimental block of 1020 steel fittedwith resistance cartridge heaters. The presentedresults indicate that cycle time does notsignificantly impact the steady-state temperatureresponseatthepartingsurfaceforawell-insulateddie that has proper thermal management.

Parting surface experimental results werecompared to values obtained numerically andthrough the use of the novel thermal finiteelement analysis software PASSAGE/Forming®.(14refs,9figs,4tables)(AA)

SHEET METAL WORKING

110104 Model of slice-push cutting forces of stacked thin materialDeibel, Karl-Robert; Lämmlein, Sarah; Wegener,Konrad [J of Materials Processing Technology, v 214, n 3, Mar 2014, Starting Page 667, Pages 6] Adding slicing to push cutting processes cansignificantly reduce cutting forces. Creatingan appropriate model for the calculation offorces is necessary to completely understandmanufacturing processes. In this investigation, amodeldetailing thecuttingforcesofstackedthinmaterialusinganasymmetricalknifeisdeveloped.Equilibrium of forces and frictional effects atthe cutting edge are analyzed to determine thecomponents in vertical and horizontal directionof the total cutting force, and their dependencyontheslice-pushratio.Thefrictioneffectsof thenew model are based on Coulomb friction. Forcomparison purposes, an existing shear frictionmodel is extended to discuss the newpresentedCoulomb frictionmodel. To support the findings,the newly developed model is experimentallyverified.(12refs,12figs,2tables)(AA)

110105 Hot tearing in polycrystalline Ni-based IN738LC superalloy: Influence of Zr contentHeydari,D;ShahkaramFard,A;Bakhshi,A;Drezet,JM [J of Materials Processing Technology, v 214, n 3, Mar 2014, Starting Page 681, Pages 7] ZirconiumisalwayspresentinNibasesuperalloysasitenhancestheircreepproperties.Inthepresentstudy,theinfluenceofverysmallZradditions,100–400 ppm, i.e. 0.01–0.04 wt.%, on hot tearing ofIN738LC superalloy is experimentally investigatedusing dedicated turbine blade castings. AlthoughtheZrcontentremainsverysmall, ithasastrongeffect on hot tearing tendency. Microstructureof hot tear in as-cast samples reveal that grainsize and secondary dendrite arm spacing havenosignificanteffectonhot tearing.On theotherhand eutectic phase volume fraction and itsdispersion or spreading along grain boundariesdrastically affect the hot tearing propensity andstrongly increase with increasing amounts of Zr.Hence grain coalescence becomes impossible atgrain boundaries covered with eutectic phasefilms.WithincreasingZrcontent,gaincoalescence

Abstracts


betweentwodistinctgrainswithnointerdendriticphase requires more undercooling. Coalescenceis retardedandoccursdeeper in themush zone,i.e. at lower temperatures resulting in a highersensitivity tohot tearing. Finally, it is shown thatareductionofZrcontentto0.02wt.%isrequiredto fully suppress hot tearing in polycrystallineIN738LCblades.(19refs,10figs,4tables)(AA)

110106 Multi-pass deformation design for incremental sheet forming: Analytical modeling, finite element analysis and experimental validationLiu, Zhaobing; Daniel, William JT; Li, Yanle; Liu,Sheng;Meehan,PaulA[J of Materials Processing Technology, v 214, n 3, Mar 2014, Starting Page 620, Pages 15] Incrementalsheetforming(ISF)isapromisingrapidprototypingtechnologywithhighpotential to shape complex three-dimensionalparts. However, a common technical problemencountered in ISF is the non-uniform thicknessdistributionofformedparts;particularlyexcessivethinning on severely sloped regions. This mayleadto fractureand limit theprocess formability.Design of multi-stage deformation passes(intermediate shapes or preforms) before thefinal part, is a desirable and practical way tocontrol the material flow in order to obtaina more uniform thickness distribution andavoid forming failure. In the present paper, asystematicmethodologyfordesigningmulti-stagedeformation passes considering the predictedthickness strains given the design shape isproposed based on the shear deformation andthe strain compensation mechanism. In thismethodology,twoanalyticalmodels(M1andM2)are developed by taking into account; the globalaverage thickness strain and only thematerial inthe final part region used in the forming (M1),and the local weighted average thickness strainand theadditionalmaterial around thefinalpartregionusedintheforming(M2),respectively.Thefeasibility of the proposed design methodologyis validated by finite element analysis (FEA) andexperimental tests using an Amino ISF machine.The results show that a more uniform thicknessstrain distribution can be derived usingM2. Theincurrenceofthehigheststrainscanbedelayedinthe intermediate stages and theflowofmaterialis allowed into the deformed region, therebyallowingacompressivestressstatetodevelopandenablingsteepershapestobeformed.Therefore,the process formability can be enhanced via theoptimizeddesignofdeformationpasses. (17refs,18figs,4tables)(AA)

110107 Integrated cut and place module for high productive manufacturing of lithium-ion cellsBaumeister, M; Fleischer, J [CIRP Annals, v 63, n 1, 2014, Starting Page 5, Pages 4] A mainreasonforthehighcostsoflithium-ioncellsisthecomplexity of the assembly process. Especially,creating the cell stack is an inefficient processdue to an immature handling and aligning ofthe limp electrodes and separators. This paperfocusesthereforeonthemethodicaldevelopmentof a functionally integrated assembly modulethat combines cutting and handling of electrodesheets to increase stacking accuracy, processreliabilityandproductivity.Basedonananalysisofrequirements and functions, a technical solutionhas been identified and will be illustrated. Attheend, therealizedmodule isdescribedand itsperformanceisprovenbyexperimentalvalidation.(12refs,10figs)(AA)

INDUSTRIAL ENGINEERING

110108 Customer preference based optimization in selecting product/service varietyNishino, Nariaki; Takenaka, Takeshi; Koshiba,Hitoshi; Kodama, Keita [CIRP Annals, v 63, n 1, 2014, Starting Page 421, Pages 4] The breadthof customer choice of products and serviceshas increased dramatically. Consequently, bothmanufacturing and services have adoptedelaborate variety management to satisfy variouscustomer needs while maintaining businessprofitability. Our study presents a formulation ofvariety selection problems considering customerpreferences by the introduction of preferenceorder from economic theory. Using FrequentShopper Program data of a large shopping mallin Japan, our proposed framework is applied tothe optimization of tenant-mix problems as acase study of service variety selection. Resultsdemonstrate how an optimized variety ofshops can satisfy various customer preferencesat a reasonable profit level. (10 refs, 3 figs,5tables)(AA)

110109 Implications of automobile parts supply network structures: A complex network approachKito, Tomomi; Ueda, Kanji [CIRP Annals, v 63, n 1, 2014, Starting Page 393, Pages 4] Thisstudy investigates the temporal structuraltransitionsofautomobilesupplynetworkswhere,under situations with various possible risks suchas economic crises and market globalisation,companies must both work together forsustainable production, and also compete witheach other for their own survival. The resulting

Abstracts


network complexity is captured by large-scaleempirical data, and analysed for the first timeusingconceptsandmetricsdevelopedincomplexnetwork science. We discuss how networkstructure reflects the effect of severalfactors including market fluctuation, productstandardisation, technological advancement, andfinancial interdependencies between companies.(18refs,4figs,3tables)(AA)

110110 Global Footprint Design based on genetic algorithms – An ‘‘Industry 4.0’’ perspectiveSchuh,Guenther;Potente,Till;Varandani,Rawina;Schmitz, Torben [CIRP Annals, v 63, n 1, 2014, Starting Page 433, Pages 4] A cost-optimizeddesign of a global production network is acomplextask.Severaloptimizationtoolsexistthatdetermine cost-minimized solutions for definedpoints of times in the future but often do nottakeintoaccountthedevelopmentofthenetworkover time. The approach of this article is toanalyze a series of different cost-optimizedscenarios for several pointsoftime in the futurewith distinct parameter settings and compareits network structures. The goal of such broadcalculations of future scenarios according tothe ideaof ‘‘Industry4.0’’ is to identifyapath inthe trade-off between the costs for migrating anetworkstructure intoanotheroneandthetotallanded costs of the regarded series of futurenetworkscenarios.Theapproachwillbevalidatedusing data from real industrial case studies.(16refs,4figs)(AA)

JOINING & ASSEMBLY

110111 Comparative study on the effect of GTAW processes on the microstructure and mechanical properties of P91 steel weld jointsArivazhagan,B;Vasudevan,M[J of Manufacturing Processes, v 16, n 2, Apr 2014, Starting Page 305, Pages 7] Modified9Cr-1Mo(P91)steeliswidelyused intheconstructionofpowerplantcomponents. In thepresent study,a comparativestudyoninfluenceofactivatedfluxtungsteninertgas (A-TIG), and gas tungsten arc (GTA) weldingprocesses on the microstructure and the impacttoughness of P91 steel welds was carried out.P91 steel welds require a minimum of 47 Jduring the hydrotesting of vessels as per theEN1557: 1997 specification. Toughness of P91steel welds was found to be low in the as-weldcondition. Hence post-weld heat treatment(PWHT) was carried out on weld with theobjective of improving the toughness ofweldments. Initially as per industrial practice,

PWHT at 760 °C – 2 h was carried out in orderto improve the toughness of welds. It has beenfoundthatafterPWHTat760°C–2h,GTAweld(132 J) has higher toughness than the requiredtoughness (47 J) as compared with A-TIG weld(20 J). The GTA weld has higher toughness dueto enhanced tempering effects due to multipasswelding, fewmicroinclusioncontentandabsenceof δ-ferrite. The A-TIG weld requires prolongedPWHT (i.e. more than 2 h at 760 °C) than GTAweld to meet the required toughness of 47 J.This is due to harder martensite, few weldingpasses that introduces less tempering effects,presence of δ-ferrite (0.5%), and more alloycontent. After PWHT at 760 °C – 3 h, thetoughnessofA-TIGweldwasimprovedandhigherthantherequiredtoughnessof47J.(14refs,9figs,3tables)(AA)

110112 Numerical modelling of the material flow during extrusion of aluminium alloys and transverse weld formationMahmoodkhani, Yahya; Wells, Mary A; Parson,Nick; Poole, WJ [J of Materials Processing Technology, v 214, n 3, Mar 2014, Starting Page 688, Pages 13] A comprehensive numerical model ofthe hot extrusion process for aluminium alloyshas been developed and validated. Reflectingthe complex thermomechanical changeseffectedinthealloysduringextrusion,themodelincorporated heat flow and plastic deformationduring extrusion. This paper presents the overallnumerical development of a hot extrusionprocess for AA3003 and validation of thenumerical model, by comparison to industrialdata. The plasticitymodulewas developed usinga commercial finite element package, DEFORM®,a 2-D transient Lagrangian model which couplesthe thermal and deformation phenomena andis able to predict the temperature, strain rateand strain distribution in the billet/extrudateat any position in the container and die. A newalgorithm using MATLAB was also developed sothat details of the material flow and formationof the transverse weld and how it is affectedby the feeder geometry could be quantified.ValidationoftheDEFORMmodelandtheMATLABalgorithm of the material flow against industrialdata indicated that it gave excellent predictionsof the pressure and temperature history duringextrusion as well as material flow effects suchas surface cladding as one billet is fed in afteranother through the die. The results indicatedthat the die feeder design has a significanteffect on the transverse weld formation withtapered dies showing lower transverse weld

Abstracts


lengths compared to regular feeder plates.(16refs,25figs,5tables)(AA)

110113 Method for double-sided friction stir spot weldingCox, Chase D; Gibson, Brian T; DeLapp, David R;Strauss,AlvinM;Cook,GeorgeE[J of Manufacturing Processes, v 16, n 2, Apr 2014, Starting Page 241, Pages 7] Arotatinganvilsimilartoapinlessfrictionstirwelding (FSW) tool canbe applied to frictionstirspotwelding(FSSW)ofthinmetalplates.FSSWis a solid-state joining process that is currentlybeing used by automotive manufacturers as analternativetorivetsandtraditionalresistancespotwelding.Theprincipaldetractorof thisprocess isthe keyhole left by pin extraction, which can bedetrimental to the weld strength. A pinless toolcan be used to eliminate the keyhole. However,this approach is limited to joining thin sheet(≤1 mm). Using a rotating anvil with the FSSWprocess permits the joining of thicker crosssections, improves the mechanical strength ofthespotweldandreducesthereactionforcesonthe spot welding frame. A numerical model oftheprocess, tensileshear testsandmacrosectionanalysis are used to evaluate the spot welds.Macrosection and numerical analysis revealsthat the material flow between the pinless tooland rotating anvil is complex and unique tothis process. It has been found that theuseof arotatinganvilforFSSWisaviablemeanstocreatequality spot welds in thicker weldments. (9 refs,9figs,1table)(AA)

110114 Inertia welding for assembly of copper squirrel cages for electric motorsAgapiou, John S [J of Manufacturing Processes, v 16, n 2, Apr 2014, Starting Page 276, Pages 8] The automotive industry is developing designsandmanufacturingprocessesfornewgenerationsofelectricmotors intended foruse inhybridandelectricvehicles.Thereis interest inreplacingthealuminum traditionally used in induction motorrotors with copper to improve motor capability.This paper focuses on solid-state welding tojoin copper end rings to copper spokes in thefabrication of copper rotors. Inertia frictionwelding was explored to examine weldability ofthesecoppercomponents.Abetterunderstandingof inertia welding characteristics will help theadvancements in its application for inductionrotors. The limitations of this application arediscussed.(17refs,17figs,1table)(AA)

110115 Vibrational energy loss analysis in battery tab ultrasonic welding

Kang, Bongsu; Cai, Wayne; Tan, Chin-An [J of Manufacturing Processes, v 16, n 2, Apr 2014, Starting Page 218, Pages 15] In ultrasonicmetalwelding processes, high-frequency ultrasonicenergyisusedtogeneratefrictionandheatattheinterface between weld parts to produce solid-state bonds. It has been observed that sufficientenergy is required to produce proper bonding,while excessive energy can cause such qualityissuesasweldfractureandperforation.Therefore,it is important to have a product/process designin ultrasonic welding to ensure efficient energyconversion from ultrasonics to welding energy,minimizing energy loss in the process. In thiswork, vibrational energy loss associated withthe longitudinal and flexural vibrations of the Cucoupon during ultrasonic welding is studied byapplying one-dimensional continuous vibrationmodels. To facilitate our modeling, experimentalresultsfromthefreeresponseofCucouponwereobtainedtodeterminethedampingcharacteristicsof the Cu coupon in the welding process. Ouranalysis shows that substantial energy loss canoccurduringweldingduetotheflexuralvibrationof the Cu coupon, especiallywhen the overhang(theupperpartof theCucouponextended fromtheanvil)of theCucouponresonatesatorcloseto the welding frequency (about 20 kHz),degrading the weld quality of battery tabs.This study contributes to understanding thefundamental dynamics of the Cu coupon duringultrasonicweldinganditsimpactonweldquality.(25refs,10figs)(AA)

110116 Comparison of mechanical properties of pure copper welded using friction stir welding and tungsten inert gas weldingLin,Jau-Wen;Chang,Hsi-Cherng;Wu,Ming-Hsiu[J of Manufacturing Processes, v 16, n 2, Apr 2014, Starting Page 296, Pages 9] Theobjectiveof thisresearchistoinvestigatethemechanicalpropertiesincluding bonding, tensile strength, and impactresistanceofpurecopperweldedusingfrictionstirwelding (FSW) method and compare them withthat of tungsten inert gas (TIG) welding. Micro-hardness tests are performed on pure copper,TIG welded copper and FSW welded copper todetermine the effect of heat on the hardness ofwelded coppers. Tensile strength tests andnotchtensilestrengthtestsareperformedtodeterminethe mechanical properties of different weldprocess. In this experiment, it is found that thenotchtensilestrengthandthenotchstrengthratiofor FSW (212MPa, 1.10) are significantly higherthanthose(190MPa,1.02)ofTIGwelding.Fortheimpacttests,theweldzoneandheat-affectedzone

Abstracts


energyabsorptionvalues for FSW (2.87 J, 2.25 J)arehigherthanthose(1.32J,0J)ofTIGwelding.XRDtestsareperformedtodeterminecomponentsofcopperbeforeandafterweldingprocessforTIGandFSW.(24refs,16figs,2tables)(AA)

110117 Influence of welding speed and power on residual stress during gas tungsten arc welding (GTAW) of thin sections with constant heat input: A study using numerical simulation and experimental validationRavisankar, A; Velaga, Satish Kumar; Rajput,Gaurav; Venugopal, S [J of Manufacturing Processes, v 16, n 2, Apr 2014, Starting Page 200, Pages 11] The temperaturedistributionandresidual stresses for aGTAWcircumferential buttjoint of AISI 304 stainless steel using numericalsimulation have been evaluated. For evaluationofweld induced residual stresses, theanalysisofheatsourcefittingwascarriedoutwithheatinputsrangingfrom200to500J/mmtoarriveatoptimalheat input forobtainingproperweldpenetrationand heat affected zone (HAZ). For this chosenheatinput,theinfluenceofdifferentweldspeedsand powers on the temperature distribution andthe residual stresses is studied. The heat sourceanalysisrevealedthebestchoiceofheatinputas300J/mm.Theresidualstressesontheinnerandoutersurfaces,andalongtheradialdirectionwerecomputed.Increaseintemperaturedistributionaswell as longitudinal and circumferential residualstresses was observedwith the increase in weldspeedandpower.Thevalidityoftheresultsobtainedfrom numerical simulation is demonstrated withfullscaleshopfloorweldingexperiments.(27refs,16figs,5tables)(AA)

LASERS

110118 Effect of beam diameter on pulsed laser polishing of S7 tool steelPfefferkorn,FrankE;Duffie,NeilA;Morrow,JustinD;Wang,Qinghua[CIRP Annals, v 63, n 1, 2014, Starting Page 237, Pages 4] ToolsteelssuchasS7areoftenusedformoldsanddies,anapplicationthat requires both an extremely smooth surfaceandtightgeometrictolerances.Pulsedlasermicropolishing(PLmP)isaprocesscapableofachievingsignificantsurfacesmoothingquicklyandwithoutremovingmaterial.Thispaperpresentstheeffectof melt pool diameter (laser spot diameter) onsurface topographyduringpulsed laserpolishing.How the manipulation of melt pool diameterduring three-pass laser polishing can reducesurfaceroughnessisalsodiscussed.(11refs,7figs,2tables)(AA)

110119 Influence of forming atmosphere on the deposition characteristics of 2Cr13 stainless steel during laser solid formingSong,Menghua;Lin,Xin;Yang,Gaolin;Cui,Xiaoya;Yang, Haiou; Huang, Weidong [J of Materials Processing Technology, v 214, n 3, Mar 2014, Starting Page 701, Pages 9] Aseriesofsingletrackclads and bulk samples were prepared by lasersolidformingunderatmospheresofair,argonandnitrogen.Theformingatmospherehaslittleeffectonthevariationofthewidthandheightofasingletrackcladwithscanningvelocity,laserpowerandfeeding rate. Under air, the width and height ofsingletrackcladsarethelargest.Underargon,theyareslightlylargerthanthoseundernitrogenwhenthelaserenergydensity ishigh.Forbulksamplesprepared under air and nitrogen, both sidewallsof thecross-sectiontilt inward in the lowerpart;with an increase in the deposition height, thesidewalls tend to be oriented vertically. Underargon,thesidewallsmaintaintheirsevere inwardtilts from the bottom to top of the bulk sample.Under air, the bulk sample is covered by oxidedross.Fineanddensemetalbeadsareattachedtothelowersidewallsunderargon,butthesebeadsarecoarseandsparseundernitrogen.Theeffectsoftheformingatmosphereontheeffectiveenergy,effective mass and deformation of the moltenpoolduringlasersolidformingwereanalyzed.Theinfluence of the atmosphere is attributed to theexothermicoxidationreactionunderair,themoreextensive plasma plume effect under argon andthe largerdeformationof themoltenpoolunderairandnitrogen.(22refs,7figs,4tables)(AA)

110120 Analysis of a laser process for permanently degrading a photo-activated adhesive jointMantena, Mahesh; Cloquell, Arnau Piza; Meter,EdwardCDe[J of Manufacturing Processes, v 16, n 2, Apr 2014, Starting Page 190, Pages 10] Apulsed,laser process has been developed to reduce thepermanent strength of photo-activated adhesivejointspriortowork-piecede-bonding.Theobjectiveof this investigation was to gain insight into therelationships between carbon black content ofthe adhesive, laser deliverymode, heat transfer,and adhesive degradation. To do so, a varietyof experiments were performed to characterizeprocess sensitivity, radiation absorption withintheadhesivejoint,andthermaldecompositionofthe adhesive. In addition, heat transfer analysiswas conducted to predict adhesive temperaturesduringtheprocess.Theresultsofthisinvestigationindicate that the strength diminishment of anadhesivejointoccursafterithasabsorbedatrainofhighpowerpulsesinrapidsuccession.Thevast

Abstracts


majority of strength diminishment occurs over averynarrowtimewindowandishighlycorrelatedtotherapidemissionofgraysmoke/vaporfromtheadhesivejoint.Forthistooccur,theadhesivemustcontain carbon black. It is also highly correlatedto a rapid increase in temperatures throughoutthe adhesivematrix. Laserpulseparameters thatdonotleadtothisrapidincrease,willnotinitiateadhesive degradation. The inclusion of carbonblackintotheadhesivepromotesheatabsorptionandincreasedtemperaturesintheadhesivejoint.These temperatures are large enough to enableadhesive decomposition. But the time span overwhich this happens is too small for significantdamage to occur. It is currently hypothesizedthat high temperatures local to the carbon blackparticlesmaybethesourceofadhesivedegradation.(22refs,13figs,2tables)(AA)

MACHINE ELEMENTS & MECHANISMS

110121 New methodology to reduce the transmission error of the spiral bevel gearsAstoul, J; Mermoz, E; Sartor, M; Linares, JM;Bernard,A[CIRP Annals, v 63, n 1, 2014, Starting 5, Pages 4] Newmethodsand toolshavebeen developed the last years to improve theunderstanding of gear meshing. Mechanicalindustriesattachgrowingattentiontothedynamicbehavior of mechanical transmissions, includingvibration and noise that result. The transmissionerrorofthegear,whichmeasurestheintensityofone of themain causes of dynamic phenomena,canbe consideredasa relevant indicatorof gearperformance. This paper presents a new designmethod of spiral bevel gears, the objective ofthis method being to reduce their quasi-statictransmission error. The proposed approach isbasedonanoptimizationprocessincludingloadedmeshing simulations. The simulation model hasbeen evaluated using a helicopter tail gearboxas bench test. Measurement results are given,showing a good correlation with predictions.(19refs,11figs,3tables)(AA)

MACHINING

110122 FE-simulation of machining processes with a new material modelBuchkremer, S; Wu, B; Lung, D; Münstermann,S; Klocke, F; Bleck, W [J of Materials Processing Technology, v 214, n 3, Mar 2014, Starting Page 599, Pages 13] This paper presents the creation

andexperimentalvalidationofa3D-FEMmodelofthelongitudinalturningprocesswithanextendedmodifiedBai–Wierzbickimaterialmodel(extendedMBW model). This newly developed materialmodelevaluatestheinfluenceofstateofstressaswellasdamageonthestrainhardeningbehavior.In addition, it takes temperature and strain rateeffects into consideration, whose influences areboth typically higher in cuttingprocesses than instructural–mechanicalproblems.Forthevalidationof the proposed material model, longitudinalturningexperimentswereconductedonAISI1045steel. Four different cutting tools and processconditionswereinvestigated,whichcoverabroadrange from finishing to roughing. A high speedcamerawas used to film the chip formation andchipflowinordertocompareittothesimulationresults.Thethreecuttingforcescomponentswerealsocollected.Measuredchiptemperaturesweretaken from the literature. The validation showedthat the implementationof theselectedmaterialmodel results in a close agreement betweenexperimentally obtained and predicted chipgeometries,cuttingforcesandchiptemperatures.(26refs,16figs,6tables)(AA)

110123 Cycle optimization in cam-lobe grinding for high productivityKrajnik, Peter; Drazumeric, Radovan; Badger,Jeffrey; Hashimoto, Fukuo [CIRP Annals, v 63, n 1, 2014, Starting Page 333, Pages 4] Cycleoptimizationincam-lobegrindingispresentedforimprovingproductivity.Itincludesnovelmodelingof the instantaneous geometry, kinematics andtemperature for anyworkpiece form.A technicalassessment of three process-control strategies– (1) constant specificmaterial removal rate, (2)constantpower,and(3)constanttemperature–ismade.Theconstant-temperatureprocessprovidesthe shortest cycletimewithout thermaldamage.A detailed analysis of this process considers therole of machine limitations, including maximumspeed, acceleration, and jerk, as well as thecam-lobe geometrical effects. The optimizationresultsarevalidatedbygrindingtestsinanactualproductionline.(10refs,10figs,1table)(AA)

110124 Finite element modeling of microstructural changes in dry and cryogenic machining of AZ31B magnesium alloyPu,Z;Umbrello,D;DillonJr.,OW;Lu,T;Puleo,DA;Jawahir,IS[J of Manufacturing Processes, v 16, n 2, Apr 2014, Starting Page 335, Pages 9] Inthispaper,a preliminary studywas conducted tomodel themicrostructuralchangesofAZ31BMgalloyduringdry and cryogenic machining using the finite

Abstracts


element(FE)methodandausersubroutinebasedonthedynamicrecrystallization(DRX)mechanismofMgalloys.Goodagreementintermsofgrainsizeand affected layer thickness was found betweenexperimental and predicted results. A numericalstudywasconductedusingthismodeltoinvestigatethe influence of rake angle on microstructuralchanges after cryogenic machining. (24 refs,12figs,4tables)(GM)

110125 Reducing drilling-induced delamination in composite tube by magnetic colloid back-upHocheng, H; Tsao, CC; Liu, CS; Chen, HA [CIRP Annals, v 63, n 1, 2014, Starting Page 85, Pages 4] Drilling is an indispensible machining processforbuildingaload-carryingstructureofcompositematerials. Delamination defect is often producedattheexitofdrilling,whichthreatenstheservicesafetyofthestructure.Thereareback-upmethodsto reduce delamination when drilling the openflat-plate composite structure, but none fordrilling into the curved-surface or hollow-shapestructures. This study describes an innovativemethodusingelectromagnetandthedeformableinexpensive colloid mixed with iron powder toproducemagneticback-upforceatdrillingexittosuppressdelaminationinindustrialtubeparts.Thedelamination extent can be reduced by 60–80%.The optimal volume ratio of powder-to-colloid isfound1:3.(17refs,12figs,2tables)(AA)

110126 Wet blasting as a deburring process for aluminumYang,Myeongseok; Choi, Jongrak; Lee, Jungchul;Hur, Nahmkeon; Kim, Dongchoul [J of Materials Processing Technology, v 214, n 3, Mar 2014, Starting Page 524, Pages 7] Lightweightaluminumhas shown high applicability in the automobileindustry for high fuel efficiency. However, themanufacturing of aluminum is limited by thedeburring process owing to the difficulty inemployingwetblasting. Inthispaper,wepresentexperimental and computational studies on thedeburring process of wet blasting for aluminum.The process conditions are analyzed to achievehigh deburring performance that minimizes thesurfacedamage.Parametersofwetblastingwithasignificantinfluenceonthedeburringprocessareinvestigatedandapromisingdeburringtechniqueforaluminumisproposed.(12refs,12figs)(AA)

NON TRADITIONAL MACHINING

110127 Compound machining of titanium alloy by super high speed EDM milling and arc machiningWang, Fei; Liu, Yonghong; Zhang, Yanzhen; Tang,

Zemin; Ji, Renjie; Zheng, Chao [J of Materials Processing Technology, v 214, n 3, Mar 2014, Starting Page 531, Pages 8] A novel compoundmachining of titanium alloy (Ti6Al4V) by superhigh speed electrical dischargemachining (EDM)milling and arc machining was proposed in thispaper. The power supply consisted of a pulsegenerator and a DC power source which wereisolatedfromeachother.Arotatingpipegraphiteelectrodewas connected to the negative pole ofthe power supply. The plasma channel was abletodeionize, andmaximummaterial removal rate(MRR) reached 21,494 mm3/min with a relativeelectrodewear ratio (REWR) of 1.7% because ofhigh current and efficient flushing. Comparedwith traditional EDM, the compound machiningachieved a significantly higherMRRbut a similarREWR. To investigate the characteristics of thecompound machining, the effects of electrodepolarity, peak voltage, peak current, andflushingpressure on the performance of the process,includingitsMRR,REWR,andradiusofovercut(ROC),were determined. In addition, scanning electronmicroscopy, X-ray diffraction, and microhardnessanalysis were conducted. Result shows thatthe proposed method can machine difficult-to-machine materials efficiently. (26 refs, 13 figs,2tables)(AA)

110128 Improvement of hole exit accuracy in electrochemical drilling by applying a potential difference between an auxiliary electrode and the anodeFang, Xiaolong; Qu, Ningsong; Zhang, Yudong;Xu,Zhengyang;Zhu,Di [J of Materials Processing Technology, v 214, n 3, Mar 2014, Starting Page 556, Pages 9] Electrochemical drilling (ECD) isa promising and low-cost process for yieldingmultiple holes simultaneously in difficult-to-machinematerials. In this process, the hole exitaccuracyisverysensitivetotheelectrodefeedingdepth. In practice, excessive electrode feedingis necessary to ensure that all holes are drilledthrough simultaneously when there is an errorin thickness of the workpiece plate. This resultsin stray removal at the hole exit and an etchedand pitted surface. In the modification of ECDdescribedhere,apotentialdifferenceisintroducedviaaninsolubleplatinumauxiliaryelectrodethatisattachedbeneathadielectricperforatedplateandarrangedoppositetotheholeexitstodiminishthedamagefromthestraycurrentandtherebyimprovethe tolerance of the exit accuracy to excessiveelectrodefeeding.Simulationresultsindicatethatan appropriate value of the potential differenceconcentrates the current at the tooltip andmay

Abstracts


reverse the current direction on the workpiecesurface. Experiments verify that this approachis effective in obtaining holes with good exitaccuracyinthecaseofexcessiveelectrodefeeding.Furthermore, it is confirmed that this method iscapableofdrillingmultipleholeswithremarkablyenhanced exit accuracy and uniformity. (17 refs,18figs,2tables)(AA)

110129 Clarification of EDM gap phenomena using transparent electrodesKitamura,Tomoo;Kunieda,Masanori[CIRP Annals, v 63, n 1, 2014, Starting Page 213, Pages 4] Thispaperdescribestheheatsourcediameterofsinglepulsedischarge inelectricaldischargemachining.Toobserve thedischargeplasma, SiCandGa2O3singlecrystalswereusedastheelectrodematerialsincetheyareopticallytransparentandelectricallyconductive. It was found that plasma diameterexpandswithinafewmicrosecondsafterdielectricbreakdownandtheplasmadiameterismuchlargerthan the discharge crater. From the measureddiameterof the crater, theheat sourcediameterwas obtained by solving the inverse problem ofheatconductionanalysis,anditwasfoundthattheheat source diameter is smaller than the plasmadiameter but larger than the crater diameter.(15refs,13figs,2tables)(AA)

110130 Generation of hierarchical micro-structures for anisotropic wetting by elliptical vibration cuttingGuo, Ping; Lu, Yong; Ehmann, Kornel F; Cao, Jian[CIRP Annals, v 63, n 1, 2014, Starting Page 553, Pages 4] Thispaperreportsenhancedanisotropicwettability using two-level hierarchical micro-structures. First- order micro-channels withsuperimposed second-order micro-textures weremachined on aluminum surfaces using ultrasonicelliptical vibration cutting (EVC). Controllablesinusoidal micro-textures with a wavelength oneorder of magnitude smaller than the widths ofthe first-order micro-channels were applied tothesurface.Anisotropicwettabilitywasevaluatedby water contact angle measurements in twoorthogonaldirections.Theresultshaveshownthatthe generated hierarchical micro-structures havenearly doubled the anisotropic contact angle incomparisontoone-levelstructures.Arelationshipbetween anisotropic wetting characteristics andprocess parameters is also presented. (13 refs,11figs)(AA)

110131 High cycle fatigue properties of selective laser sintered parts in polyamide 12Hooreweder,Brecht Van; Jean-PierreKruth[CIRP

Annals, v 63, n 1, 2014, Starting Page 241, Pages 4] Selective laser sinteredparts inpolyamideareincreasinglybeingusedinfunctionalapplications.The monotonic properties of these parts arewell-knownanddocumented. The cyclicmaterialproperties,ontheotherhand,arelargelyunknown.Therefore, in this paper a systematic analysis ismadeoffatiguepropertiesandfailuremechanismsof selective laser sintered parts subjected tofluctuating loading in tension/compression. Bothplainandnotchedspecimensareproducedalongperpendicular building directions. The fatiguebehaviourofthesepartsisanalysedandcomparedto injection moulded samples. In addition, theinfluence of the test frequency and the notchmanufacturingmethod isstudied. (6refs,10figs,1table)(AA)

LASER MACHINING

110132 Time-optimized hole sequence planning for 5-axis on-the-fly laser drillingErkorkmaz, Kaan; Alzaydi, Ammar; Elfizy, Amr;Engin, Serafettin [CIRP Annals, v 63, n 1, 2014, Starting Page 377, Pages 4] On-the-fly laserdrillingrequirestheuseofaccelerationcontinuoustrajectories,whicharetypicallyplannedusingtimeparameterized spline functions. In thisoperation,thechoiceofholedrillingsequence,andpositioningtimingsinbetweentheholes,playacriticalroleindeterminingtheachievablecycletime.Thispaperpresents a new algorithm for sequencing 5-axison-the-flylaserdrillingholelocationsandtimings.Thealgorithmconsidersmachinetoolandprocessconstraints,aswellasthetemporalnatureofthefinalcommandedsplinetrajectory.Theachievableproductivityandmotionsmoothnessimprovementaredemonstratedintheproductionofagasturbinecombustionchamberpanel.(6refs,8figs)(AA)

110133 Microwave cladding: A new approach in surface engineeringGupta, Dheeraj; Sharma, Apurbba Kumar [J of Manufacturing Processes, v 16, n 2, Apr 2014, Starting Page 176, Pages 7] The present workmainlyfocusesonanoveldevelopmentinsurfaceengineeringtechniques intheformofmicrowavecladding. Clads of tungsten carbide (WC) basedWC10Co2Ni powder on austenitic stainless steelwere produced using microwave hybrid heating.Microwavecladsweredevelopedbyexposingthepreplaced,preheatedpowderforadurationof120s to microwave radiation at 2.45 GHz frequencyand 900Wpower in a homemicrowave system.Characterizationofthecladswascarriedoutintheformofmicrostructuralandelementalcomposition

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studies. Investigations show crack-free interfacerevealinggoodmetallurgicalbondassociatedwithpartial dilution of the stainless steel substrateand full melting of WC particles. Typical X-raydiffraction results confirm presence of metalliccarbidesinthecladwhichisprimarilyresponsibleforsignificantlyhighermicrohardnessoftheclad.Processmechanismhasbeendiscussed. (36 refs,9figs,2tables)(GM)

110134 Fabrication of transparent superhydrophobic surface on thermoplastic polymer using laser beam machining and compression molding for mass productionChun, Doo-Man; Davaasuren, Gaasuren; Ngo,Chi-Vinh; Kim, Chung-Soo; Lee, Gil-Yong; Ahn,Sung-Hoon[CIRP Annals, v 63, n 1, 2014, Starting Page 525, Pages 4] Superhydrophobicsurfacehasunique characteristics such as water repellenceand self-cleaning, and especially transparentsuperhydrophobicsurfaceshavewideapplicationsfor self-cleaned solar cells, protectiveoptics, andbuilding windows. In this research, laser beammachining with ultra-violet (UV) nanosecondpulse laser was utilized for fabrication of thesurface textured metal mold, and the replicaof thermoplastic polymer was fabricated usingcompressionmoldingformassproduction.Waterdroplet contact angle and transmittance weremeasured to confirm the superhydrophobicityand transparency. By controlling pattern size,the transparent superhydrophobic surface wasfabricated, and the effect of pattern size wasstudied with wetting states. (15 refs, 13 figs,1table)(AA)

110135 Influence of displacement constraints in thermomechanical analysis of laser micro-spot welding processDesai,RS;Bag,S[J of Manufacturing Processes, v 16, n 2, Apr 2014, Starting Page 264, Pages 12] The evolution of mechanical components intosmallersizegeneratinganeedformicroweldingofthesecomponentsusing laserwhichoffersbettercontrolascomparedtoarcandplasmaprocessing.The present article describes the numericalsimulationoflasermicro-spotweldingusingfiniteelement method. A two dimensional Gaussiandistributedsurfaceheatfluxasafunctionoftimeisusedtoperformasequentiallycoupledthermaland mechanical analysis. The model is used forsimulating laser micro-spot welding of stainlesssteel sheetunderdifferentpower conditionsandconfigurations of mechanical constraints. Thetemperature dependent physical properties ofSS304 have been considered for the simulation

andanisotropicstrainhardeningmodelhasbeenused. The simulatedweld bead dimensions havebeen compared with experimental results andtemperature profiles have been calculated. Themaximumdeformationof0.02mmisobtainedwithmaximumlaserpowerof75W.Thethermalstressis more inducing factor to temperature inducedresidualstressesandplasticstrainascomparedtomechanicalconstraints.Theplasticstrainchangessignificantly by displacement constraints ascomparedtoresidualstress.(35refs,16figs)(AA)

LASER WELDING

110136 Dynamic keyhole profile during high-power deep-penetration laser weldingLi, S; Chen, G; Zhang, M; Zhou, Y; Zhang, Y [J of Materials Processing Technology, v 214, n 3, Mar 2014, Starting Page 565, Pages 6] Basedon a butt-joint configuration assembled fromtransparentglassandstainlesssteel,thedynamickeyhole profilewas observed during 10-kWfiberlaser welding. The “gauffers” and vapor flow onthe front keyholewallmoved downwards to thebottom of the keyhole. The downward-flowingvapormettheupward-flowingvaporatthebottomof the keyhole, which resulted in a whirlpool ofvapor. The suspended droplets were drove tomove in a random fashion by thewhirlpool. Thefluctuatingvaporflowandpressurewerethekeyfactors causing the fluctuating keyhole wall andresultinginavapor-generatedwave(VGW)ontherear keyholewall. The dynamic VGWwas a veryimportant factor affecting the dynamic weldingprocess. When the VGW broke at the keyholeoutlet, it was accompanied by swellings, spatter,columns, a decrease of the diameter of keyholeinlet, and a change in the direction of plume.(15refs,5figs,1table)(AA)

110137 Electrical performance of laser braze-welded aluminum–copper interconnectsSolchenbach, Tobias; Plapper, Peter; Cai, Wayne[J of Manufacturing Processes, v 16, n 2, Apr 2014, Starting Page 183, Pages 7] The reportedinvestigation is related to laser beam braze-welding technology for dissimilar aluminum–copper interconnects for Li-ion battery assembly.The correlation between the brittle and high-resistivity intermetallic compounds and theelectrical contact resistance showed that a thinintermetallic layer is highly desirable. It wasproved that highest shear strength and lowestcontact resistance can be achieved within thesameparametersetwhichisofparticularinteresttobatteryelectricalvehicleapplicationsrequiring

Abstracts


both high mechanical reliability and electricalperformance. A study on the weld seam layoutfurthershowedthattwoparallelweldseamswithoptimized spacing and overlap design providelowest contact resistance. (20 refs, 13 figs,2tables)(AA)

110138 Experimental and numerical investigation of an electromagnetic weld pool support system for high power laser beam welding of austenitic stainless steelBachmann,Marcel; Avilov, Vjaceslav; Gumenyuk,Andrey; Rethmeier, Michael [J of Materials Processing Technology, v 214, n 3, Mar 2014, Starting Page 578, Pages 14] Athree-dimensionalturbulentsteadystatenumericalmodelwasusedto investigate the influence of an alternatingcurrent (AC) magnetic field during high powerlaser beam keyhole welding of 20 mm thickstainlesssteelAISI304beingmodeledasanidealnon-ferromagnetic material. Three-dimensionalheat transfer and fluid dynamics as well as theelectromagneticfieldequationsweresolvedwiththefiniteelementpackageCOMSOLMultiphysics4.2 taking into account the most importantphysical effects of the process. Namely, thethermo-capillary (Marangoni) convection at theweld pool boundaries, natural convection due togravity and density differences in the meltvolume as well as latent heat of solid–liquidphase transitions at the phase boundaries wereincludedinthemodel.Itisshownthatthegravitydrop-out associated with the welding of thickplates due to the hydrostatic pressure can bepreventedbytheapplicationofACmagneticfieldbetween 80 mT and 135 mT for correspondingoscillation frequencies between 1 kHz and 10kHz below the weld specimen. Experimentally, avalue of the magnetic flux density of around230 mT was found to be necessary to allow forsingle-passlaserbeamweldingwithoutsaggingordrop-out ofmelt for a 20mm thick combinationof austenitic stainless steel AISI 304 and ferriticconstruction steel S235JRC at an oscillationfrequency of around 2.6 kHz. (33 refs, 20 figs,6tables)(AA)

MANUFACTURING SYSTEMS

110139 Experimental study of work system networking in production environmentSkulj, Gasper; Vrabic, Rok; Butala, Peter [CIRP Annals, v 63, n 1, 2014, Starting Page 401, Pages 4] In the context of distributedmanufacturing, existing models for themanagementofordersandworksystemsassume

that the entirety of information about thestate of the production environment is known.Instead, this paper studies the implications ofnetworkinginanenvironmentinwhichnoelementpossesses information about the entire state.An experiment in the form of a productionsimulation game is designed and carried out toexplore the emergence and behaviour of sucha network. Network structure and dynamicsas well as the social aspects of networking arediscussedandevaluated.(19refs,3figs)(AA)

110140 Holistic and rapid sustainability assessment tool for manufacturing SMEsChen, Danfang; Thiede, Sebastian; Schudeleit,Timo; Herrmann, Christoph [CIRP Annals, v 63, n 1, 2014, Starting Page 437, Pages 4] Sustainabledevelopment is a broad term and is complex innature because it has three dimensions. Whilecontinuous management is necessary, especiallyforSMEs,thereisa lackofeasilyapplicabletoolsthat assess the status of sustainability basedon key performance indicators and that derivepriorities for systematic improvement. Based onthis information, this paper presents a holisticsustainability assessment tool for manufacturingSMEs. The tool is applicable on a factory levelwith reasonable effort, provides decisionsupport for improvements and enables a cross-industry comparison. A case study at a Swedishcompany has been performed to verify theusability.(22refs,3figs,2tables)(AA)

110141 Intelligent dynamic part routing policies in Plug & Produce Reconfigurable Transportation SystemsCarpanzano,E;Cesta,A;Orlandini,A;Rasconi,R;Valente,A [CIRP Annals, v 63, n 1, 2014, Starting Page 425, Pages 4] ReconfigurableTransportationSystems (RTSs) are conceived as multipleindependent modules to implement alternativeinboundlogisticsystems’configurations.Togetherwith mechatronic interfaces and distributedcontrol solutions, the full exploitation of RTSplug & produce features rely on flexibleproduction management policies. The currentwork proposes an innovative approach todynamically compute part routings in RTSs. It isdesignedasfullydistributedacrosstransportationmodules; based on current RTS’ topology andstatus, itensures the autonomy in selectingrouting decisions while embracing global andlocalevolvingoptimizationstrategies.Thebenefitsof the approach have been investigated withreference to an industrial case study. (15 refs,6figs)(AA)

Abstracts


110142 Long term impacts of international outsourcing of manufacturing on sustainabilityRad,SeyedHamedMoosavi;Kara,Sami;Hauschild,Michael Zwicky [CIRP Annals, v 63, n 1, 2014, Starting Page 41, Pages 4] International outsourcing seems to be a cost efficient way ofproduction. However, there are serious concernsaboutitslongtermimpactsontheenvironmental,social and economic sustainability. This paperaims to quantify these impacts by using inputoutput analysis, linear programming and systemdynamics in a case study including Europeanelectrical industry (outsourcer),Chineseelectricalindustry (outsourcee) and their main suppliers.Results depict the differences related to thetotal CO2 emissions, the number of employeesand the gross value added of these two regionsbetween a 10% international outsourcingscenario and the baseline scenario due to theirdifferences in production technologies. (20 refs,2figs,3tables)(AA)

110143 Cloud-based approach for WEEE remanufacturingWang,Lihui;Wang,XiVincent;Gao,Liang;Vancza,Jozsef [CIRP Annals, v 63, n 1, 2014, Starting Page 409, Pages 4] The modern manufacturingindustry calls foranewgenerationof integrationmodels that are more interoperable, intelligent,adaptable and distributed. Evolved from service-oriented architecture,web- basedmanufacturingand cloud computing, cloud manufacturing isconsideredworldwideanewenablingtechnologyformanufacturing enterprises to respondquicklyandeffectivelytothechangingglobalmarket.ForWasteElectricalandElectronicEquipment(WEEE)in particular, it is a critical necessity to recycle,reuseandremanufactureWEEEproductsbysettingup a cloud-based information system. In thispaper, a novel service-oriented remanufacturingplatform is proposed based on the cloudmanufacturingconcept.(11refs,8figs)(AA)

MATERIALS & TREATMENT

110144 Morphological evolution of semi-solid Mg2Si/AM60 magnesium matrix composite produced by ultrasonic vibration processYan,Hong;Rao,Yuansheng;He,Ru[J of Materials Processing Technology, v 214, n 3, Mar 2014, Starting Page 612, Pages 8] The application of ultrasonicvibrationtreatment(UVT)producedanearlynon-dendritic and refined semi-solid microstructureof Mg2Si/AM60 composite. The effects of UVTtemperature and time on microstructure of the

semi-solid slurrywerestudied.Agoodsemi-solidslurrywithaveragegrainsizeof75μmandshapecoefficientof0.53couldbeobtainedbyapplyingUVT at 620 °C for 60 s, which were decreasedbya factorof17/20and increasedbya factorof3 respectively as compared to the samplewithout treatment. The Mg2Si and Mg17Al12intermetallics are mainly located along thegrain boundaries or dispersed uniformly in themetallic liquid matrix with network morphology.Mechanisms involved in the development ofmicrostructure are discussed. (21 refs, 12 figs,1table)(AA)

110145 Warm die compaction and sintering of titanium and titanium alloy powdersLuo, SD; Yang, YF; Schaffer, GB; Qian, M [J of Materials Processing Technology, v 214, n 3, Mar 2014, Starting Page 660, Pages 7] A study hasbeenmadeof the effect of non-lubricatedwarmdie (200 °C) compaction on the densification ofhydride–dehydride (HDH) Ti powder, pre-alloyed(PA) Ti-6Al-4V and Ti-10V-2Fe-3Al powders,and HDH Ti and V-Fe-Al master alloy powderblends, compared to cold die compaction.Depending on the compaction pressure, whichwasvariedfrom200to1000MPa,non-lubricatedwarmdie (200 °C) compactionwasveryeffectivefor −100 mesh HDH Ti powder, increasing thegreendensityby5.0–9.4%theoreticaldensity(TD).Die wall lubrication with stearic acid showed noinfluence on the green densitywhen compactedat800MPa.Withwarmdie(200°C)compaction,achieving a green density of greater than90%TD was straightforward for HDH Ti powderwhen compacted at ≥750 MPa. Accordingly,near pore-free (≥99.5%TD) Ti microstructureswere obtained after sintering at 1300 °C for 120min in vacuum when compacted at 1000 MPa.The resulting increment in the sintered densitywas between 2.0%TD and 4.4%TD. Warm die(200 °C) compaction showed no effect on PATi-10V-2Fe-3AlpowderandonlyasmalleffectonPA Ti-6Al-4V powder when compacted at 1000MPa. However, it was still virtually effective forTi-10V-2Fe-3Al powder blends made of HDH Tipowder and V-Fe-Al master alloy powder. Theobservationswere comparedwith literaturedataand discussed in accordance with the yieldstrengthof Ti, Ti-6Al-4V, Ti-10V-2Fe-3Al andAl3Vas a function of temperature. (17 refs, 9 figs,2tables)(AA)

110146 Comparative impact assessment for flax fibre versus conventional glass fibre reinforced composites: Are bio-based reinforcement

Abstracts


materials the way to go?Duflou, Joost R; Yelin, Deng; Acker, Karel Van;Dewulf,Wim[CIRP Annals, v 63, n 1, 2014, Starting Page 45, Pages 4] Inmanyapplicationstheuseofcompositematerials can offer significant weightreductionopportunities,whichcanhaveapositiveinfluenceonthelifecycleimpactofacomponentorsystemprimarilythroughenergysavingeffectsin the use phase. The impact associated withthe production and end-of-life (EOL) phases,however, forms a possible counter indicationfor systematic replacement of conventionalstructuresbycompositesolutions.Bio-compositesare considered a promising strategy to limitproduction and EOL impact. In this paper acomparative LCA study is presented for flax fibrereinforced composites based on PP on the onehand, and functionally equivalent glass fibrereinforced PP composites on the other. Theanalysis results and conclusions derived froma comparative attributional LCA study aresummarised in this paper. (17 refs, 5 figs,3tables)(AA)

110147 Analysis and optimization of temperature distribution in carbon fiber reinforced composite materials during microwave curing processLi, Nanya; Li, Yingguang; Hang, Xiang; Gao,James [J of Materials Processing Technology, v 214, n 3, Mar 2014, Starting Page 544, Pages 7] Vacuum assisted microwave curing technologiesandmodified optical sensing systems have beenemployed to investigate the influence of plyorientation and thickness on through-thicknesstemperaturedistributionofcarbonfiberreinforcedcomposite laminates. Two different types ofepoxy systems have been studied. The resultsdemonstrated that the ply orientation did notaffect the temperature distribution of compositematerials. However, the thickness was animportant influencing factor. Nearly 10 °Ctemperature difference was found in 22.5 mmthick laminates. Through analyzing the physicalmechanisms during microwave curing, thetemperature difference decreased when theheat-loss in surface laminates was reducedand the absorption of microwave energyin the center laminates was improved. Themaximumtemperaturedifferenceof the samplesformed using the modified microwave curingtechnologies in this research could be reducedby 79% to 2.1 °C. Compared with the 5.29 °Ctemperaturedifferenceoflaminatesusingthermalheating process, the maximum temperaturedifferenceinlaminatesusingmodifiedmicrowavecuring technologies was reduced by 60%, and

the curing time was cut down by 25%. (22 refs,8figs,3tables)(AA)

110148 Characterisation of kinematic hardening and yield surface evolution from uniaxial to biaxial tension with continuous strain path changeMerklein, Marion; Suttner, Sebastian; Brosius,Alexander[CIRP Annals, v 63, n 1, 2014, Starting Page 297, Pages 4] With respect to multistageforming processes the material behaviour andthe history of the strain path during the processis of special interest for the improvement ofthe numerical prediction of forming processes.While different researchers investigated theBauschinger effect during a load reversal andbiaxial loading with pre-strained specimens,in thispaper theyield locusevolution in thefirstquadrant of the principles stress space underbiaxial loading of amodified cruciform specimenwithout test interruption is presented. Themovement of the yield surface centre causedby kinematic hardening is approximated by analternative approach based on experimentalresults.(19refs,6figs,3tables)(AA)

110149 Distribution of TiB2 reinforcements in magnesium matrix composites by a multi-physical coupling fieldFang, Canfeng; Wang, Laohu; Hao, Hai; Zhang,Xingguo [J of Materials Processing Technology, v 214, n 3, Mar 2014, Starting Page 551, Pages 5] TiB2/AZ31magnesiummatrixcompositeswere prepared under the separate effects ofan electromagnetic field, ultrasound and ofboth in combination. The electromagnetic fieldappearedtoexpandthezoneofultrasonicaction,resulting in fine grained and more uniformmicrostructure with a more homogeneousdistributionofthereinforcingTiB2particleclustersin the magnesium alloy matrix. Subsequent hot-rolling further improved the microstructuralhomogeneity. The resulting TiB2/AZ31 compositesheets exhibited excellent overall mechanicalproperties, with an ultimate tensile strength of350MPa and a tensile ductility approaching 8%.(14refs,5figs,1table)(AA)◘

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Editorial Board Vol. 14 No. 2 February 2015 Technical Papers FEB... · 2015-03-30 · Vol. 14 No. 2...

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