Browse Topic: Forming

Items (5,590)
ABSTRACT This paper reviews research that has been conducted to develop inductively assisted localized hot forming bending technologies, and to use standardized welding tests to assess the practicality and potential benefits of adopting stainless based consumables to weld both existing and evolving armor alloys. For the titanium alloy Ti6Al4V it was determined that warming the plate to circa 600°F would improve the materials ductility (as measured by reduction of area) from ~18 to 40% without exposing the material to a temperature at which atmospheric contamination would be significantly deleterious. For the commercial alloy BB and class 1 armor alloy it was found that there was little effect on the charpy impact toughness and the proof strength as a result of processing at 900 °F with either air cool or water quench and there was an added benefit of lower residual stresses in the finished bends compared to cold formed bends. Heating “alloy BB” to 1600 °F followed by water quench
Lawmon, JohnAlexandrov, BoianDuffey., MatthewNgan., Tiffany
ABSTRACT Lower cost aluminum silicon carbide (Al-SiC) metal matrix composite (MMC) produced by stir-casting is emerging as an important material in cost effectively improving the reliability of high power electronic devices; e.g. electronic (IGBT) baseplates, thermal spreaders & stiffeners for flip-chip microelectronics, and heat slugs or MCPCB base layers for high brightness LEDs. This paper will review the properties and competitive cost of these new Al-SiC materials as well as the ability to tailor the coefficient of thermal expansion (CTE) of the Al-SiC to minimize thermal fatigue on solder joints and reduce component distortion. The impact on the final component cost through the use of conventional forming techniques such as (a) rolling sheet followed by stamping, and, (b) die casting, will be described, as will be the opportunity of eliminating a thermal interface material (TIM) layer by integrating the thermal spreader with the heat sink for high power microelectronic packages
Drake, AllenSchuster, DavidSkibo, Michael
ABSTRACT Barriers to the introduction of composite materials for ground vehicle applications include material property selection and cost effective material processing. Advancements in processing of thermoplastic composites for use in applications for semi structural and structural applications have created opportunities in “Out of Autoclave” processing utilizing preconsolidated unidirectional reinforced tapes. Traditional tooling for the bending formation of high temperature reinforced structural thermoplastic laminates typically involves matched metal tooling consisting of steel or aluminum and are costly and heavy. In this research, a comparative analysis was performed to evaluate the use of a large scale 3D printed forming tool in comparison to a traditional metallic mold. Material processing considerations included the development of a technique for localized laminate heating to achieve optimized energy input in the forming process. Considerations in tooling development included
Erb, DavidDwyer, BenjaminRoy, JonathanYori, WilliamLopez-Anido, Roberto A.Smail, AndrewHart, Robert
This work aims to define a novel integration of 6 DOF robots with an extrusion-based 3D printing framework that strengthens the possibility of implementing control and simulation of the system in multiple degrees of freedom. Polylactic acid (PLA) is used as an extrusion material for testing, which is a thermoplastic that is biodegradable and is derived from natural lactic acid found in corn, maize, and the like. To execute the proposed framework a virtual working station for the robot was created in RoboDK. RoboDK interprets G-code from the slicing (Slic3r) software. Further analysis and experiments were performed by FANUC 2000ia 165F Industrial Robot. Different tests were performed to check the dimensional accuracy of the parts (rectangle and cylindrical). When the robot operated at 20% of its maximum speed, a bulginess was observed in the cylindrical part, causing the radius to increase from 1 cm to 1.27 cm and resulting in a thickness variation of 0.27 cm at the bulginess location
Srivastava, KritiKumar, Yogesh
This specification covers a discontinuously reinforced aluminum alloy (DRA) made by mechanical alloying 2124A aluminum powder and silicon carbide particulate (SiC). It is produced in the form of extruded bar, rod, wire, and shapes with cross section inclusive of 1-inch (25.4-mm) diameter or less (see 8.7
AMS D Nonferrous Alloys Committee
This specification covers a discontinuously reinforced aluminum alloy (DRA) made by mechanical alloying 2124A aluminum powder and silicon carbide (SiC) particulate. It is produced in the form of extruded bar, rod, wire, and shapes with cross section inclusive of 1-inch (25.4-mm) diameter or less (see 8.7
AMS D Nonferrous Alloys Committee
This specification covers an aluminum alloy in the form of extruded bars, rods, and profiles (shapes) with a maximum cross-sectional area of 25 square inches (161 cm2), a maximum circle size of 12 inches (305 mm), and a nominal thickness up to 3.250 inches (82.54 mm), inclusive (see 8.6
AMS D Nonferrous Alloys Committee
In this investigation, AA6351 alloy matrix composites with a larger volume proportion of SiC (20 wt%) were fabricated and tested for microstructure and mechanical behavior. Composites were hot extruded from mechanically milled matrix and reinforcements. Hot extrusion uniformly distributed reinforcements in the matrix and strengthened phase interaction. Mechanical ball milling causes AA6351 powder to become more homogeneous, reducing the mean particle size from 38.66 ± 2.31 μm to 23.57 ± 2.31 μm due to particle deformation. The micrograph shows that the SiC particles are equally dispersed in the AA6351 matrix, avoiding densification and reinforcing phase integration issues during hot extrusion. In hot extrusion, SiC particles are evenly distributed in the matrix, free of pores, and have strong metallurgical bonds, resulting in a homogenous composite microstructure. SiC powders and mechanical milling increase microhardness and compressive strength, giving MMC-A 54.9% greater than AA6351
Saiyathibrahim, A.Murali Krishnan, R.Jatti, Vinaykumar S.Jatti, Ashwini V.Jatti, Savita V.Praveenkumar, V.Balaji, K.
Bemis Manufacturing and BASF collaborated to develop a lighter-weight and lower-cost hydraulic tank for compact excavators that was recognized with a lightweighting award traditionally reserved for automotive innovations. Receiving an honorable mention in the Enabling Technology category of this year's Altair Enlighten Awards, the development team leveraged a combination of injection molding and vibration welding techniques to lower costs by approximately 20% and reduce mass by about 5% compared to the traditional roto-molding process. The solution also is more eco-efficient, delivering both environmental savings (reductions in lifecycle CO2 emissions) and reducing lifecycle costs
Gehm, Ryan
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, profiles, and tubing (see 8.6
AMS D Nonferrous Alloys Committee
This specification covers an aluminum alloy in the form of extruded bars, rods, and profiles up to 0.499 inches (12.67 mm) in nominal diameter, or least thickness, and under 10 in2 (65 cm2) in cross-sectional area
AMS D Nonferrous Alloys Committee
This specification covers an aluminum alloy procured in the form of extruded bars, rods, wire, profiles (shapes), and tubing up to 1.499 inches (38.07 mm), inclusive, in nominal diameter or least thickness (bars, rods, wire, or profiles) or nominal wall thickness (tubing) (see 8.6
AMS D Nonferrous Alloys Committee
The use of aluminum to manufacture injection molds aims to maximize the productivity of plastic parts, as its alloys present higher heat conductivity than tool steel alloys. However, it is essential to accurately control the injection molding parameters to assure that the design tolerances are achieved in the final molded plastic part. The purpose of this research is to evaluate the use of aluminum alloys in high-volume production processes. It delves into the correlation between the type of material used for mold production (steel or aluminum) and the thickness of the injected part, and how these variables affect the efficiency of the process in terms of the quantity and quality of the produced parts. The findings suggest that replacing steel molds with aluminum alloys significantly reduces injection molding cycle time, the difference ranging from 57.1% to 72.5%. Additionally, the dimensional accuracy and less distortion provided by aluminum have improved product quality. In case of
Marconi, PedroAmarante, EvandroFerreira, CristianoBeal, ValterRibeiro Júnior, Armando
This research examines the impact of different amounts of copper (Cu) powder on the wear characteristics of acrylonitrile butadiene styrene (ABS)–Cu composites. Various formulations of ABS–Cu composites have been produced using injection molding, with different amounts of surfactant. Wear properties were evaluated by conducting tribological testing in accordance with ASTM standards. The findings indicated a decrease in wear loss, particularly when using a mixture consisting of 23% ABS, 70% Cu, and 7% surfactant. Machine learning regression algorithms successfully forecasted wear behavior with R-squared values over 0.97. The models used in the analysis included linear, stepwise linear, tree, support vector machine (SVM), efficient linear, Gaussian progression, ensemble, and neural network regression models. This research emphasizes the significance of composite materials in fulfilling contemporary technical requirements. The acquired insights enable the development of materials with
Jatti, Vijaykumar S.Saiyathibrahim, A.Murali Krishnan, R.Balaji, K.
Water management in PEMFC power generation systems is a key point to guarantee optimal performances and durability. It is known that a poor water management has a direct impact on PEMFC voltage, both in drying and flooding conditions: furthermore, water management entails phenomena from micro-scale, i.e., formation and water transport within membrane, to meso-scale, i.e., water capillary transport inside the GDL, up to the macro-scale, i.e., water droplet formation and removal from the GFC. Water transport mechanisms through the membrane are well known in literature, but typically a high computational burden is requested for their proper simulation. To deal with this issue, the authors have developed an analytical model for the water membrane content simulation as function of stack temperature and current density, for fast on-board monitoring and control purposes, with good fit with literature data. The water flow from the catalyst layer to the GFC through the GDL is modelled
Sicilia, MassimoCervone, DavidePolverino, PierpaoloPianese, Cesare
Aitiip is a leading Spanish research and development institute and serves companies in the aeronautics, automation, industrial, and packaging sectors. The institute possesses strong platforms for the characterization of materials and processes and is known as a powerful integrator of technologies, which is constantly on the lookout for the next transformative technology. A year ago, Aitiip implemented an NXE 400 industrial resin 3D printer platform from Nexa3D to explore integrations of additive manufacturing and injection molding. Nexa3D is the Ventura, California-based provider of high-speed industrial printing technologies whose portfolio continues to grow, reflected in its acquisition of Essentium, one of the world's most well-known providers of extrusion 3D printing, earlier this year. Liebherr is one of the world's largest providers of a variety of industrial goods, services and products. Aerospace and transportation systems is one of 13 different product segments supplied by the
The photochemical etching (PCE) process is distinguished by its capacity to fabricate metal parts with unparalleled accuracy. This process sidesteps the typical stresses and deformations linked to conventional metal-working, like stamping or laser cutting, which can compromise material integrity. Such fidelity is crucial in the manufacture of components for thermal management systems, where material integrity and component precision are non-negotiable for ensuring effective heat creation or dissipation. PCE’s ability to craft parts with smooth, burr-free edges and exact dimensions means heat management components work more effectively, bolstering the reliability and extending the service life of micro electronic devices
In applications demanding high performance under extreme conditions of pressure and temperature, a range of Mechanically Attached Fittings (MAFs) is offered by various Multinational Corporations (MNCs). These engineered fittings have been innovatively designed to meet the rigorous requirements of the aerospace industry, offering a cost-effective and lightweight alternative to traditional methods such as brazing, welding, or other mechanically attached tube joints. One prominent method employed for attaching these fittings to tubing is through Internal Swaging, a mechanical technique. This process involves the outward formation of rigid tubing into grooves within the fitting. One of the methods with which this intricate operation is achieved is by using a drawbolt - expander assembly within an elastomeric swaging machine. Traditionally, elastomeric swaged joints find extensive application among Aerospace Industry Original Equipment Manufacturers (OEMs) and are compatible with materials
Sandhu, TaranjeetAher, RaviSoni, RaviBarsawade, NikhilKamthe, SwapnilSajjan Phalle, Vijay
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, profiles, and tubing up to 5.000 inches (127.00 mm), inclusive, in nominal diameter or least thickness (see 8.5
AMS D Nonferrous Alloys Committee
Ultrahigh-strength steels are traditionally defined as those steels with a minimum yield strength of approximately 1380 MPa. Notable examples of steels in this category include AISI 4130, AISI 4140, and AISI 4340. In many cases, maximizing the performance of these alloys requires a rather complex approach that involves a series of tempering, annealing, or stress-relieving treatments. As a result, they are produced using a variety of traditional processing methods such as casting, rolling, extrusion, or forging. These traditional methods — combined with the ultrahigh strength of the steels — often meant that the production of complex, near-net shape parts of high quality was quite difficult. In addition, these production methods often entailed repetitive treatments or long production cycles, both of which resulted in elevated production costs
Innovators at NASA Johnson Space Center have developed a novel, double capsule control system that allows for high temperature and high-pressure geologic research to be performed in a contained environment relevant to a broad array of materials. It can also yield the speciation of redox-sensitive elements and is even capable of creating geologic conditions necessary to birth diamonds when used in conjunction with a multi-anvil press
This specification covers a magnesium alloy in the form of extruded bars, rods, wire, tubing, and profiles up to 40 square inches (258 cm2) in cross-sectional area (solids) and up to 8.5 inches (216 mm) OD by 1.188 inches (30.18 mm) wall thickness (tubing) (see 8.5
AMS D Nonferrous Alloys Committee
AISI H13 hot work tool steel is commonly used for applications such as hot forging and hot extrusion in mechanical working operations that face thermal and mechanical stress fluctuations, leading to premature failures. Cryogenic treatment was applied for AISI H13 steel to improve the surface hardness and thereby fatigue resistance. This work involves failure analysis of H13 steel specimens subjected to cryogenic treatment and gas nitriding. The specimens were heated to 1020°C, oil quenched followed by double tempering at 550°C for 2 h, and subsequently, deep cryogenically treated at −185°C in the cryochamber. Gas nitriding was carried out for 24 h at 500°C for 200 μm case depth in NH3 surroundings. The specimens were subjected to rotating bending fatigue at constant amplitude loading at room temperature. Measurement of surface roughness, hardness, and microstructural analysis indicated improved fatigue life for cryogenically treated specimens as compared to gas nitride, which could be
Shinde, TarangMutalikdesai, SachinJomde, AmitShamkuwar, Sonal
Soft magnetic cores of electric motors and generators are normally manufactured by stamping individual circular laminates from non-oriented electrical steel (NOES) sheets and stacking them layer by layer to reach the required height. The traditional lamination method can only achieve the average performance of the NOES since the magnetization is in all the directions of the sheet plane. Although NOES is ideal to have isotropic magnetic properties in all the directions of the sheet plane, commercially available electrical steel sheets always show apparent anisotropy in the rotating magnetization directions lying in the sheet plane. The anisotropy in magnetic properties not only causes fluctuations in the rotating magnetic field, but also leads to oscillations in electromagnetic torque, and thus needs to be minimized. In this paper, a novel electrical steel lamination technique is developed, which takes the advantage of the inherent magnetic anisotropy of electrical steel sheets to
He, YouliangSebesta, DamirPodlesny, Maciej
Often, when assessing the distraction or ease of use of an in-vehicle task (such as entering a destination using the street address method), the first question is “How long does the task take on average?” Engineers routinely resolve this question using computational models. For in-vehicle tasks, “how long” is estimated by summing times for the included task elements (e.g., decide what to do, press a button) from SAE Recommended Practice J2365 or now using new static (while parked) data presented here. Times for the occlusion conditions in J2365 and the NHTSA Distraction Guidelines can be determined using static data and Pettitt’s Method or Purucker’s Method. These first approximations are reasonable and can be determined quickly. The next question usually is “How likely is it that the task will exceed some limit?” This question, addressed using discrete event simulations such as IMPRINT, requires the distribution types and parameters (mean, standard deviation, etc.) for each task
Green, Paul
Multiple hybrid bead designs were investigated in this study to control the springback on DP780 samples using post-stretching technique. The performance of the four different hybrid bead designs was evaluated by measuring the minimum blank-lock tonnage required to control the springback during a U-channel stamping process. A finite element (FE) model of the U-channel stamping process was developed to simulate the process and predict the minimum blank-lock tonnage required for springback control using each of the hybrid bead designs. It is shown that the developed FE model predicts both the required minimum blank-lock tonnage for post-stretching, and the springback profile, with good accuracy
Nazari, Sobhan T.Zhu, FengMakrygiannis, JohnZhang, JimmyWang, Yu-Wei
Fiber-reinforced plastics (FRPs), produced through injection molding, are increasingly preferred over steel in automotive applications due to their lightweight, moldability, and excellent physical properties. However, the expanding use of FRPs presents a critical challenge: deformation stability. The occurrence of warping significantly compromises the initial product quality due to challenges in part mounting and interference with surrounding parts. Consequently, mitigating warpage in FRP-based injection parts is paramount for achieving high-quality parts. In this study, we present a holistic approach to address warpage in injection-molded parts using FRP. We employed a systematic Design of Experiments (DOE) methodology to optimize materials, processes, and equipment, with a focus on reducing warpage, particularly for the exterior part. First, we optimized material using a mixture design in DOE, emphasizing reinforcements favorable for warpage mitigation. After careful consideration of
Seo, Kyeong-BaePark, Sang SunLee, ChoonSoo
At the dawn of battery electric vehicles (BEVs), protection of automotive battery systems as well as passengers, especially from severe side impact, has become one of the latest and most challenging topics in the BEV crashworthiness designs. Accordingly, two material-selection concepts are being justified by the automotive industry: either heavy-gauge extruded aluminum alloys or light-gauge advanced high-strength steels (AHSSs) shall be the optimal materials to fabricate the reinforcement structures to satisfy both the safety and lightweight requirements. In the meantime, such a justification also motivated an ongoing C-STARTM (Cliffs Steel Tube as Reinforcement) Protection project, in which a series of modularized steel tube assemblies, were demonstrated to be more cost-efficient, sustainable, design-flexible, and manufacturable than the equivalent extruded aluminum alloy beams as BEV reinforcement structures. Tangent to this comparative study, the present work shed some light on the
Hu, JunSun, YetingYu, MiaoWang, Yu-WeiThomas, Grant
Fracturing in a tight radius during bending is one of the major manufacturing issues in forming Advanced High Strength Steels (AHSS). The study investigated the bendability of AHSS under two forming conditions: bending with and without stretched over the die radius. The bendability was evaluated by conducting modified Bending Under Tension (BUT) test for stretch bending and 90o v bend test for bending without stretch. The study also examined the effect of material properties on the limiting bend ratio. Various strength high strength steels, range from 420 MPa to 1700 MPa tensile strength, were selected in the study. Results indicated that critical radius-to-thickness ratios between the two tests are different but correlated in a relationship which was depicted in the bendability diagram. The map and constitutive relation curve derived from limiting bend ratios identified the multiple bendability (stretched and no-stretch) of each strength grade of test steel, which is recommended as
Shih, Hua-Chu
Roller offsetting is an incremental forming technique used to generate offset stiffening or mating features in sheet metal parts. Compared to die forming, roller offsetting utilizes generic tooling to create versatile designs at a relatively lower forming speed, making it well-suited for low volume productions in automotive and other industries. However, more significant distortion can be generated from roller offset forming process resulting from springback after forming. In this work, we use particle swarm optimization to identify the tool path and resulting feature geometry that minimizes distortion. In our approach, time-dependent finite element simulations are adopted to predict the distortion of each candidate tool path using a quarter symmetry model of the part. A multi-objective fitness function is used to both minimize the distortion measure while constraining the minimal radius of curvature in the tool path. We find that the predicted reduction of distortion in a quarter
Veeresh, PawanHuang, LuLee, Tae HwaWang, Hui-PingSolomon, JoshuaOswald, Jay
Multiple experimental studies were performed on galling intiation for variety of tooling materials, coatings and surface treatments, sheet materials with various surface textures and lubrication. Majority of studies were performed for small number of samples in laboratory conditions. In this paper, the methodology of screening experiment using different combinations of tooling configurations and sheet material in the lab followed by the high volume small scale U-bend performed in the progressive die on the mechanical press is discussed. The experimental study was performed to understand the effect of the interface between the sheet metal and the die surface on sheet metal flow during stamping operations. Aluminum sheet AA5754 2.5mm thick was used in this experimentation. The sheet was tested in laboratory conditions by pulling between two flat insert with controllable clamping force and through the drawbead system with variable radii of the female bead. Comparing pulling forces during
Reinberg, NataliaMurray, RyanAscencio Barrera, SindiPineda Carranza, CristinaGolovashchenko, Sergey
During the vehicle lifecycle, customers are able to directly perceive the outer panel stiffness of vehicles in various environmental conditions. The outer panel stiffness is an important factor for customers to perceive the robustness of the vehicle. In the real test of outer panel stiffness after prototype production, evaluators manually press the outer panel in advance to identify vulnerable areas to be tested and evaluate the performance only in those area. However, when developing the outer panel stiffness performance using FEA (Finite Element Analysis) before releasing the drawing, it is not possible to filter out these areas, so the entire outer panel must be evaluated. This requires a significant amount of computing resources and manpower. In this study, an approach utilizing artificial intelligence was proposed to streamline the outer panel stiffness analysis and improve development reliability. A deep learning-based prediction technology was developed to predict force
Uhm, TaekyoungOh, Seunghyeok
Fracture characterization of automotive metals under simple shear deformation is critical for the calibration of advanced fracture models employed in forming and crash simulations. In-plane shear fracture tests of high ductility materials have proved challenging since the sample edge fails first in uniaxial tension before the fracture limit in shear is reached at the center of the gage region. Although through-thickness machining is undesirable, it appears required to promote higher strains within the shear zone. The present study seeks to adapt existing in-plane shear geometries, which have otherwise been successful for many automotive materials, to have a local shear zone with a reduced thickness. It is demonstrated that a novel shear zone with a pocket resembling a “peanut” can promote shear fracture within the shear zone while reducing the risk for edge fracture. An emphasis was placed upon machinability and surface quality for the design of the pocket in the shear zone. A mild
Pilozo-Hibbit, LucasNarayanan, AdvaithAbedini, ArminButcher, Cliff
This specification covers an aluminum alloy in the form of extruded bars, rods, and profiles 0.250 to 2.000 inches (6.35 to 50.80 mm) in nominal thickness and up to 32 square inches (206 cm2), inclusive, in cross-sectional area (see 8.5
AMS D Nonferrous Alloys Committee
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, profiles, and tubing, flash-welded rings fabricated from extruded stock, and stock for flash-welded rings (see 8.6
AMS D Nonferrous Alloys Committee
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, shapes, and tubing 5.000 inches (127.00 mm) and under in nominal diameter or least thickness (wall thickness of tubing) (see 8.5
AMS D Nonferrous Alloys Committee
This specification covers a corrosion-resistant steel in the form of bars, wire, forgings, extrusions, mechanical tubing, flash-welded rings, and stock for forging, extruding, or flash-welded rings
AMS F Corrosion and Heat Resistant Alloys Committee
This specification covers a titanium alloy in the form of extruded bars, shapes, and flash-welded rings up through 3.000 inches (76.20 mm), inclusive, in nominal diameter or least distance between parallel sides, and stock for flash-welded rings of any size (see 8.7
AMS G Titanium and Refractory Metals Committee
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