This document discusses using additive manufacturing to produce wire drawing dies with conformal cooling channels. It begins with an introduction explaining the challenges with conventional wire drawing dies like high temperatures causing accelerated wear. The document then reviews wire drawing processes and how temperature increases limit drawing speeds. Experimental results are presented showing conformal cooling channels significantly reduced die temperatures. It is concluded additive manufacturing enables conformal cooling to reduce die wear and increase wire drawing throughput.
IRJET- Performance Analysis of Cryogenically Treated Vanadis23 Tool under Dry...IRJET Journal
This document summarizes research on analyzing the performance of cryogenically treated Vanadis23 tool steel under dry turning conditions. The research aims to study the effect of cryogenic treatment on tool wear and propose a mathematical model to evaluate wear. Experiments are designed using Taguchi's orthogonal array method. Tool life depends on factors like part geometry, cutting conditions, machine tool characteristics and can generally only be estimated from production testing or experience. Cryogenic treatment below -80°C in addition to conventional heat treatment is investigated to improve tool steel properties like wear resistance.
This document summarizes research on elevated temperature wire drawing using Azadirachta indica and Jatropha curcas seed oils as lubricants. Experiments were conducted drawing mild steel and medium carbon steel wire at temperatures ranging from ambient to 850°C. The maximum reduction in cross-sectional area achieved was 40-48%. Both lubricants proved effective across all temperatures. Tungsten carbide dies performed best. Drawing forces decreased with increasing temperature due to lower flow stresses. However, friction also increased, balancing the effects. The lubricants effectively addressed tribology issues at higher temperatures. In conclusion, wire can be successfully drawn at elevated temperatures using these natural oil lubricants.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Study the Chip Tool Interactions & Tool Life in Plain Turining with High Velo...IJERA Editor
Introduction of green concepts in machining operations is being envisaged by introducing different echo
friendly cooling systems in the modern machine shops. The role of cutting fluids usage in metal cutting is
predominant as it influences the surface quality and production cost. The current work mainly focuses on the
study of chip tool interactions viz. contact pressure, temperature and chip flow pattern on the rake surface in
plain turning operation for different cutting parameters without any cooling medium and analyze the influence
of high pressure air jet as the cooling medium on the chip tool interactions like contact pressure reducing the
tool wear, cutting temperatures thereby increasing tool life.
Studies on jet penetration and kerf width at various operating pressure in ma...eSAT Journals
Abstract Abrasive Water Jet (AWJ) machining is one of the non-traditional machining method popular method for machining of hard, heat sensitive and brittle materials. The present work attempts to investigate the effect of operating pressure on depth of penetration and kerf characteristics generated while machining of D2 heat treated steel. It is found that increase in operating pressure increases the depth of penetration and decreases the surface taper on the work-piece. Keywords: Kerf width, Depth of cut, Operating pressure, AWJ Machining
Design of ‘plastic injection mold’ for an ‘air vent bezel’ through flow analy...eSAT Journals
Abstract Designer's of plastic injection Molds need to study from this point of view, the type of Mold to be designed, the physical Mold orientation, the dimensions for each of the element in the Mold, the location of the gate, runner, requirement of insert, draft angle requirement, shrinkage factor, location of cooling channels. Design can also be simplified by using standardized parts of the mold such as ejector pins. By eliminating the obstruction to smooth flow of plastic a good of quality component can be achieved. The effort of this thesis work is to find out the nuances in the Plastic Injection Mold Design while borrowing the inputs from the Flow Analysis (CAE) conducted for the 'Air vent bezel' to study the behavior of the Melt during flow. The Mold Design would incorporate suitable checking to ensure the best quality product in terms of `defect-free’ output. This thesis work consist methodology of plastic injection molding process, material requirement, how to overcome weld mark, shrinkage etc to satisfactorily assemble the component. Keywords: Draft angle, Shrinkage, CAE, weld mark
Design of Micro Cooling Channel for Plastic Injection Moulding by using Mold ...IRJET Journal
This document describes research on designing micro cooling channels for plastic injection molds to improve cooling efficiency and reduce cycle times. It discusses heat transfer modes during molding and calculating cooling requirements. Methods include creating conformal micro channels near the mold surface using 3D printing. Simulations using Moldflow Advisor analyze different channel designs, showing micro channels provide more uniform cooling over smaller areas. The results indicate micro channels can reduce non-uniformity compared to standard channels, decreasing cycle times for plastic parts.
This document summarizes a study that used finite element analysis to model and analyze welding distortions in T-joints made through seam and skip arc welding processes. The study created a 3D finite element model to simulate the temperature distribution and resulting distortions. The model results were verified through experimental welding of T-joints made of mild steel, with distortions then measured using a coordinate measuring machine. Varying factors like plate width and thickness allowed analyzing their effects on distortions developed through each welding process.
IRJET- Performance Analysis of Cryogenically Treated Vanadis23 Tool under Dry...IRJET Journal
This document summarizes research on analyzing the performance of cryogenically treated Vanadis23 tool steel under dry turning conditions. The research aims to study the effect of cryogenic treatment on tool wear and propose a mathematical model to evaluate wear. Experiments are designed using Taguchi's orthogonal array method. Tool life depends on factors like part geometry, cutting conditions, machine tool characteristics and can generally only be estimated from production testing or experience. Cryogenic treatment below -80°C in addition to conventional heat treatment is investigated to improve tool steel properties like wear resistance.
This document summarizes research on elevated temperature wire drawing using Azadirachta indica and Jatropha curcas seed oils as lubricants. Experiments were conducted drawing mild steel and medium carbon steel wire at temperatures ranging from ambient to 850°C. The maximum reduction in cross-sectional area achieved was 40-48%. Both lubricants proved effective across all temperatures. Tungsten carbide dies performed best. Drawing forces decreased with increasing temperature due to lower flow stresses. However, friction also increased, balancing the effects. The lubricants effectively addressed tribology issues at higher temperatures. In conclusion, wire can be successfully drawn at elevated temperatures using these natural oil lubricants.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Study the Chip Tool Interactions & Tool Life in Plain Turining with High Velo...IJERA Editor
Introduction of green concepts in machining operations is being envisaged by introducing different echo
friendly cooling systems in the modern machine shops. The role of cutting fluids usage in metal cutting is
predominant as it influences the surface quality and production cost. The current work mainly focuses on the
study of chip tool interactions viz. contact pressure, temperature and chip flow pattern on the rake surface in
plain turning operation for different cutting parameters without any cooling medium and analyze the influence
of high pressure air jet as the cooling medium on the chip tool interactions like contact pressure reducing the
tool wear, cutting temperatures thereby increasing tool life.
Studies on jet penetration and kerf width at various operating pressure in ma...eSAT Journals
Abstract Abrasive Water Jet (AWJ) machining is one of the non-traditional machining method popular method for machining of hard, heat sensitive and brittle materials. The present work attempts to investigate the effect of operating pressure on depth of penetration and kerf characteristics generated while machining of D2 heat treated steel. It is found that increase in operating pressure increases the depth of penetration and decreases the surface taper on the work-piece. Keywords: Kerf width, Depth of cut, Operating pressure, AWJ Machining
Design of ‘plastic injection mold’ for an ‘air vent bezel’ through flow analy...eSAT Journals
Abstract Designer's of plastic injection Molds need to study from this point of view, the type of Mold to be designed, the physical Mold orientation, the dimensions for each of the element in the Mold, the location of the gate, runner, requirement of insert, draft angle requirement, shrinkage factor, location of cooling channels. Design can also be simplified by using standardized parts of the mold such as ejector pins. By eliminating the obstruction to smooth flow of plastic a good of quality component can be achieved. The effort of this thesis work is to find out the nuances in the Plastic Injection Mold Design while borrowing the inputs from the Flow Analysis (CAE) conducted for the 'Air vent bezel' to study the behavior of the Melt during flow. The Mold Design would incorporate suitable checking to ensure the best quality product in terms of `defect-free’ output. This thesis work consist methodology of plastic injection molding process, material requirement, how to overcome weld mark, shrinkage etc to satisfactorily assemble the component. Keywords: Draft angle, Shrinkage, CAE, weld mark
Design of Micro Cooling Channel for Plastic Injection Moulding by using Mold ...IRJET Journal
This document describes research on designing micro cooling channels for plastic injection molds to improve cooling efficiency and reduce cycle times. It discusses heat transfer modes during molding and calculating cooling requirements. Methods include creating conformal micro channels near the mold surface using 3D printing. Simulations using Moldflow Advisor analyze different channel designs, showing micro channels provide more uniform cooling over smaller areas. The results indicate micro channels can reduce non-uniformity compared to standard channels, decreasing cycle times for plastic parts.
This document summarizes a study that used finite element analysis to model and analyze welding distortions in T-joints made through seam and skip arc welding processes. The study created a 3D finite element model to simulate the temperature distribution and resulting distortions. The model results were verified through experimental welding of T-joints made of mild steel, with distortions then measured using a coordinate measuring machine. Varying factors like plate width and thickness allowed analyzing their effects on distortions developed through each welding process.
Problems of Heat, Mass and Momentum Transfer in Manufacturing Processes: A Br...drboon
In machining processes the chip flows over the tool rake and carries heat away as it moves. This is a case of mass transportation with heat transfer. Similarly, during hot forging, upsetting or coining processes heat is transferred from the hot billet to the relatively cooler dies, punches or hammers with momentum transfer under high impact load. Also, in high energy rate fabrication (HERF) processes, such as electromagnetic forming, explosive forming, impact extrusion, etc. heat is generated almost instantaneously, in milliseconds, and its dissipation is a serious industrial problem due to the very short process cycle time. In the present paper some of the problems related to heat, mass and momentum transfer in the above mentioned manufacturing processes are reviewed and compared with experimental results.
IRJET- Advanced Welding Processes for Distortion Reduction: A ReviewIRJET Journal
This document reviews various advanced welding processes for reducing distortion compared to conventional arc welding processes. It summarizes research comparing the effects of cold metal transfer (CMT) welding, autogenous laser welding, hybrid laser-gas metal arc (GMA) welding, and hybrid laser-magnetic welding on distortion. Studies show these advanced processes generate less heat input and result in lower distortion compared to submerged arc welding and pulsed GMA welding. Specifically, laser welding and laser hybrid welding produce the least amount of angular distortion and transverse displacement. The document concludes advanced welding techniques offer benefits over conventional arc welding in terms of improved weld quality and reduced distortion.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Formability of superplastic deep drawing process with moving blank holder for...eSAT Journals
Abstract In this present work, a statistical approach based on Taguchi Techniques and finite element analysis were adopted to determine the formability of conical cup using warm deep drawing process. The process parameters were temperature, coefficient of fric-tion, strain rate and blank holder velocity. The experimental results were validated using a finite element software namely D-FORM. The AA1050–H18 sheets were used for the superplastic deep drawing of the conical cups. The strain rate by itself has a significant effect on the effective stress and the height of the conical cup drawn. The formability of the conical cups was outstand-ing for the surface expansion ratio greater than 2.0.
Keywords: AA1050-H18, superplastic deep drawing, blank holder velocity, temperature, coefficient of friction, strain rate, conical cups, formability.
Literature Review on Tribological behaviour of Nitronic-SteelDeepuDavid1
The document discusses the tribological behavior of nitronic steel under cavitation erosion, solid particle erosion, and sliding erosion conditions. It aims to study these behaviors in hydro turbine blades and other nitronic steel products. The document describes the experimental setup used to test nitronic steel samples against cavitation erosion in a vibratory setup and solid particle erosion using an air jet erosion tester. It analyzes the microstructure, mechanical properties, and erosion behavior of the as-received and heat treated nitronic steel samples and compares it to 316L stainless steel. The results show that cavitation erosion resistance increases with finer grain size, and the as-received steel with the finest grain size exhibited the best erosion resistance among the samples tested.
Thickness optimization of thick walled circular cylinder by heat treatmentIRJET Journal
1. The document analyzes the thickness optimization of thick walled circular cylinders through heat treatment. It determines the maximum internal pressure capacities of untreated and heat treated cylinders using analytical calculations and finite element analysis in ANSYS.
2. The untreated cylinder can sustain a maximum internal pressure of 80MPa. The heat treated cylinder's maximum pressure capacity is improved to 110MPa. Further reducing the heat treated cylinder's thickness by 5mm reduces its maximum pressure to 90MPa.
3. Modal analysis of the reduced thickness heat treated cylinder shows natural frequencies from analytical calculations agree with ANSYS results within 3%. Its working frequencies from 21.5-45.7Hz avoid resonance conditions.
Effect of Load on Dry Abrasive Wear in Blades of Hand Hacksaw.IJERA Editor
In this study, the abrasive wear is calculated in the High Carbon Steel (HCS) blades of Hand Hacksaw at
different Loads. The wear is calculated by Mass Loss of blade before and after cutting the prepared specimen of
Mild steel. The Wear is calculated for different specimen of blades at different Loads ie. 5N,10N,15N and 20N
with the help of the experimental Setup prepared. The result indicates that the wear in the blades increases with
the increase in load.
Synopsis on Tribological behaviour of Nitronic-SteelDeepuDavid1
This document summarizes a synopsis report on the tribological behavior of nitronic steel. It discusses using nitronic steel for underwater parts in hydroelectric projects as 13Cr-4Ni martensitic stainless steel currently used has limited wear life. The objectives are to study cavitation erosion, solid particle erosion, and sliding erosion in hydro turbine blades made of nitronic steel and compare its erosion behavior to 13/4 martensitic stainless steel and 316L stainless steel. The work plan includes literature review and experiments to study structure-property correlation and involve metallography, tensile tests, hardness measurements, X-ray diffraction, and cavitation testing.
Optimization of friction stir welding process parameter using taguchi method ...eSAT Journals
Abstract Friction stir welding (FSW) is relatively new solid state joining process. This joining technique is energy efficient, environment friendly and versatile. Welding is a multiinput-output process in which quality of welded joint is depends upon a input parameter. Therefore optimization of input process parameter is required to achieve good quality of welding. There are so many methods of optimization in which Taguchi method and Response surface methodology are selected for optimization of process parameter. In this review the effect of process parameter on welded joint studied and optimizes the parameter by using Taguchi method and Response surface methodology. The study of Friction stir welding of Aluminium alloy and High density polyethylene sheets shows the improvement in welded joint quality by optimization of process parameter. The main process parameters which affect the strength of welded joint is tool rotational speed, welding speed, axial force and tool pin profile. Keywords: Friction stir welding (FSW), Optimization, Taguchi Method Response surface Methodology Prediction models
OPTIMIZATION OF MACHINING PARAMETERS WITH TOOL INSERT SELECTION FOR S355J2G3 ...AVINASH JURIANI
The key goal of modern manufacturing industries is increased productivity & high quality
Surface Roughness is major concern for quality aspects affecting performance.
Speed, Feed & Depth of cut mainly influences SR & MRR in Turning
Taguchi & Grey Relational Technique is used for optimization followed by ANOVA for contribution
MADM is the need for better Tool Insert Selection to get requisite surface finish
IRJET- Numerical Investigation on Cold Formed Press Braking Steel Zed Section...IRJET Journal
This document describes a numerical investigation on cold formed press braking steel Z-section columns under axial compression. Various Z-section profiles were analyzed using the finite strip method (CUFSM) and finite element analysis (ANSYS) to determine buckling behavior. A parametric study was conducted by varying the yield stress of the steel sheets while keeping thickness and length constant. Theoretical analysis using the direct strength method and Indian code provisions were also carried out and compared to the numerical results. The scope of the study was to determine the most effective Z-section profile for carrying ultimate load with minimum buckling values.
The document discusses the design of a forging die for a planetary gear blank. It begins with an introduction to forging as a metalworking process and advantages it provides over other manufacturing methods. It then outlines the objectives and methodology for the die design project. The methodology involves designing the final gear part geometry, determining stock size requirements, and designing the forging die. Key die design considerations discussed include parting line selection, drafting angles, fillet and corner radii, flash and gutter design, and shrinkage allowance. The document concludes with CAD drawings of the designed forging die.
Finite Element Simulation and Experiment of Chip Formation Process during Hig...IDES Editor
As an advanced manufacturing technology which
has been developed rapidly in recent years, high speed
machining is widely applied in many industries. The chip
formation during high speed machining is a complicated
material deformation and removing process. In research area
of high speed machining, the prediction of chip morphology is
a hot and difficult topic. A finite element method based on the
software ABAOUS which involves Johnson-Cook material
model and fracture criterion was used to simulate the serrated
chip morphology and cutting force during high speed
machining of AISI 1045 hardened steel. The serrated chip
morphology and cutting force were observed and measured by
high speed machining experiment of AISI 1045 hardened steel.
The effects of rake angle on cutting force, sawtooth degree
and space between sawteeth were discussed. The investigation
indicates that the simulation results are consistent with the
experiments and this finite element simulation method
presented can be used to predict the chip morphology and
cutting force accurately during high speed machining of
hardened steel.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
The document discusses a new material removal process called arc ablation. Preliminary results show it can remove materials like hardened steel, Inconel, and titanium at rates far exceeding plasma cutting for the same power levels. Arc ablation uses an electric arc to melt material, which is then removed by a rotating copper tool. Tests achieved removal rates up to 97 mm3/sec at 4kW on steel. Challenges include extending it to hole making and achieving removal rates of 1000 mm3/sec at 40kW. The document describes experimental setup, parameters tested, and results obtained, finding arc ablation has potential for fast, low-cost material removal.
Chip flow and notch wear mechanisms during the machining of high austenitic s...Lepuufu
This document discusses notch wear mechanisms during the machining of high austenitic stainless steels. Special step-turning tests were conducted on four stainless steel alloys to study the degree of work hardening ahead of the tool and the side flow of work material at the depth of cut line. Microhardness measurements and SEM analysis showed severe localized shear and chip side flow interacting strongly with the tool, leading to notch wear initiation. Notch wear was found to be most sensitive to cutting parameters for the alloy with the highest nickel content, and increased with feed and depth of cut. Hardness was highest in the side flow region, indicating work hardening affects notch wear progression.
Evaluating Static Analysis of the Damper Grommets for CompressorIRJET Journal
This document summarizes research evaluating the static analysis of damper grommets used in compressors. Grommets are rubber structures that reduce vibration in reciprocating machines like refrigerators. The study tests grommet material properties according to the ASTM D412 standard and simulates grommet behavior under different loads using ABAQUS software. Results from physical testing are compared to simulation outputs to evaluate grommet displacement and stress levels under static compressor weight conditions.
Influence of tellurium addition on drilling of microalloyed steel (din 38mns6)Lepuufu
This study evaluated the influence of tellurium content and minimum quantity lubrication (MQL) flow rate on drilling performance when drilling microalloyed steel. Two grades of steel were tested, one with high tellurium content and one with low tellurium content. Drilling tests were conducted using two cutting speeds, two feed rates, two drill geometries, and two MQL flow rates. Statistical analysis showed that tellurium content most significantly impacted performance, doubling drill life for the high tellurium steel. MQL flow rate had the lowest influence, with a higher flow only reducing life 9%. Addition of tellurium improved machinability by reducing forces during chip formation.
Determining the influence of cutting fluids on tool wear and surface roughnes...Lepuufu
Knowledge of the performance of cutting fluids in machining different work materials is
of critical importance in order to improve the efficiency of any machining process. The
efficiency can be evaluated based on certain process parameters such as flank wear, surface
roughness on the work piece, cutting forces developed, temperature developed at the tool
chip interface, etc. The objective of this work is to determine the influence of cutting fluids
on tool wear and surface roughness during turning of AISI 304 with carbide tool. Further
an attempt has been made to identify the influence of coconut oil in reducing the tool
wear and surface roughness during turning process. The performance of coconut oil is also
being compared with another two cutting fluids namely an emulsion and a neat cutting oil
(immiscible with water). The results indicated that in general, coconut oil performed better
than the other two cutting fluids in reducing the tool wear and improving the surface finish.
Coconut oil has been used as one of the cutting fluids in this work because of its thermal
and oxidative stability which is being comparable to other vegetable-based cutting fluids
used in the metal cutting industry.
Is Additive Metal Manufacturing the Next Technological Wonder Drug? An article in Canadian Metalworking Magazine reviewing AMM's success with their two (2) EOS Model M290 e-Manufacturing DMLS Systems.
LayerWise is a company that specializes in 3D metal printing for biomedical applications using selective laser melting. They have experience producing standard implants as well as patient-specific implants using metals such as titanium, stainless steel, cobalt-chromium, and tantalum. They also have expertise in additively manufacturing porous biomaterials that can integrate with bone and avoid stress-shielding. LayerWise produces implants and components with precise dimensions and mechanical properties, as well as complex geometries that would be difficult with conventional methods. Their process is certified and they have experience serially manufacturing FDA and CE approved implants.
Problems of Heat, Mass and Momentum Transfer in Manufacturing Processes: A Br...drboon
In machining processes the chip flows over the tool rake and carries heat away as it moves. This is a case of mass transportation with heat transfer. Similarly, during hot forging, upsetting or coining processes heat is transferred from the hot billet to the relatively cooler dies, punches or hammers with momentum transfer under high impact load. Also, in high energy rate fabrication (HERF) processes, such as electromagnetic forming, explosive forming, impact extrusion, etc. heat is generated almost instantaneously, in milliseconds, and its dissipation is a serious industrial problem due to the very short process cycle time. In the present paper some of the problems related to heat, mass and momentum transfer in the above mentioned manufacturing processes are reviewed and compared with experimental results.
IRJET- Advanced Welding Processes for Distortion Reduction: A ReviewIRJET Journal
This document reviews various advanced welding processes for reducing distortion compared to conventional arc welding processes. It summarizes research comparing the effects of cold metal transfer (CMT) welding, autogenous laser welding, hybrid laser-gas metal arc (GMA) welding, and hybrid laser-magnetic welding on distortion. Studies show these advanced processes generate less heat input and result in lower distortion compared to submerged arc welding and pulsed GMA welding. Specifically, laser welding and laser hybrid welding produce the least amount of angular distortion and transverse displacement. The document concludes advanced welding techniques offer benefits over conventional arc welding in terms of improved weld quality and reduced distortion.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Formability of superplastic deep drawing process with moving blank holder for...eSAT Journals
Abstract In this present work, a statistical approach based on Taguchi Techniques and finite element analysis were adopted to determine the formability of conical cup using warm deep drawing process. The process parameters were temperature, coefficient of fric-tion, strain rate and blank holder velocity. The experimental results were validated using a finite element software namely D-FORM. The AA1050–H18 sheets were used for the superplastic deep drawing of the conical cups. The strain rate by itself has a significant effect on the effective stress and the height of the conical cup drawn. The formability of the conical cups was outstand-ing for the surface expansion ratio greater than 2.0.
Keywords: AA1050-H18, superplastic deep drawing, blank holder velocity, temperature, coefficient of friction, strain rate, conical cups, formability.
Literature Review on Tribological behaviour of Nitronic-SteelDeepuDavid1
The document discusses the tribological behavior of nitronic steel under cavitation erosion, solid particle erosion, and sliding erosion conditions. It aims to study these behaviors in hydro turbine blades and other nitronic steel products. The document describes the experimental setup used to test nitronic steel samples against cavitation erosion in a vibratory setup and solid particle erosion using an air jet erosion tester. It analyzes the microstructure, mechanical properties, and erosion behavior of the as-received and heat treated nitronic steel samples and compares it to 316L stainless steel. The results show that cavitation erosion resistance increases with finer grain size, and the as-received steel with the finest grain size exhibited the best erosion resistance among the samples tested.
Thickness optimization of thick walled circular cylinder by heat treatmentIRJET Journal
1. The document analyzes the thickness optimization of thick walled circular cylinders through heat treatment. It determines the maximum internal pressure capacities of untreated and heat treated cylinders using analytical calculations and finite element analysis in ANSYS.
2. The untreated cylinder can sustain a maximum internal pressure of 80MPa. The heat treated cylinder's maximum pressure capacity is improved to 110MPa. Further reducing the heat treated cylinder's thickness by 5mm reduces its maximum pressure to 90MPa.
3. Modal analysis of the reduced thickness heat treated cylinder shows natural frequencies from analytical calculations agree with ANSYS results within 3%. Its working frequencies from 21.5-45.7Hz avoid resonance conditions.
Effect of Load on Dry Abrasive Wear in Blades of Hand Hacksaw.IJERA Editor
In this study, the abrasive wear is calculated in the High Carbon Steel (HCS) blades of Hand Hacksaw at
different Loads. The wear is calculated by Mass Loss of blade before and after cutting the prepared specimen of
Mild steel. The Wear is calculated for different specimen of blades at different Loads ie. 5N,10N,15N and 20N
with the help of the experimental Setup prepared. The result indicates that the wear in the blades increases with
the increase in load.
Synopsis on Tribological behaviour of Nitronic-SteelDeepuDavid1
This document summarizes a synopsis report on the tribological behavior of nitronic steel. It discusses using nitronic steel for underwater parts in hydroelectric projects as 13Cr-4Ni martensitic stainless steel currently used has limited wear life. The objectives are to study cavitation erosion, solid particle erosion, and sliding erosion in hydro turbine blades made of nitronic steel and compare its erosion behavior to 13/4 martensitic stainless steel and 316L stainless steel. The work plan includes literature review and experiments to study structure-property correlation and involve metallography, tensile tests, hardness measurements, X-ray diffraction, and cavitation testing.
Optimization of friction stir welding process parameter using taguchi method ...eSAT Journals
Abstract Friction stir welding (FSW) is relatively new solid state joining process. This joining technique is energy efficient, environment friendly and versatile. Welding is a multiinput-output process in which quality of welded joint is depends upon a input parameter. Therefore optimization of input process parameter is required to achieve good quality of welding. There are so many methods of optimization in which Taguchi method and Response surface methodology are selected for optimization of process parameter. In this review the effect of process parameter on welded joint studied and optimizes the parameter by using Taguchi method and Response surface methodology. The study of Friction stir welding of Aluminium alloy and High density polyethylene sheets shows the improvement in welded joint quality by optimization of process parameter. The main process parameters which affect the strength of welded joint is tool rotational speed, welding speed, axial force and tool pin profile. Keywords: Friction stir welding (FSW), Optimization, Taguchi Method Response surface Methodology Prediction models
OPTIMIZATION OF MACHINING PARAMETERS WITH TOOL INSERT SELECTION FOR S355J2G3 ...AVINASH JURIANI
The key goal of modern manufacturing industries is increased productivity & high quality
Surface Roughness is major concern for quality aspects affecting performance.
Speed, Feed & Depth of cut mainly influences SR & MRR in Turning
Taguchi & Grey Relational Technique is used for optimization followed by ANOVA for contribution
MADM is the need for better Tool Insert Selection to get requisite surface finish
IRJET- Numerical Investigation on Cold Formed Press Braking Steel Zed Section...IRJET Journal
This document describes a numerical investigation on cold formed press braking steel Z-section columns under axial compression. Various Z-section profiles were analyzed using the finite strip method (CUFSM) and finite element analysis (ANSYS) to determine buckling behavior. A parametric study was conducted by varying the yield stress of the steel sheets while keeping thickness and length constant. Theoretical analysis using the direct strength method and Indian code provisions were also carried out and compared to the numerical results. The scope of the study was to determine the most effective Z-section profile for carrying ultimate load with minimum buckling values.
The document discusses the design of a forging die for a planetary gear blank. It begins with an introduction to forging as a metalworking process and advantages it provides over other manufacturing methods. It then outlines the objectives and methodology for the die design project. The methodology involves designing the final gear part geometry, determining stock size requirements, and designing the forging die. Key die design considerations discussed include parting line selection, drafting angles, fillet and corner radii, flash and gutter design, and shrinkage allowance. The document concludes with CAD drawings of the designed forging die.
Finite Element Simulation and Experiment of Chip Formation Process during Hig...IDES Editor
As an advanced manufacturing technology which
has been developed rapidly in recent years, high speed
machining is widely applied in many industries. The chip
formation during high speed machining is a complicated
material deformation and removing process. In research area
of high speed machining, the prediction of chip morphology is
a hot and difficult topic. A finite element method based on the
software ABAOUS which involves Johnson-Cook material
model and fracture criterion was used to simulate the serrated
chip morphology and cutting force during high speed
machining of AISI 1045 hardened steel. The serrated chip
morphology and cutting force were observed and measured by
high speed machining experiment of AISI 1045 hardened steel.
The effects of rake angle on cutting force, sawtooth degree
and space between sawteeth were discussed. The investigation
indicates that the simulation results are consistent with the
experiments and this finite element simulation method
presented can be used to predict the chip morphology and
cutting force accurately during high speed machining of
hardened steel.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
The document discusses a new material removal process called arc ablation. Preliminary results show it can remove materials like hardened steel, Inconel, and titanium at rates far exceeding plasma cutting for the same power levels. Arc ablation uses an electric arc to melt material, which is then removed by a rotating copper tool. Tests achieved removal rates up to 97 mm3/sec at 4kW on steel. Challenges include extending it to hole making and achieving removal rates of 1000 mm3/sec at 40kW. The document describes experimental setup, parameters tested, and results obtained, finding arc ablation has potential for fast, low-cost material removal.
Chip flow and notch wear mechanisms during the machining of high austenitic s...Lepuufu
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Determining the influence of cutting fluids on tool wear and surface roughnes...Lepuufu
Knowledge of the performance of cutting fluids in machining different work materials is
of critical importance in order to improve the efficiency of any machining process. The
efficiency can be evaluated based on certain process parameters such as flank wear, surface
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chip interface, etc. The objective of this work is to determine the influence of cutting fluids
on tool wear and surface roughness during turning of AISI 304 with carbide tool. Further
an attempt has been made to identify the influence of coconut oil in reducing the tool
wear and surface roughness during turning process. The performance of coconut oil is also
being compared with another two cutting fluids namely an emulsion and a neat cutting oil
(immiscible with water). The results indicated that in general, coconut oil performed better
than the other two cutting fluids in reducing the tool wear and improving the surface finish.
Coconut oil has been used as one of the cutting fluids in this work because of its thermal
and oxidative stability which is being comparable to other vegetable-based cutting fluids
used in the metal cutting industry.
Is Additive Metal Manufacturing the Next Technological Wonder Drug? An article in Canadian Metalworking Magazine reviewing AMM's success with their two (2) EOS Model M290 e-Manufacturing DMLS Systems.
LayerWise is a company that specializes in 3D metal printing for biomedical applications using selective laser melting. They have experience producing standard implants as well as patient-specific implants using metals such as titanium, stainless steel, cobalt-chromium, and tantalum. They also have expertise in additively manufacturing porous biomaterials that can integrate with bone and avoid stress-shielding. LayerWise produces implants and components with precise dimensions and mechanical properties, as well as complex geometries that would be difficult with conventional methods. Their process is certified and they have experience serially manufacturing FDA and CE approved implants.
This document discusses selective laser melting (SLM) technology for manufacturing conformal cooling inserts for injection molds. It describes how SLM allows for complex internal channel geometries to optimize cooling. Several case studies show how SLM inserts improved temperature uniformity, reduced cycle times, and eliminated part warping compared to traditional drilled inserts. Mold designers can leverage SLM to integrate optimized cooling at the design phase for maximum benefits.
This is introducing possibilities with improving moulding tool cavity and core blocks,inserts, sliders, lifters by providing conformal cooling and thus eliminating "hot spots". This will help improve cycle time, improve part quality and make you money. Payback period is generally matter of weeks.
Tips for Additive Manufacturing in MetalDesign World
With simple changes such as automated transfers and print run layout, an additive manufacturing production process can be optimized to maximize output. Hear how ExOne takes “3D printing” into the realm of manufacturing production. Tom Pasterik, Manager of Application Engineering for The ExOne Company, will discuss what it takes to shift from 3D printing/prototyping to additive manufacturing production, using an example of a traditionally manufactured control arm from a domestic super car and making it using additive manufacturing processes.
Learn how to shift from 3D printing/prototyping to additive manufacturing
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This document discusses salt hydrolysis and buffer solutions. It explains that salt hydrolysis occurs when the cation or anion of a salt reacts with water, producing acidic or basic solutions depending on the relative strengths of the products. There are four types of salt hydrolysis based on the salt containing strong/weak acids and bases. Buffer solutions resist pH changes upon adding acids or bases. They work by containing a weak acid and its conjugate base or weak base and conjugate acid. Common examples are discussed along with the Henderson-Hasselbalch equation for calculating buffer pH.
Selective laser melting (SLM) can be used to 3D print metal injection molds with complex internal cooling channels that conform to the shape of the part, allowing for shorter molding cycles. Case studies showed cycle time reductions of 10-40% for automotive and packaging parts, improving quality and decreasing costs. SLM molds offer benefits over traditional molds like improved thermal control and reduced energy usage.
A LEAN VIEW OF CHAINED METAL ADDITIVE MANUFACTURING AND CNC MACHINING PROCESSESTheodore Panagiotidis
This document provides a summary of a final report for an MSc major project on a lean view of chained metal additive manufacturing and CNC machining processes. It includes an abstract, introduction, literature review on relevant manufacturing paradigms like CNC, subtractive manufacturing, additive manufacturing and lean manufacturing. It then models the basic structure of a hybrid manufacturing system by decomposing it into nine subsystems. The report investigates how hybrid manufacturing follows lean thinking and how it can be optimized using lean tools. It finds that three out of nine hybrid system subsystems show potential for waste reduction through lean implementation. The document provides a starting point for defining a standard way to describe hybrid system structure and for further research on lean assessment and implementation within
The document summarizes key concepts about materials including:
1) At the atomic level, materials are composed of elements with distinct atomic structures, which bond together in crystalline or noncrystalline forms. Common bonding types include ionic, covalent, and metallic.
2) Crystalline materials have long-range ordered atomic structures with repeating unit cells, while noncrystalline materials lack long-range order.
3) Metals typically have body-centered cubic, face-centered cubic, or hexagonal crystalline structures and metallic bonding, making them strong yet ductile. Ceramics and polymers have other bonding types and properties.
The document discusses additive manufacturing (AM) techniques like direct metal laser sintering (DMLS) and selective laser sintering (SLS). It describes how AM works by building 3D objects layer by layer from a digital model. The document outlines various AM techniques, materials used, industries adopting AM, benefits like reduced tooling and weight optimization, limitations like large volume production issues. It provides examples of companies like EOS that manufacture AM equipment and cost illustrations. Application examples discussed are aerospace parts, potential aero engine parts, and the outlook for AM.
Study on the Mold Temperature Control for the Core Plate during Injection Mol...IOSR Journals
Abstract: During injection molding process, the mold temperature is one of the most important influences on
the product quality. In this paper, the temperature of the core plate with the size of 100 mm × 100 m × 40 mm
will be examined for different product sizes. Different types of heating and cooling channels are inserted in the
core plate. The size of the plastic product will be changed from 40 mm to 80 mm, with varying heights.
Simulation method will be utilized to observe the heating and cooling steps. The temperature values and
distribution will be collected and compared. Results show that when the product size changes, the heating and
cooling steps have a slight variation. However, the product height has a strong effect on the mold temperature.
When the height increases from 1 mm to 9 mm, the highest heating temperature reduces from 104 °C to 82.5 °C.
The simulation results were verified by an experiment. The comparison between the simulated and the
experimental results shows a good agreement between them. Keywords: Injection Molding, Mold Temperature Control, Mold Heating, Mold Cooling, plastic process
Sirris_am in aviation and aerospace_state of the artSirris
Metal additive manufacturing (AM) uses a layer-by-layer process to produce metal parts without tools. It offers nearly unlimited freedom of design and the ability to produce complex geometries. While initially used for prototyping, AM is gaining acceptance for low-volume production in industries like aerospace and aviation due to its design optimization capabilities. For AM to see widespread adoption, challenges like reproducibility, costs, and standardization must still be addressed.
This document summarizes a study on the tensile behavior of aluminum plates welded using friction stir welding. Various welding parameters like rotational speed, welding speed, and pin diameter were experimented with to weld an aluminum alloy. Mathematical models were developed using a statistical design of experiments approach to understand the effects of the parameters on tensile strength. It was found that tensile strength decreases with increasing rotational speed, increases with increasing welding speed, and decreases with increasing pin diameter. The maximum tensile strength was achieved at low rotational speed and high welding speed. Regression models for tensile strength were developed and validated to be adequate predictors within 95% confidence level.
Study on Effect of Manual Metal Arc Welding Process Parameters on Width of He...IJMER
This document summarizes a study on the effect of welding parameters on the width of the heat affected zone (HAZ) during manual metal arc welding (MMAW) of mild steel. The welding parameters investigated included current, voltage, welding speed, and heat input. Samples were welded with varying combinations of these parameters. The microstructure and width of the HAZ was then analyzed for each sample. The goal of the study was to determine the relationship between welding parameters and HAZ width in order to control and minimize the HAZ during MMAW welding of mild steel.
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Using arc welding, gas welding and other welding process, it is very difficult to weld the aluminum alloys. Friction stir welding, on the other hand, can be used to join most Al alloys and
better surface finishing is achieved. Although the work piece does heat up during friction stir weld, the temperature does not reach the melting point.
IRJET- Review Paper on of Single Point Cutting Tool with Taguchi Robust ApproachIRJET Journal
This document presents a review paper on simulating a single point cutting tool process using the Taguchi robust design approach. It discusses using finite element modeling (FEM) software to numerically simulate the turning process and analyze three input factors (depth of cut, cutting speed, and rack angle) and two responses (stress and strain). The Taguchi design of experiments technique is used to develop relationships between factors and responses. Regression modeling is then used to develop equations relating the input parameters to output results. Previous research on measuring cutting temperatures, forces, and modeling metal cutting processes is also reviewed to provide context and validate the current study's approach.
3 dimensional nonlinear finite element analysis of both thermal and mechanica...Alexander Decker
This document discusses a 3D finite element analysis of the thermal and mechanical response during friction stir welding of 2024-T3 aluminum plates. A coupled thermal-mechanical model is used to sequentially analyze the temperature distribution during welding and resulting thermal residual stresses. Both the heat input from the tool shoulder and pin are considered. The model predicts the highest tensile stresses occur in the longitudinal direction within the heat affected zone. Various process parameters are analyzed, including bottom surface heat transfer conditions and thermal contact conductance at interfaces. The results agree well with published experimental data.
Experimental Analysis to Optimize parameters of Friction Stir Welding of Alum...IJSRD
This document summarizes research on optimizing parameters for friction stir welding (FSW) of aluminum alloys. It first provides background on FSW and discusses how parameters like tool rotation speed, tilt angle, and travel speed affect weld strength. The document then reviews several other studies investigating these parameters. One study found that a tool rotation speed of 900 rpm, travel speed of 75 mm/min, and axial force of 3 kN produced the highest tensile strength for an aluminum alloy. Another identified tilt angle as the most influential parameter for weld strength. Finally, the document describes using the Taguchi method to optimize FSW parameters for aluminum alloy, identifying tilt angle as most significant. It concludes that tool rotation speed, travel
Modeling and Simulation of Base Plate of Friction Stir Welding-Advanced Weldi...ijsrd.com
Friction stir processing is an emerging technique based on the principles of friction stir welding (FSW). It is a solid-state joining method that is energy efficient, environmentally friendly, and versatile. It is considered by many to be the most significant development in metal joining in a decade. The basic concept of friction stir processing is remarkably simple. A rotating tool with pin and shoulder is inserted in the material to be joined, and traversed along the line of interest. The heating is localized, and is generated by friction between the tool and the work piece, with additional adiabatic heating from metal deformation. A processed zone is produced by movement of material from the front of the pin to the back of the pin.
Finite Element Modelling of Chip Formation in Orthogonal Machining for AISI 1050paperpublications3
Abstract: Finite element method has gained immense popularity in the area of metal cutting for providing detailed insight in to the chip formation process. This report presents an overview of the application of finite element method in the study of metal cutting process. The basics of both metal cutting and finite element methods, being the foremost in understanding the applicability of finite element method in metal cutting, have been discussed in brief. In this project, thermo mechanical simulation of turning process has been developed using commercially available finite element analysis software, ABAQUS 6.10. A 2-D orthogonal cutting has been modelled using an Arbitrary Lagrangian - Eulerian (ALE) formulation. The Johnson-Cook plasticity model has been assumed to describe the material behaviour during the process. Adaptive meshing dynamic explicit is also employed in this model to avoid the severe deformation. This study is aimed at temperature and stresses distributions during machining of AISI 1050 steel with three different speed 120m/min, feed 0.1 mm/rev. and depth of cut 1.5 mm. The results showed for speed 120 m/min, feed 0.1 and depth of cut 1.5 that the maximum stress for -7oC rake angle is 1.35 GPa while the maximum temperature results shown that 699°C.
Optimization of Process Parameters of Tungsten Inert Gas Welding by Taguchi M...ijsrd.com
Tungsten Inert Gas welding (TIG) is one of the most important joining technologies in welding-related fabrication. High quality weld joints without spattering and slags qualify this welding technology for the major part of metals. As the filler-metal supply is separated from the arc, the molten pool can be controlled in the best way possible an advantage which ensures the quality of the execution of the weld but entails a relatively low deposition rate and welding speed. When manufacturing consumer products where appearance is of importance; then the choice has to be TIG welding. Jobs that call for code requirements such as nuclear work, piping, and high profile consumer goods often require at least the first weld in the pipe joint to be TIG welding for an effective bond. In some cases all the passes on a multi-pass pipe weld may have to be TIG welding, if demand has high quality and code requirements.
Process planning and cost estimation unit ivs Kumaravel
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Finite Element Simulation of Serrated Chip Formation in High Speed CuttingIJRES Journal
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Design and Experimental study of Friction stir welding of AA6061-T6 Alloy for...IRJET Journal
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Experimental study of heat transfer enhancement in a pipe using twisted tapesIAEME Publication
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IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Effect of various process parameters on friction stir welded jointeSAT Journals
Abstract Pure and ZnS added ADP (ammonium dihydrogen phosphate) single crystals have been grown at room temperature by the free evaporation method. A total of six crystals have been grown and characterized structurally, chemically, thermally, optically, mechanically and electrically by using the suitable standard methods. Results obtained indicate that the impurity molecules have entered into the ADP crystal matrix. ZnS addition is found to increase the SHG efficiency significantly. All the grown crystals exhibit good optical transmission in the entire visible region. Results of AC and DC electrical measurements indicate a normal dielectric behaviour for all the six crystals grown. The electrical parameters, viz., DC electrical conductivity, dielectric constant, dielectric loss factor and AC electrical conductivity are found to increase with the increase in temperature. The optical, mechanical and electrical parameters are found to vary nonlinearly with the impurity (ZnS) concentration. Keywords: ADP crystal, Crystal growth, Doped crystals, Physical properties, X-ray diffraction.
This document summarizes a research article that proposes a new rapid prototyping process called composite metal foil manufacturing (CMFM). CMFM combines laminated object manufacturing and soldering techniques to produce high-quality metal parts directly from CAD models using thin metal foils and solder paste. The researchers developed an experimental setup to demonstrate CMFM and produced test specimens from copper foil. They then evaluated the specimens using lap-shear testing, peel testing, microstructural analysis, and comparison to other methods to validate the effectiveness of CMFM for producing metal prototypes.
1. 279
USING METAL ADDITIVE MANUFACTURING FOR
CONFORMAL COOLING OF DIES IN WIRE DRAWING
A.C. VAN STADEN, G.A. OOSTHUIZEN, P.A. HUGO, D.F. TREURNICHT
UNIVERSITY OF STELLENBOSCH
Abstract
During wire drawing the die is subjected to high pressures causing frictional
heat. At elevated temperatures, wear is accelerated, and the die life is
decreased. This study investigates heat accumulation in the wire drawing die
and the reduction of this heat through the incorporation of conformal cooling
channels.Areduction in heat accumulation will help to extend the dies life and
the possibility of increased wire-drawing speeds.
Aliterature survey covers temperature development within the drawing tool.A
die casing, incorporating conformal cooling channels, is designed and
manufactured using additive manufacturing (AM) technology. Its ability to
reduce the drawing tool temperatures is tested. During experimentation the
reduction per pass and the drawing speeds are kept constant, while input and
output temperatures for each reduction pass is measured.
Experimental results, comparing the conventional standard die casing with
the conformal cooled die casing, indicate a significant temperature reduction.
It is concluded that conformal cooling is viable for temperature reduction in the
drawing die. The rate of die wear is reduced. Indications are that wire
throughput and productivity per die set can be increased.
Keywords: Additive manufacturing, conformal cooling, selective laser
melting, wire drawing
1. INTRODUCTION
The SouthAfrican (SA) manufacturing industry faces specific challenges such
as a relatively limited market, a need for reduced part count, higher design
flexibility, cost reductions from design to finishing, as well as competition from
eastern sources (e.g. China's tooling industry). Furthermore, a rising need for
customised industrial application solutions exists. Customised tools can
provide a competitive advantage allowing SA to compete on a global scale.
Customisation is not limited to application, but extends to tool geometry and
material properties. The systems, methods, and processes for tooling are
developing continuously and this, together with additive manufacturing (AM)
processes, are being concentrated on in order to improve tooling performance
(Wohlers, 2012).
2. 280Journal for New Generation Sciences: Volume 14 Number 3
The process with which the cross section of wire is reduced by pulling it
through a die opening is referred to as drawing (Kalpakjian & Schmid, 2001),
(Schey, 1987). The construction of each individual die (nib) consists of a hard
wearing material which achieves the reduction in wire diameter, as well as a
die casing in which the die is fitted. This casing facilitates installation of the die
into the wire drawing machine. The drawing machine comprises of multiple
reduction stations where the raw wire stock is fed through a die at various
stations, progressively reducing its size.
The percentage of cross-sectional reduction, die angle, drawing speed, and
friction along the interfaces are the major variables affecting heat generation
in the drawing process (El-Domiaty & Kassab, 1998). The wire drawing
process subjects the die to high pressures and creates friction between the
wire stock and the wire-drawing die. Due to high working pressures acting on
the surface of the forming die, die wear must be considered before tool design
(Kim, Kim & Choi, 1997). The high pressure on the die surface makes
minimization of tool wear particularly important for wire drawing (Lee, Lee, &
Kim, 2012). Increased down time is the result of an increased frequency in
worn die replacement, which is caused by high wear rates. Throughput is
increased by a higher drawing speed and reduced by a shortened die life. The
temperature developed within the die is positively correlated to the operational
drawing speed (Wright, 2011). At elevated temperatures the die material's
mechanical properties are compromised, wear is accelerated, and die lifetime
is decreased. According to Lee (Lee, et al., 2012) premature die wear
accounts for more than 70% of tool replacements, mechanical fatigue for
25%, and the remaining 5% are due to plastic deformation and thermal-
mechanical fatigue.
Rapid die wear may be minimized by controlling the temperature developed
within the tool. Tool wear reduction could result in increased productivity and
hence a cost reduction. Another distinct advantage is an increase in drawing
speed capability of the drawing process. Current industry practice uses water
cooling systems by submersion of the drawing tool in a circulating water bath.
This method proves to be of limited efficiency.
An improved technique, such as conformal cooling, necessitates additive
manufacturing (AM) to achieve geometries otherwise impossible with
machined tooling (Wohlers, 2012). According to Kruth, Leu & Nakagawa,
1998) notable progress has been achieved in AM applications, making direct
metalAM technology mature enough for relatively complex applications, such
as conformal cooling.
Die cooling through the use of conventional or conformal cooling channels
offers the distinct advantage of increasing the rate of heat transfer between
the work material and the machine tool. Conformal cooling, involving intricate
channels that follow the complex shape of a part, allows for optimum and
uniform cooling design.
3. 281
Additive manufacturing (AM) has the aptitude to manufacture such tools due
to its flexibility in material applications and its ability to produce complex
geometries.
Currently conformal cooling of wire drawing tools is not an available option
and no previous work is readily available on the use of conformal cooling
methods in wire drawing applications. As such, the application and
performance of a conformally cooled drawing tool is unexplored and forms the
objective of this paper.
2 THE WIRE DRAWING PROCESS
2.1 Wire Drawing Station
Wire in excess of several thousand meters and smaller cross-sections are
drawn by a rotating drum, also known as a capstan or bull block (Kalpakjian &
Schmid, 2001). Drawing, using blocks, is dependent on the capability of the
stock to be coiled around a capstan or bull block after being drawn. The stock
is attached to the bull block after been fed through the die as illustrated in
figure 1. Once attached the bull block rotates, pulling the stock through the die
while it coils the as-drawn wire around the bull block (Wright, 2011).
Figure 1:Acommercial multiple-block wire drawing station
Single capstan drawing is often used in manufacturing facilities; however
multiple-block systems are most commonly used as indicated in figure 1. The
stock is wrapped around each capstan a few times before it enters the
following die. The contact surface between the wrapped wire and the capstan
has enough frictional contact to transmit pulling force to the undrawn stock
(Wright, 2011). This effectively lessens the amount of pulling force required by
the bull block.
4. 282Journal for New Generation Sciences: Volume 14 Number 3
2.2 Drawing as forming technology
Wire-drawing is a bulk deformation process, pulling the work material through
the die, as opposed to being pushed through the die as in the case of extrusion
(Kalpakjian & Schmid, 2001), (Groover, 2011), (Dieter, 1961). Deformation
forces are present at the exit of the die in drawing, as opposed to the forces
being at the entrance of the die, as in the case of extrusion (Lange, 1985). In
the deformation zone, a combination of tensile and compressive stresses is
encountered (Lange, 1985).The deformation of the drawing process is often
referred to as indirect compression (Dieter, 1961), (Schey, 1987). During
drawing, the draw force should be kept lower than the strength of the drawn
wire thus limiting the attainable reduction to lower than 50% (Schey, 1987).
According to Lange (1985) the maximum achievable natural strain, φmax, is
between 0.25 and 0.3 for steels and non-ferrous metals. Schey (1987)
suggests that further limitations to the drawing process arise from a possible
non-uniformity during deformation. The compression zone depth may not be
sufficient to ensure homogeneous deformation which could potentially result
in arrowhead (or centerburst) defects in less ductile metals (Schey, 1987).
2.3 Temperature Changes
The temperature in the forming process affects the final mechanical
properties of the wire, the work required, the forces, as well as the economic
outcomes of the process (Dieter, 1961). Wire drawing at high speed, for
increased productivity, affects the heat generated (El-Domiaty & Kassab,
1998). Wright (Wright, 2011) suggests that the effect of the drawing speed, v
[m.s-1], is held within the initial wire temperature, T0 [K], rather than having a
direct influence. In a multi-pass drawing setup the heat generated with each
reduction pass is not completely removed through inter-pass cooling and thus
T0 will increase relative to each reduction pass (Wright, 2011). Convective
and conductive heat loss to air and lubricant is generally included in inter-pass
cooling. Furthermore, conductive heat loss occurs upon wire contact with the
capstan (Wright, 2011). At high drawing speeds the heat generated does not
have sufficient time to dissipate. A rise in temperature therefore results and
this has a detrimental effect on the quality of the final wire product (Kalpakjian
& Schmid, 2001), (El-Domiaty & Kassab, 1998), (Lee, et al., 2010). According
to Lee, et al. (2010) in a high speed wet wire drawing process, an excessive
rise in wire temperature increases wire breakage as well as reduces the wire
quality.
Lange (1985) presents an example based on elementary plasticity theory. He
shows that surface temperatures along the deformation zone increases with
drawing speed. Wright (2011) concludes that the wire surface temperature
rises at the die exit with an increase in drawing speed. Other factors that
influence the temperature is plastic deformation, friction at the die-material
interface, heat transfer between the tool and work material, and the heat
exchange between the die and the surrounding environment (El-Domiaty &
5. 283
Kassab, 1998), (Lee, et al., 2010). The coefficient of friction at the wire-die
interface is independent of pressure and temperature, and it may be assumed
to be constant (El-Domiaty & Kassab, 1998).
Lange (1985) presents experimental results regarding the temperature field
when a round bar is drawn. The temperature rises steeply at the material
boundary as it enters the deformation zone. Thereafter the temperature
stabilises and increases once more at the die exit. It is also clear that the
temperature does not vary significantly near the centre of the bar, even if the
drawing velocity varies (Lange, 1985).According to Lange (1985) the frictional
heat generated for all drawing velocities remains constant. Due to the time
dependence of heat conduction, however, the frictional heat will be
concentrated in a localised layer near the boundary (Lange, 1985). High
pressures in the die and the resultant friction results in accelerated die wear,
specifically when speeds are increased. Die reliability, wire dimensional
precision, and surface properties are largely determined by die wear
progression (Kim, et al., 1997), (Lee, et al., 2012), (Hillery & McCabe, 1995).
2.4 Wear during drawing
According to Kim, et al. (1997) the theory of wear can be classified according
to the contact conditions between the drawing tool and the wire product.
Amongst these wear theories the abrasive-wear theory is generally applied to
cold-forming processes and the die-wear mechanism associated with it (Kim,
et al., 1997), (Lee, et al., 2012). According to Shaw, Stableford, and Sansome
(1970) die wear, in a wire drawing process, may occur in any of the following
forms: (1) Abrasive wear and pick up can be caused by the adhesive
mechanism in which particles of the work piece material are dislodged by
subsequent material and carried down the die face; (2) Plastic deformation
can result in mechanical wear; (3) Pitting may occur as a result of cyclic
stressing of a microscopic point. The cyclic stressing could be caused by
temperature or load variations caused by unstable lubricant films; (4)
Corrosion could be a direct result of chemicals being added to the lubricant to
provide extreme pressure and/or boundary lubrication qualities. Lubricant
breakdown could also result in corrosion.
Emmens (1988) investigated the influence of surface roughness on die wear.
Generally it was found that higher values of friction are a result of higher
grades of surface roughness leading to higher rates of die wear. Frictional
forces can be explained by the welding theory (Shaw, et al., 1970). Friction is
declared as the breaking of welded junctions, between asperities of
contacting surfaces, together with a certain degree of surface ploughing
(Shaw, et al., 1970). As friction increases the temperature will rise during the
drawing process. Over long periods, dies have to be able to withstand the high
working temperatures encountered (Hillery & McCabe, 1995).
6. 284Journal for New Generation Sciences: Volume 14 Number 3
2.5 Temperature Control
In order to reduce increased temperatures in the drawing process,
improvement in the thermal management of the drawing tools is required.
Conventionally the die and casing is installed in a die box which is filled with
circulating water in order to control the operating temperatures during the
process.
Metal additive manufacturing has demonstrated the potential to fabricate tools
with complex internal conformal channels to improve the cooling uniformity
and efficiency (Xu, 1999). These channels conform to the shape of the tool
(Wohlers, 2012). In comparison, conventional tools make use of straight-line
cooling channel configurations which have lower rates of cooling than
conformal cooling channels (Wohlers, 2012).
3. ADDITIVE MANUFACTURING
Final Part properties are influenced by several additive manufacturing (AM)
process variables. Powder-based AM, specifically, involves variability in the
material, the process, and the energy source used to sinter the material
(Campanelli, 2010).
Selective Laser Melting (SLM) is based on the fusion of metallic powder
materials using a laser. Almost all metallic materials may be used and parts
are constructed on a layer-by-layer basis (Sinirlioglu, 2009). Theoretically
100%-part density is achievable through the use of a SLM technology like
Laser-Cusing. Such a dense structure yields mechanical properties as high as
(or higher than) conventionally machined parts (Sinirlioglu, 2009). Densities of
parts with conformal cooling channels are important to ensure that no
leakages will occur during operation. Part stability, the corresponding
increased part density, and the associated mechanical properties are
dependent on uniform single layers. It has been found that hatch spacing,
laser power, and scan speed are the dominant factors in determining how well
individual scan tracks are formed (Gu & Shen, 2009), (Yadroitsev, et al.,
2010).
The SLM process develops residual stresses in the material, derived from the
high thermal gradients induced in the material. Cracking, warping, uprooting,
and/or delamination are but a few defects that could result from excessive
residual stresses (Campanelli, 2010). Residual stresses can be reduced with
various heat treatments and annealing processes.
Literature and previous in-house studies have proved that SLM technologies
can successfully be used for production of conformally cooled inserts for
injection moulding. Reductions of up to 31% in cycle time have been achieved.
These inserts showed no signs of cracks, delamination or leakages during
multiple years of operation.
7. 285
3.1 Conformal Cooling Design forAM
Manufacturing constraints associated with layer manufacturing includes the
achievable channel diameter and feature angle without the use of filler or
scaffolding to support the feature. The final process/machine where an am
part will be used also poses certain geometric constraints. Cooling channels
are required to be of adequate size to achieve the desired thermal control
without compromising the mechanical properties of the tool or the functionality
of the tool (Xu, 1999).
Uniform cooling of the product yields a uniform microstructure in metal
products, ensuring an even distribution of mechanical properties within the
metal product. Better temperature control over the cooling channel is
accomplished by decreasing the distance between the cooling channels and
the tool surfaces.
4. RESEARCH METHODOLOGY& EXPERIMENTALSETUP
This study investigates the temperature reductions that could be achieved
when using conformally cooled die casings compared to conventional die
casings. All experiments were conducted at Allens Meshco (Pty) Ltd. A die
casing serves as an encasement for the die nib and serves to hold the nib in
position during the drawing process, the die nib being the tool achieving the
desired wire reduction.
The standard die casing is classified under two die wall sizes, namely thin and
thick walled. The thick walled die casing is used, in general, for medium to
small wire diameters. The thin walled die casing is used, in general, for
intermediate wire diameters. The standard die casing is used as the basis for
the proposed casing design, incorporating conformal cooling channels. The
wire drawing process used for the study involves a four stage process as
illustrated in Figure 2.
Figure 2: Four stage wire-drawing process indicating the diameter (Ø) of the
die
Stage 1 uses a rotating die box. This serves to aid the initial drawing of the wire
stock which has surface defects present due to environmental exposure and
lack of treatment prior to being drawn. These defects could potentially
damage the drawing die if a stationary die is used for the initial reduction,
resulting in surface damage to the drawn wire. Any surface damage will
potentially damage drawing dies further down the drawing line. Furthermore,
8. 286Journal for New Generation Sciences: Volume 14 Number 3
a rotating die box allows for simplified continuous inspection, improved
lubrication application, and temperature development reduction during the
initial reduction pass (Frigerio &Arnoldi, 1992).
Stage 2 is included in the drawing schedule to guide the wire. This serves to
provide stability, increase the application of lubrication to the drawn product,
and to include a greater inter-pass cooling zone before the reductions
achieved in Stages 3 and 4.
Stage 3 achieves a 13.2% reduction in wire diameter from the initial reduction
pass. This reduction pass corresponds to the low drawing speed described
previously.
Stage 4 achieves a 15.2% reduction in wire diameter from the second
reduction pass. This reduction pass corresponds to the high drawing speed
described previously.
The variability of the drawing speed is present in the rotational speed of
successive capstans. A distinction is drawn between two drawing speeds: a
low drawing speed at stage 3 and a high drawing speed at stage 4. A thin-
walled casing is used at stage 3 and a thick-walled casing at stage 4.
4.1 Die Casing Design (Conformal Cooling Layout)
Cooling channels can be placed either far from the tool surface, or close to the
tool surface. With channel placement far from the tool surface, heat generated
during tool use will progressively increase to a steady state between heat
generation and extraction. With channel placement close to the tool surface, a
reduction in thermal mass within the tool is achieved. The optimal conformal
cooling condition can be satisfied by increasing the channel diameter, using
tool materials with increased thermal diffusivity, decreasing the distance
between adjacent cooling channels and the tool surface, or increasing the
heat transfer coefficient of the coolant used.
Xu, Sachs, and Allen (2001) presented a design framework for designers
based on the diameter of the cooling channels and the length of the cooling
channels. Figure 3 clearly indicates the feasible area describing the cooling
channel diameter and length corresponding to design constraints associated
with geometry, coolant pressure drop, coolant temperature uniformity, and
manufacturing constraints. The proposed design framework has been
developed for injection molding operations; however the principles were
adapted and used here for selection of the appropriate process conditions and
geometric parameters.
9. 287
Figure 3: A design framework defined by cooling channel diameter and
cooling channel length (Adapted from Xu, et al., 2001)
Designing for coolant pressure drop involves determining the desirable
combination of coolant flow rate, cooling channel diameter, and cooling
channel length to ensure a resultant pressure drop lower than the given
pressure budget. Maintaining coolant temperature change within a specified
range is essential. An unusually high change in coolant temperature results in
insufficient heat being transported away from the production tool. The
designer may reduce the change in coolant temperature by increasing coolant
flow, using a coolant with a high specific heat, decreasing the length of the
cooling channels, or previously stated by decreasing the distance between
the adjacent cooling channels and tool surfaces.
The current cooling system operating at Allens Meshco (Pty) Ltd. provides
coolant for a multitude of drawing lines, as well as other production processes
and more is than capable of supporting any high pressure requirements. The
proposed die casing designs will have a negligible pressure drop and
pressure drop was excluded as a design constraint in this study.
The die box in which the drawing tool is fitted is standardized throughout the
entire facility at Allens Meshco (Pty) Ltd. The cylindrical characteristic of a die
casing required the channels to take the shape of a coil, revolving around a
single axis. The final conformal cooling channel parameters are summarized
inTable 1.
10. 288Journal for New Generation Sciences: Volume 14 Number 3
Table1: Design parameter summary of the die casings
Conventional Cooled Die Casing Conformal Cooled Die Casing
DESIGN PARAMETERS
Thin Walled
Casing
Thick Walled
Casing
Thin Walled
Casing
Thick Walled
Casing
Channel Diameter [mm] - - 4 4
Pitch [mm] - - 8 8
No. of Coil Revolutions - - 2.5 2.75
Figure 4 & 5 shows the resultant die casings designed, incorporating 2.5
channel rotations in stage 3 and 2.75 channel rotations in stage 4. Structural
integrity of the die sleeves are ensured with sufficient material between
adjacent channels. Standard nibs, consisting of hard wearing materials, are
used in each casing during the process.
4.2 Die Casing Manufacture
The two die casings are manufactured on a SLM machine, namely a M2
Laser-Cusing Machine, from Concept Laser as illustrated with its
specifications in figure 6. Both parts are printed in one build in a time of 12
hours using 30µm layers.
11. 289
Figure 6: M2 Laser-Cusing machine used to manufacture the conformally
cooled die casingsToolsteel 1.3970 (CL50WS) is used and the building
chamber flooded with nitrogen. Parts are built directly onto a toolsteel building
plate and removed from the plate afterwards by means of wire-cutting.1.1
Experimental Setup
Only temperatures in and out of stage 3 and 4 are considered for the study in
order to directly compare the conventional and conformally cooled die
casings. A Raytek MX4 TD infrared thermometer is used with DataTempMX
software. Data is captured at 4 temperature readings per second. Three
intervals of 10 minutes each are recorded. The drawing machine is set up and
operated according to standard operational specifications. This procedure is
followed for both the standard and proposed die casings.
M2 Laser-Cusing Machine:
A large variety of Metals
including Re-Active Materials
likeTitanium andAluminium
Chamber flooded with Gas
(Nitrogen orArgon)
250 x 250 x 280 Building
Envelope
• 20 – 50 µm layers
200 W Fibre-Laser
•
•
•
Figure 7: Experimental setup: (a) Temperature recording into each die and (b)
out of each dieThe thermometer is positioned to record the temperature of
wire surface as it enters and exits each drawing stage. The thermometer is
placed approximately 200mm from the wire surface, as per the operational
specifications of the recording equipment. Figure 7 illustrates this
experimental setup.
12. 290Journal for New Generation Sciences: Volume 14 Number 3
Figure 2 indicates the temperature points at each stage.
4.4 Equipment validation
The Raytek MX4 TD infrared thermometer is validated by testing it on a block
of ice. A reference temperature of 0°C (or 273.15 K) is used for ice. A block of
ice, approximately 2199.115cm3 in size, is used for this purpose. The
thermometer is set up to record the temperature of the ice at 4 temperature
readings per second. Three intervals of 10 minutes each are recorded. The
results are shown in Figures 8-10 below.
Figure 8: Temperature
development recorded
for validation
measurement
1.measurement 2.
Figure 9: Temperature
development recorded
for validation
measurement 2.
Figure 10:
Temperature
development recorded
for validation
measurement 3.
The graphs show a consistent temperature measurement throughout the
validation process for all three measurements. The results indicate a steady
temperature measurement between -0.2 and 0.2 ºC with a median value of
0.03ºC. This corresponds, within a reasonable range, to the expected
temperature value for ice as stated by Cengel and Boles (2008).
5. EXPERIMENTALRESULTS
In order to confirm the feasibility of the proposed die casing designs, the
averaged results for the standard die casings are graphed together with the
averaged results for the proposed die casing.
5.1 Temperature measurement into stage 3
Stages 1 and 2 remain unaltered for both experimentation phases. This
implies that the temperature coming out of stage 2 (the temperature going into
stage 3) should be similar in value for both the standard and conformally
cooled die casings.
13. 291
The similarity assumption stated previously is confirmed by Figure 11. The
difference in the median values for the average temperatures measured into
stage 3 is small. This indicates a correct replication of the experimental
procedure for both the conventional and new casings at stage 3.
5.2 Temperature measurement out of stage 3
The average output temperatures measured for stage 3 are presented here.A
significant rise in temperature can be seen from the input to the output
temperatures.
Figure 11: Average temperatures measured into stage 3.
40.00
41.00
42.00
43.00
Standard Casings Proposed Casings
Temperature[ºC]
Casing Type
66.00
68.00
70.00
72.00
74.00
76.00
78.00
80.00
82.00
84.00
86.00
88.00
Standard Casings Proposed Casings
Temperature[ºC]
Casing Type
Figure 12: Average temperatures measured out of stage 3.
14. 292Journal for New Generation Sciences: Volume 14 Number 3
Figure 12 presents the average temperatures measured out of stage 3.Aclear
reduction in temperature is visible. The conformally cooled die casing design
achieves a 13.08 ºC (or 15.54%) reduction in median temperature from the
standard operating condition.
5.3 Temperature measurement into stage 4
Upon exiting stage 3 the wire product temperature decreases as a result of
inter-pass cooling. The input temperature for stage 4 is, however,
considerably higher than the input temperature associated with stage 3.
60.00
62.00
64.00
66.00
68.00
70.00
72.00
74.00
76.00
78.00
80.00
Standard Casings Proposed Casings
Temperature[ºC]
Casing Type
Figure 13: Average temperatures measured into stage 4.
Figure 13 presents the average temperatures measured into stage 4 for both
die casing types. The accumulated effect of the conformal cooling
mechanism, as well as the inter-pass cooling mechanism, results in a
temperature reduction of 14.87ºC (or 19.41%) in median temperature from the
standard operating condition.
5.4 Temperature Measurement out of stage 4
The effect of heat accumulation on the temperature exiting Stage 4 is evident
in the experimental results. A substantial increase in temperature occurs
during the final drawing stage that could potentially degrade the die life more
rapidly and have a detrimental effect on the final wire product, as opposed to
the associated die life and product quality for the wire drawing tools in previous
drawing stages.
15. 293
A significant reduction in the accumulated and developed temperatures, as
measured out of Stage 4, is evident for the conformally cooled dies presented
in figure 14. The conformal cooling system accomplishes a 33.27 ºC (or
24.21%) reduction in median temperature from the standard operating
condition.
5.5 Wire Surface Roughness
A total of six wire samples were taken during the process and their
microscopic images are shown in Figure 15. The die wear development can
evidently be seen over the length of the wire.
Figure 14: Average temperatures measured out of stage 4.
95.00
100.00
105.00
110.00
115.00
120.00
125.00
130.00
135.00
140.00
145.00
Standard Casings Proposed Casings
Temperature[ºC]
Casing Type
Sample 1 Sample 2 Sample 3 Sample 4 Sample 5
ConventionalDie
Casing
ConformalCooled
DieCasing
Figure 15: Wire Surface Roughness for 6 Samples Taken
16. 294Journal for New Generation Sciences: Volume 14 Number 3
The degree of wire surface degradation is more prominent for the standard die
casing as illustrated by the sixth samples. This indicates that a decrease in the
temperatures developed within the drawing tool results in a decreased rate of
die wear development.
6. CONCLUSION
The purpose of the study was to understand the degree conformally cooled
die casings would reduce heat during certain stages of a wire-drawing
process.
Additive manufacturing was successfully used to build the two die casings for
stage 3 and 4 of the process in toolsteel. No cracks, delamination or leakages
are observed during operation of the system.
Conformal cooling proves to be exceptionally effective as a method to control
thermal heat formation during the wire-drawing process. The temperature
reduction indicates a possible increase in the die life as well as the ability to
increase the operational drawing speed of the process. The reduction in
median temperature values (per reduction stage) at stage 3 was 13.08 ºC (or
15.54%) and 33.27 ºC (or 24.21%) at stage 4.
The effect that the die surface roughness, non-uniform lubrication and initial
wire surface roughness has on temperature development was excluded from
this study.These factors should be included in future studies.
Further studies should be carried out to determine by how much the tool life
could be extended and how this will relate to increased wire-drawing speeds
and wear.
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