scholarly journals Parametric Investigation of Effect of Abnormal Process Conditions on Self-Piercing Riveting

2020 ◽  
Vol 10 (7) ◽  
pp. 2520 ◽  
Author(s):  
Taek-Eon Jeong ◽  
Dong-Hyuck Kam ◽  
Cheolhee Kim
Keyword(s):  
Process Parameters ◽  
Dissimilar Materials ◽  
High Strength ◽  
Process Conditions ◽  
Al Alloy ◽  
Main Process ◽  
Cross Sectional ◽  
Practical Applications ◽  
Parametric Investigation ◽  
Offset Distance

Self-piercing riveting (SPR) is one of the mechanical joining processes, and its application to Al/Fe dissimilar materials combination, which is hard to weld, is expanding in the automotive industry. The main process parameters in SPR are types of rivet and die, setting force, and rivet setting speed. Previously, the relationship between the main process parameters and output parameters such as cross-sectional characteristics and joint strength has been studied to optimize the SPR process. In practical applications, there are unexpected and abnormal process conditions such as poor fit-up, angular misalignment, edge offset distance, and inaccurate setting and pre-clamping forces, and their effects on the joining quality have not been discussed. In this study, parametric investigation was performed using an experimental design on SPR joints for 1 mm-thick high strength steel (590 DP) and 2 mm-thick Al alloy (Al5052-H32). The main effect of each level of the abnormal process parameters on the output parameters was statistically investigated, and the analysis of variance was performed for each abnormal process parameter. In the range of abnormal process conditions applied, the set force was the most significant factor affecting the output parameters, and the effect of pre-clamping force on the output parameters was the least significant.

Experimental Research on the Stiffness of Hyperboloid Shallow Shell

2014 ◽  
Vol 940 ◽  
pp. 179-183
Author(s):  
Li Hong Zhao ◽  
Cheng Xi Lei ◽  
Zhong Wen Xing ◽  
Bin Wu
Keyword(s):  
High Strength ◽  
Process Conditions ◽  
Main Process ◽  
Technical Approach ◽  
Shallow Shells ◽  
Process Guidance ◽  
Experiment Method ◽  
Automobile Panel ◽  
Blank Holding Force ◽  
Panel Stiffness

Stiffness is a very important property of automobile panel, especially for high-strength thinning sheet due to personnel security and energy conservation on auto industry. It is difficult to study because of the complexity streamline feature of auto body. An experiment method for determining stiffness was presented. The experiment study models of which based on the hyperboloid shallow shells that could represent automobile panel’s surface features was established. The criterion and research technique of automobile panel stiffness were introduced. The experiment research works of effects of two main process conditions on stiffness which blank holding force (BHF) and boundary condition during the stiffness test were obtained. All conclusions provided a particularly effective process guidance and technical approach in the automobile panel production.

Research on Synchronized Cooling Hot Forming Process of 6016 Aluminum Alloy

2012 ◽  
Vol 452-453 ◽  
pp. 81-85 ◽  
Author(s):  
Ming He Chen ◽  
Y.Y. Cao ◽  
W. Chen ◽  
Guo Liang Chen
Keyword(s):  
Aluminum Alloy ◽  
Process Parameters ◽  
High Strength ◽  
Strengthening Mechanism ◽  
Alloy Sheet ◽  
Hot Forming ◽  
Al Alloy ◽  
Forming Process ◽  
Process Step ◽  
6016 Aluminum Alloy

In order to improve formability of high strength Al-alloy sheet metal, in this paper, it come up with the synchronized cooling hot forming process. Taking the aluminum alloy of 6016 H18 aluminum alloy, which carried out its technology test by Gleeble3500 hot-mechanical simulator. The process parameters such as deformation temperature T, holding time t and cooling rate v is investigated by the orthogonal test and the microstructure is analyzed simultaneously. The results show that the synchronized cooling hot forming process can be applied to 6016 H18 aluminum alloy, it both improves the formability of 6016 H18 aluminum alloy significantly and obtains the high strength after forming, it can meet the purpose of implementing deformation and enhanced in one process step, the proper combination of process parameters are T=450 °C, t=210 s, v=60 °C/s. Strengthening mechanism is which there is a large number of strengthening phase precipitated from matrix in technology process, the strengthening phases are coarser and the dispersed uniformity is a bit worse compared with that of T4 state.

scholarly journals Characterization and Optimization of Mechanical Properties of ABS Parts Manufactured by the Fused Deposition Modelling Process

2014 ◽  
Vol 2014 ◽  
pp. 1-13 ◽  
Author(s):  
Godfrey C. Onwubolu ◽  
Farzad Rayegani
Keyword(s):  
Tensile Strength ◽  
Additive Manufacturing ◽  
Process Parameters ◽  
Group Method ◽  
Fused Deposition Modelling ◽  
Process Conditions ◽  
Research Issues ◽  
Practical Applications ◽  
Fused Deposition ◽  
Study Results

While fused deposition modelling (FDM) is one of the most used additive manufacturing (AM) techniques today due to its ability to manufacture very complex geometries, the major research issues have been to balance ability to produce aesthetically appealing looking products with functionality. In this study, five important process parameters such as layer thickness, part orientation, raster angle, raster width, and air gap have been considered to study their effects on tensile strength of test specimen, using design of experiment (DOE). Using group method of data handling (GMDH), mathematical models relating the response with the process parameters have been developed. Using differential evolution (DE), optimal process parameters have been found to achieve good strength simultaneously for the response. The optimization of the mathematical model realized results in maximized tensile strength. Consequently, the additive manufacturing part produced is improved by optimizing the process parameters. The predicted models obtained show good correlation with the measured values and can be used to generalize prediction for process conditions outside the current study. Results obtained are very promising and hence the approach presented in this paper has practical applications for design and manufacture of parts using additive manufacturing technologies.

scholarly journals Effect of SLM Process Parameters on the Quality of Al Alloy Parts; Part II: Microstructure and Mechanical Properties

2018 ◽  
Author(s):  
Ahmed H. Maamoun ◽  
Yi F. Xue ◽  
Mohamed A. Elbestawi ◽  
Stephen C. Veldhuis
Keyword(s):  
Mechanical Properties ◽  
Process Parameters ◽  
High Strength ◽  
Al Alloy ◽  
Microstructure And Mechanical Properties ◽  
Wide Range ◽  
Powder Characteristics ◽  
High Strength Aluminum Alloys ◽  
Selection Of

Additive manufacturing (AM) provides customization of the microstructure and mechanical properties of components. Selective laser melting (SLM) is the commonly used technique for processing high strength Aluminum alloys. Selection of SLM process parameters could control the microstructure of fabricated parts and their mechanical properties. However, process parameter limits and defects inside the as-built parts present obstacles to customized part production. This study is the second part of a comprehensive work that investigates the influence of SLM process parameters on the quality of as-built Al6061 and AlSi10Mg parts. The microstructure of both materials was characterized for different parts processed over a wide range of SLM process parameters. The optimized SLM parameters were investigated to eliminate the internal microstructure defects. Mechanical properties of the parts were illustrated by regression models generated with design of experiment (DOE) analysis. The results reported in this study were compared to previous studies, illustrating how the process parameters and powder characteristics could affect the quality of produced parts.

scholarly journals Effect of Selective Laser Melting Process Parameters on the Quality of Al Alloy Parts: Powder Characterization, Density, Surface Roughness, and Dimensional Accuracy

Materials ◽  
2018 ◽  
Vol 11 (12) ◽  
pp. 2343 ◽  
Author(s):  
Ahmed Maamoun ◽  
Yi Xue ◽  
Mohamed Elbestawi ◽  
Stephen Veldhuis
Keyword(s):  
Surface Roughness ◽  
Selective Laser Melting ◽  
Process Parameters ◽  
Dimensional Accuracy ◽  
High Strength ◽  
Melting Process ◽  
Al Alloys ◽  
Al Alloy ◽  
Laser Melting

Additive manufacturing (AM) of high-strength Al alloys promises to enhance the performance of critical components related to various aerospace and automotive applications. The key advantage of AM is its ability to generate lightweight, robust, and complex shapes. However, the characteristics of the as-built parts may represent an obstacle to the satisfaction of the parts’ quality requirements. The current study investigates the influence of selective laser melting (SLM) process parameters on the quality of parts fabricated from different Al alloys. A design of experiment (DOE) was used to analyze relative density, porosity, surface roughness, and dimensional accuracy according to the interaction effect between the SLM process parameters. The results show a range of energy densities and SLM process parameters for AlSi10Mg and Al6061 alloys needed to achieve “optimum” values for each performance characteristic. A process map was developed for each material by combining the optimized range of SLM process parameters for each characteristic to ensure good quality of the as-built parts. This study is also aimed at reducing the amount of post-processing needed according to the optimal processing window detected.

Influence of Die Materials on the Microstructural Evolution of HSS Sheets in Hot Stamping

2011 ◽  
Vol 473 ◽  
pp. 201-208 ◽  
Author(s):  
Andrea Ghiotti ◽  
Stefania Bruschi ◽  
Daniele Pellegrini
Keyword(s):  
Hot Stamping ◽  
Sheet Thickness ◽  
High Strength Steels ◽  
High Strength ◽  
Process Conditions ◽  
Main Process ◽  
Metal Sheets ◽  
Die Materials ◽  
Set Up ◽  
Tools Wear

Hot stamping of High Strength Steels sheets is gaining more and more popularity, particularly in the automotive industry, due to the sound microstructures achieved at the end of the process. The significant improvement of the mechanical properties achieved in the process enables to reduce the initial sheet thickness in favour of cost and fuel consumption reduction. However, a martensitic microstructure implies significant drawbacks in final trimming and cutting operations, which becomes more difficult and expensive due to tools wear and high blanking forces. This paper aims at investigating the performances of non-metallic materials to be used in heated dies, in order to inhibit the martensite formation by locally reducing the sheet cooling rate. To analyze the influence of the main process parameters, a new experimental set-up was designed and developed in a laboratory environment that allow applying controlled pressure and temperatures to HSS metal sheets. An analytical model was set-up in order to evaluate the influence of process conditions on the cooling profiles in different areas of the specimen. Accordingly, experiments were carried out to investigate the material behaviour when cooled in the different conditions. The experimentally acquired temperatures were analyzed and evaluated together with hardness measurements of metal sheets in order to assess the feasibility of the proposed approach in producing microstructurally-tailored components.

Optimising Weld Process Conditions for Enhanced Fatigue Performance

2007 ◽  
Vol 348-349 ◽  
pp. 561-564 ◽  
Author(s):  
M. Neil James ◽  
Hannalie Lombard ◽  
D.G. Hattingh ◽  
Axel Steuwer
Keyword(s):  
Neutron Diffraction ◽  
Aluminium Alloy ◽  
Process Parameters ◽  
High Strength Steel ◽  
High Strength ◽  
Fatigue Performance ◽  
Process Conditions ◽  
Synchrotron Diffraction ◽  
Friction Stir ◽  
Residual Strains

This paper presents some ideas on incorporating output from advanced synchrotron and neutron scanning strain methods in improved assessment of the influence of weld process parameters on residual strains at welds and on their fatigue performance. It very briefly outlines two different cases involving synchrotron diffraction strain scanning of friction stir welds in a strain hardened aluminium alloy and neutron diffraction strain scanning of MIG welds in high strength steel.

scholarly journals Effect of SLM Process Parameters on the Quality of Al Alloy Parts; Part I: Powder Characterization, Density, Surface Roughness, and Dimensional Accuracy

2018 ◽  
Author(s):  
Ahmed H. Maamoun ◽  
Yi F. Xue ◽  
Mohamed A. Elbestawi ◽  
Stephen C. Veldhuis
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Dimensional Accuracy ◽  
High Strength ◽  
Al Alloys ◽  
Al Alloy ◽  
Part Quality ◽  
Density Surface ◽  
Critical Components

Additive manufacturing (AM) of high strength Al alloys promises to enhance the performance of critical components related to various aerospace and automotive applications. The key advantage of AM is its ability to generate lightweight, robust, and complex shapes. However, the characteristics of the as-built parts may represent an obstacle to satisfy the part quality requirements. The current study investigates the influence of selective laser melting (SLM) process parameters on the quality of parts fabricated from different Al alloys. A design of experiment (DOE) is used to analyze relative density, porosity, surface roughness, and dimensional accuracy according to the interaction effect between the SLM process parameters. The results show a range of energy densities and SLM process parameters for the AlSi10Mg and Al6061 alloys needed to achieve “optimum” values for each performance characteristic. A process map is developed for each material by combining the optimized range of SLM process parameters for each characteristic to ensure good quality of the as-built parts. The second part of this study investigates the effect of SLM process parameters on the microstructure and mechanical properties of the same Al alloys. This comprehensive study is also aimed at reducing the amount of post-processing needed.

scholarly journals Upset Protrusion Joining (UPJ) Characteristics of Cast AM60 Magnesium Alloy to Join With Dissimilar Material

2021 ◽  
Author(s):  
Nicholas Andreae ◽  
Dharmendra Chalasani ◽  
Mukesh K. Jain
Keyword(s):  
Process Parameters ◽  
Weight Ratio ◽  
Alloy Sheet ◽  
Great Promise ◽  
Optimum Process ◽  
Process Conditions ◽  
Shear Mode ◽  
Al Alloy ◽  
Lap Shear ◽  
Structural Applications

Abstract Magnesium alloys have a significant benefit over the steel and aluminum alloys in manufacturing of components for many automotive and structural applications because of their extreme lightweight, low density, and high strength to weight ratio. However, one of the glaring impediments to the success of steels, aluminum, and magnesium-based multi-material integration for automotive industries is the ability to join these materials together without any cracking and corrosive damages during a performance. The present work aims to demonstrate a cost-effective, novel, and versatile joining technique, named Upset Protrusion Joining (UPJ), to mechanically and rapidly (1-2 seconds) join die-cast AM60 alloy to aluminum alloy sheet and evaluate its UPJ characteristics. Cast Mg plate has a cylindrical protrusion (11 mm diameter and 14 mm height) emanated perpendicular to its flat surface, and an aluminum sheet has a hole that accommodates the protrusion. Mg and Al alloy components are then clamped together, electrically heated, and compressed perpendicular to the protrusion axis. During compression, the protrusion expanded circumferentially to fill the hole as well as the region above the hole, and entrapped the Al sheet between the deformed (in a mushroom shape) head and the Mg plate. The effect of different UPJ process parameters such as applied current, current duration, compression loading rate, and compression distance is studied. The process demonstrated repeatability at given process conditions, and optimum process parameters were identified that produce visibly good joints (defect-free) and sufficient joint strengths when tested in the lap-shear mode under uniaxial tension. AM60 alloy showed a great promise as a candidate alloy to suit the UPJ method to adapt to automotive and other industrial manufacturing units to join with dissimilar wrought Al alloy sheets.

The stabilization of B.C.C. Cu in Cu/Nb nanolayered composites

1996 ◽  
Vol 54 ◽  
pp. 228-229
Author(s):  
H. Kung ◽  
A.J. Griffin ◽  
Y.C. Lu ◽  
K.E. Sickafus ◽  
T.E. Mitchell ◽  
...  
Keyword(s):  
Electrical Resistivity ◽  
Layer Thickness ◽  
Volume Fraction ◽  
Ion Beam ◽  
High Strength ◽  
Cross Sectional ◽  
Metastable Structure ◽  
High Resolution Tem ◽  
Potential Improvement ◽  
Two Phases

Materials with compositionally modulated structures have gained much attention recently due to potential improvement in electrical, magnetic and mechanical properties. Specifically, Cu-Nb laminate systems have been extensively studied mainly due to the combination of high strength, and superior thermal and electrical conductivity that can be obtained and optimized for the different applications. The effect of layer thickness on the hardness, residual stress and electrical resistivity has been investigated. In general, increases in hardness and electrical resistivity have been observed with decreasing layer thickness. In addition, reduction in structural scale has caused the formation of a metastable structure which exhibits uniquely different properties. In this study, we report the formation of b.c.c. Cu in highly textured Cu/Nb nanolayers. A series of Cu/Nb nanolayered films, with alternating Cu and Nb layers, were prepared by dc magnetron sputtering onto Si {100} wafers. The nominal total thickness of each layered film was 1 μm. The layer thickness was varied between 1 nm and 500 nm with the volume fraction of the two phases kept constant at 50%. The deposition rates and film densities were determined through a combination of profilometry and ion beam analysis techniques. Cross-sectional transmission electron microscopy (XTEM) was used to examine the structure, phase and grain size distribution of the as-sputtered films. A JEOL 3000F high resolution TEM was used to characterize the microstructure.

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