Browse Topic: Forming
This research investigates the fabrication and evaluation of Delrin (polyoxymethylene, POM) composites reinforcing 5-20 wt.% chopped ramie fiber (RF). The polymer composites were fabricated via the injection moulding technique. Glass transition temperature (Tg), thermal conductivity, Vicat softening temperature (VST), heat deflection temperature (HDT), melt flow index (MFI), and coefficient of linear thermal expansion (CLTE) were the various thermal characteristics of the sustainable composites that were systematically evaluated as per the ASTM standards. The addition of RF drastically altered the Delrin matrix's performance. Among the formulations, the composite with 15 wt.% RF had the best combination of properties: higher VST and HDT values, which provide greater dimensional stability at high temperatures; lower CLTE, resulting in less thermal expansion; comparatively better thermal conductivity; and improved heat dissipation. Eventually, there was a moderate drop in the MFI
Qualification of new aerospace alloys requires extensive mechanical testing to capture anisotropy and ensure reliable performance under complex loading conditions. This process is costly and time-consuming, particularly with emerging manufacturing routes such as additive manufacturing. Advanced yield surface prediction offers a route to reduce test campaigns by linking microstructural features to macroscopic constitutive models. In this work, Digimat is employed as a multi-scale material modeling platform to generate yield surfaces of polycrystalline metals using computational homogenization. Representative volume elements (RVEs) are constructed from experimental texture and grain morphology data, and their response under multiaxial loading is simulated using a crystal plasticity framework. The computed yield loci are then fitted with phenomenological functions (e.g. Yld2000-2D), enabling calibration of anisotropic yield models from virtual testing. As a case study, an AA6016-T4 sheet
This specification covers a columbium alloy in the form of bars, rods, and extrusions.
Machina Labs recently closed its latest round of financing with $124 million, enough to develop a facility featuring up to 50 of its RoboCraftsman cells capable of producing thousands of complex structural assemblies for aerospace and defense customers - a list that already includes Lockheed Martin and the U.S. Air Force, among others. Founded in 2019, Machina Labs is a California-based company that seeks to reinvent metal manufacturing with a robot that uses artificial intelligence (AI) to rapidly form and assemble complex military grade structures directly from digital design files. RoboCraftsman is the company's manufacturing robot that leverages its proprietary “RoboForming” process to integrate multiple manufacturing processes - including metal forming, trimming, scanning, and heat treating - into a single containerized machine.
This specification covers a magnesium alloy in the form of extruded bars, rods, wire, tubing, and profiles.
Tire noise reduction is important for improving ride comfort, especially in electric vehicle due to lack of engine noise and majority of the noise generated in-cabin is from tire-road interaction. Therefore, the tire tread pattern contribution is one of the important criteria for NVH performance apart from other structurally generated noise and vibration. In this work a GUI-based pitch sequence optimization tool is developed to support tire design engineers in generating acoustically optimized tread sequences. The tool operates in two modes: without constraints, where the pitch sequence is optimized freely to reduce tonal noise levels; and with constraints, where specific design rules are applied to preserve pattern consistency and manufacturability. The key point to be considered in this pitch sequence is that it should be reducing the tonal sound and equally spread i.e., the same pitch cannot be concentrated on one side which may lead to non-uniformity. So, the restriction is that
Aluminum alloy wheels have become the preferred choice over steel wheels due to their lightweight nature, enhanced aesthetics, and contribution to improved fuel efficiency. Traditionally, these wheels are manufactured using methods such as Gravity Die Casting (GDC) [1] or Low Pressure Die Casting (LPDC) [2]. As vehicle dynamics engineers continue to increase tire sizes to optimize handling performance, the corresponding increase in wheel rim size and weight poses a challenge for maintaining low unsprung mass, which is critical for ride quality. To address this, weight reduction has become a priority. Flow forming [3,4], an advanced wheel rim production technique, which offers a solution for reducing rim weight. This process employs high-pressure rollers to shape a metal disc into a wheel, specifically deforming the rim section while leaving the spoke and hub regions unaffected. By decreasing rim thickness, flow forming not only enhances strength and durability but also reduces overall
David Martin, CBMM Asia Bernardo Barile, CBMM Europe BV Caio Pisano, CBMM Europe BV Automotive high strength steels have specific microstructure-dependent forming characteristics. Global formability is generally associated with high uniform strain values which imply good drawability and stretch forming properties driven by pronounced work hardening. Local formability on the other hand is often measured by various fracture strain values—generally higher in single phase steels. In this respect, the so-called ‘local/global formability map’ concept has been established not only to provide a comprehensive methodology to characterize existing automotive steels but also to enable improvement strategies toward more balanced forming characteristics. Niobium (Nb) microalloying is a powerful tool to achieve both property improvement in general and property balance in particular. More than two decades of research has demonstrated that Nb-induced microstructural optimization is applicable to HSLA
Dangling from a weather balloon 80,000 feet above New Mexico, a pair of antennas sticks out from a Styrofoam cooler. From that height, the blackness of space presses against Earth’s blue skies. But the antennas are not captivated by the breathtaking view. Instead, they listen for signals that could make air travel safer.
Yamaha Motor Engineering Co., Ltd. provides plastic processing technology based on fuel tank press forming technology, and is developing various plastic processing methods, including forging, and developing mold equipment to realize them. This time, the core parts of the YECVT unit mounted on Yamaha Motor Co., Ltd.'s small premium scooter "NMAX" were not made by welding individual parts to each other, but by integrally forming them from a single thick plate using the cold forming method, resulting in lightweight, compact, high-strength, high-precision parts. By incorporating a composite plastic processing method that takes advantage of the characteristics of the material while making full use of analysis technology and mold technology, we were able to develop a composite plastic processing method (plate forging method) that creates new added value and mass produce it. In addition,this development has made it possible to achieve a thickness increase of 1.7 times the standard material
Innovators at NASA Johnson Space Center have developed additively manufactured thermal protection system (AMTPS) comprised of two printable heat shield material formulations. These formulations are directly applied by 3D printer or other robotic extrusion system and bonded to a spacecraft to devise a heat shield suitable for atmospheric entry. This technology could significantly decrease heat shield or thermal protection system (TPS) fabrication cost and time.
Bruno Boutantin, Extrude Hone
When it comes to plastics applications, cars are rarely the first products that come to mind. However, with modern vehicles containing 1,000 to 1,500 plastic parts — including dashboards, control elements, clips, trim parts, brackets, door panels, bumpers, and radiator grilles — the material is more important for mobility than we might assume. Some of these plastic parts are relevant for the drivers’ safety: for instance, airbag covers must open correctly in an accident and seat belt guides and retractors could cause severe injuries if they break or deform under load. Their quality is vital. At the same time however, cost pressure and new regulations — for instance regarding an increased use of recycled materials that is under way in the European Union — pose new challenges, especially in plastic injection molding. Digital solutions for measurement technology help control and stabilize the complex process and may even lead to increased product quality despite tougher conditions.
Researchers have developed a soft, thin-film auditory brainstem implant (ABI). The device uses micrometer-scale platinum electrodes embedded in silicone, forming a pliable array just a fraction of a millimeter thick. This novel approach enables better tissue contact, potentially preventing off-target nerve activation and reducing side effects.
This specification covers an aluminum alloy in the form of extruded bars, rods, and profiles (shapes) from 0.375 to 1.300 inches (9.53 to 33.02 mm) in diameter or thickness, produced with cross-sectional area of 22.5 square inches (145 cm2), maximum, and a circumscribing circle diameter (circle size) of 17.4 inches (44.2 cm), maximum (see 2.4 and 8.8).
This standard establishes the dimensional and visual quality requirements, lot requirements, and packaging and labeling requirements for O-rings machined from AMS3617 polyamide material. It shall be used for procurement purposes.
This specification covers a corrosion- and heat-resistant iron alloy in the form of investment castings.
This specification covers a corrosion- and heat-resistant nickel alloy in the form of investment castings.
This specification covers a corrosion- and heat-resistant nickel alloy in the form of investment castings.
This specification controls surface condition, manufacturing defects and inspection requirements, and defines methods of measurement for elastomeric toroidal sealing rings (O-rings) for static (including gasket) applications.
This SAE Standard covers normalized electric-resistance welded flash-controlled single-wall, low-carbon steel pressure tubing intended for use as pressure lines and in other applications requiring tubing of a quality suitable for bending, double flaring, beading, forming, and brazing. Material produced to this specification is not intended to be used for single flare applications, due to the potential leak path caused by the Inside Diameter (ID) weld bead or scarfed region. Assumption of risks when using this material for single flare applications shall be defined by agreement between the producer and purchaser. This specification also covers SAE J356 Type-A tubing. The mechanical properties and performance requirements of SAE J356 and SAE J356 Type-A are the same. The SAE J356 or SAE J356 Type-A designation define unique manufacturing differences between coiled and straight material. Nominal reference working pressures for this tubing are listed in ISO 10763 for metric tubing, and SAE
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, profiles, and tubing up to 32 square inches (206 cm2) in area (see 8.6).
Stretch broken carbon fiber (SBCF) offers enhanced formability as compared to continuous carbon fiber (CCF). However, robust, quantitative evaluation of forming defects remains a challenge. This study introduces a unified formability index (UFI) that integrates multiple defect types, including texture anomalies, bridging, wrinkling, thickness variation, spring-back, and resin distribution variation (RDV), into a single weighted score. Each defect is ranked on a scale of 0-5 using normalized metrics with a tunable parameter, α, allowing users to balance defect magnitude and frequency as desired. The full scoring pipeline is demonstrated for texture defects using measured data, while normalized legacy scores from previous work are used for non-texture defects to enable complete formability index computation. Case studies on three laminates illustrate how variations in α affect both texture scoring and the overall formability index and demonstrate the geometry-agnostic nature of the
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