Identification of an Empirical Equation for Predicting Free Surface Roughness Evolution in Thin Sheets of Aluminum Alloy and Pure Copper

2018 ◽  
Vol 140 (3) ◽  
Author(s):  
Tsuyoshi Furushima ◽  
Hideki Sato ◽  
Ken-ichi Manabe ◽  
Sergei Alexandrov
Keyword(s):  
Numerical Simulation ◽  
Surface Roughness ◽  
Aluminum Alloy ◽  
Free Surface ◽  
Empirical Equation ◽  
Pure Copper ◽  
Numerical Results ◽  
Experimental Program ◽  
Thin Sheets ◽  
Surface Roughness Evolution

This paper deals with the identification of an empirical equation for predicting free surface roughness evolution. The equation has been proposed elsewhere, and, in contrast to widely used equations, assumes that the evolution of free surface roughness is controlled by two kinematic variables, the equivalent strain, and the logarithmic strain normal to the free surface. Therefore, an experimental program is designed to account for the effect of the mode of deformation on free surface roughness evolution. Thin sheets of aluminum alloy A5052-O and pure copper C1220P-O alloys are used to conduct the experimental program. In addition, numerical simulation is performed to calculate the evolution of free surface roughness under the same conditions. Comparison of experimental and numerical results shows that the accuracy of the numerical results is good enough. Then, numerical simulation is extended to the domain in which no experimental results are available. Discrete functions so found are fitted to polynomials. As a result, continuous functions that represent the empirical equation for predicting free surface roughness evolution for A5052-O and C1220P-O alloys are determined. These equations can be used in conjunction with solutions to boundary value problems in plasticity for predicting the evolution of free surface roughness in metal forming processes.

scholarly journals A New Compression Test for Determining Free Surface Roughness Evolution in Thin Sheet Metals

Metals ◽  
2019 ◽  
Vol 9 (4) ◽  
pp. 451 ◽  
Author(s):  
Tsuyoshi Furushima ◽  
Kohei Aoto ◽  
Sergei Alexandrov
Keyword(s):  
Surface Roughness ◽  
Free Surface ◽  
Compression Test ◽  
Thin Sheet ◽  
Principal Strain ◽  
Strain Rates ◽  
Thin Sheets ◽  
Strain Paths ◽  
Effect Of The Support ◽  
Metallic Sheet

In sheet microforming processes, in-surface principal strain rates may be compressive such that the thickness of the sheet increases in the process of deformation. In general, the evolution of free surface roughness depends on the sense of the principal strain normal to the free surface. Therefore, in order to predict the evolution of free surface roughness in processes in which this normal principal strain is positive by means of empirical equations, it is necessary to carry out experiments in which the thickness of the sheet increases. Conventional experiments, such as the Marciniak test, do not provide such strain paths. In general, it is rather difficult to induce a sufficiently uniform state of strain in thin sheets of increasing thickness throughout the process of deformation because instability occurs at the very beginning of the process. The present paper proposes a compression test for thin sheets. Teflon sheets are placed between support jigs and the metallic sheet tested to prevent the occurrence of instability and significantly reduce the effect of the support jigs on the evolution of surface roughness. The test is used to determine the evolution of surface roughness in thin sheets made of C1220-O under three strain paths.

Top surface roughness evolution during selective laser melting of AlCu5MnCdVA aluminum alloy

2021 ◽  
Vol 64 ◽  
pp. 1180-1195
Author(s):  
Zhiheng Hu ◽  
Yang Qi ◽  
Balasubramanian Nagarajan ◽  
Xiaojia Nie ◽  
Hu Zhang ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Selective Laser Melting ◽  
Laser Melting ◽  
Surface Roughness Evolution

Enhancement of EDM Performance by Using Copper-Silver Composite Electrode

2020 ◽  
Vol 38 (9A) ◽  
pp. 1352-1358
Author(s):  
Saad K. Shather ◽  
Abbas A. Ibrahim ◽  
Zainab H. Mohsein ◽  
Omar H. Hassoon
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Composite Electrode ◽  
Removal Rate ◽  
Pure Copper ◽  
High Speed Steel ◽  
Pulse On Time ◽  
Pulse Off Time

Discharge Machining is a non-traditional machining technique and usually applied for hard metals and complex shapes that difficult to machining in the traditional cutting process. This process depends on different parameters that can affect the material removal rate and surface roughness. The electrode material is one of the important parameters in Electro –Discharge Machining (EDM). In this paper, the experimental work carried out by using a composite material electrode and the workpiece material from a high-speed steel plate. The cutting conditions: current (10 Amps, 12 Amps, 14 Amps), pulse on time (100 µs, 150 µs, 200 µs), pulse off time 25 µs, casting technique has been carried out to prepare the composite electrodes copper-sliver. The experimental results showed that Copper-Sliver (weight ratio70:30) gives better results than commonly electrode copper, Material Removal Rate (MRR) Copper-Sliver composite electrode reach to 0.225 gm/min higher than the pure Copper electrode. The lower value of the tool wear rate achieved with the composite electrode is 0.0001 gm/min. The surface roughness of the workpiece improved with a composite electrode compared with the pure electrode.

An implicit scheme for simulation of free surface non-Newtonian fluid flows on dynamically adapted grids

2021 ◽  
Vol 36 (3) ◽  
pp. 165-176
Author(s):  
Kirill Nikitin ◽  
Yuri Vassilevski ◽  
Ruslan Yanbarisov
Keyword(s):  
Free Surface ◽  
Numerical Model ◽  
Newtonian Fluid ◽  
Viscoelastic Fluid ◽  
Fluid Flows ◽  
Numerical Results ◽  
Implicit Scheme ◽  
New Approach

Abstract This work presents a new approach to modelling of free surface non-Newtonian (viscoplastic or viscoelastic) fluid flows on dynamically adapted octree grids. The numerical model is based on the implicit formulation and the staggered location of governing variables. We verify our model by comparing simulations with experimental and numerical results known from the literature.

The behaviour of heavily loaded line contacts with transverse roughness

1999 ◽  
Vol 213 (4) ◽  
pp. 309-320 ◽  
Author(s):  
C. J. Hooke
Keyword(s):  
Surface Roughness ◽  
Full Range ◽  
Numerical Results ◽  
Operating Conditions ◽  
Entrainment Velocity ◽  
Original Surface ◽  
Line Contacts ◽  
Transverse Roughness ◽  
Inlet Length

In heavily loaded, piezoviscous contacts the surface roughness tends to be flattened inside the conjunction by any relative sliding of the surfaces. However, before it is flattened, the roughness affects the inlet to the contact, producing clearance variations there. These variations are then convected through the contact, at the entrainment velocity, producing a clearance distribution that differs from the original surface. The present paper explores this behaviour and establishes how the amplitude of the convected clearance varies with wavelength and operating conditions. It is shown that the primary influence is the ratio of the wavelength to the inlet length of the conjunction. Where this ratio is large, the roughness is smoothed and there is little variation in clearance under the conjunction. Where the ratio is small, significant variations in clearance may occur but the precise amplitude and phasing depend on the ratio of slide to roll velocities and on the value of a piezoviscous parameter, c. The numerical results agree closely with existing solutions but extend these to cover the full range of operating conditions.

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