This document describes a methodology used to increase the service life of hot forging tools. The methodology combines numerical simulation of the forging process and thermomechanical stress analysis with experimental validation. Simulation results show that thermal stresses contribute significantly to the total stress field in critical cracking areas of the tool. Modifying process parameters such as billet temperature and forging rate could potentially increase tool life by reducing thermal stresses. The methodology was applied to a cemented carbide punch used in hot forging and identified areas with high thermal stress contribution.
IRJET- Manufacturing of Mould Die for Nut Ring and Process Cycle OptimizationIRJET Journal
This document describes research on optimizing the compression molding process for manufacturing nitrile rubber nut rings. A mold die was designed and fabricated. Nut ring samples were produced using various temperature (165, 175, 185°C) and curing time (2, 3, 5 minutes) combinations. Finite element analysis of the mold die was performed in ANSYS to analyze deformation, stresses, and strains. Hardness testing found the 185°C, 2 minute and 185°C, 3 minute combinations produced samples closest to the optimum 75 Shore A hardness. Simulation results matched the experimental findings and showed maximum deformation, stresses, and strains increased with higher temperatures.
Multiresponse optimization of surface grinding operation of en19 alloy steel ...IAEME Publication
This document describes an experimental study that used grey relational analysis to optimize surface grinding parameters for EN19 alloy steel using water-based nanofluids. The study considered nanofluid type (Al2O3 and CuO), nanofluid concentration (2-6%), depth of cut (5-10um), and feed rate (1000-2500mm/min) as process parameters. Multiple responses including surface roughness, temperature, grinding wheel wear, and material removal rate were measured. Grey relational analysis was used to convert the multi-response optimization into a single response problem to simplify the optimization. Analysis of variance was conducted to determine significant process parameters affecting the grey relational grade. The optimal levels of parameters were selected and a confirmation
Multi-Response Optimization of WEDM Process Parameters of Monel 400 using Int...ijceronline
Non-traditional machining processes such as Wire Electric Discharge Machining (WEDM) are increasingly been employed to machine difficult-to-machine materials. Monel 400 an alloy of Nickel and Copper is taken in this study and it is cut through Wire Electric Discharge Machining process. It is utilized mainly in corrosion resistant applications. Further, the process parameters are optimized to get the desired machining conditions which can improve the quality of machining. Design of Experiments is done through Central Composite Design (CCD). Response Surface Methodology (RSM) and Genetic Algorithm (GA) which is an evolutionary algorithm are the techniques employed for the optimization of parameters in WEDM. The multi response optimization for achieving maximum material removal rate (MRR) and minimum surface roughness, the optimum process parameters are found to be ‘Current’ of 2.031 A, ‘T-On’ of 3 µs, ‘T-Off’ of 10 µs, the obtained maximum MRR is 6.339 mm 3 /min and minimum surface roughness is 1.846 µm.
International Journal of Computational Engineering Research (IJCER) ijceronline
International Journal of Computational Engineering Research(IJCER) is an intentional online Journal in English monthly publishing journal. This Journal publish original research work that contributes significantly to further the scientific knowledge in engineering and Technology
Investigation of significance in phase transformation of powder metallurgy steelIAEME Publication
This document summarizes research on modeling and simulating the heat treatment of powder metallurgy steel components. It describes developing a database of material properties including heat transfer coefficients, mechanical properties, and phase transformation kinetics for different porosity levels. A commercial simulation software called DANTE was modified to include porosity and used to predict dimensional changes, residual stresses, and microstructure of a test component during heat treatment. The model predictions matched well with measurements on industrial parts, demonstrating the model's ability to simulate heat treatment of porous powder metallurgy steels.
Analysis Of The Structure Of A Material Used In The Manufacture Of Thermal Ch...IJERA Editor
The dynamic stability of machine has its own importance in the quality of the machined product. With the development of new technologies for cutting tools, as the geometries and materials, cutting speeds used today reach values inconceivable for two decades. In the automotive industry steel and cast iron are gradually being replaced by lower density material and even lower costs. In complex shapes tools, heterogeneous material removal in roughing, sudden changes of sections, etc. Stress relieving treatment should be carried out to minimize dimensional variations of form during quenching and tempering. Materials for manufacture of thermal fixing most appropriate for that operating system still needs to be further investigated. Therefore, this study investigated the elastic behavior of the material used in the manufacture of tooling systems for cutting tools. Has been evaluated In fastening system, the temperature variation exerted on the mandrel body region and the thermal expansion where H13 steel can withstand the assembly process by thermal interference. This method can determine the amount of number of cycles until the onset of fatigue that material.
The document presents a study that aims to optimize welding variables and predict weld bead geometry in gas metal arc welding (GMAW) process. Experiments were conducted using a central composite design to study the relationship between input process parameters (current, speed, angle, distance, pinch) and output parameters (bead width, height, depth, dilution). Mathematical models were developed using regression analysis. A neural network was then used to predict welding outputs, and a simulated annealing algorithm was applied to optimize the process parameters to achieve optimum dilution.
Experimental investigation of tool wear in turning of inconel718 material rev...EditorIJAERD
This document summarizes an experimental investigation into tool wear during turning of Inconel718 material. It reviews the effects of various cutting conditions, tool geometries, and tool treatments on tool wear and other output parameters like cutting force, temperature, vibration, power consumption, surface roughness, and material removal rate. The goal is to analyze tool wear based on literature to optimize machining of Inconel718 using a CNC machine. Various studies investigating factors like cutting speed, feed rate, depth of cut, tool material, and cooling conditions are summarized to reduce tool wear during machining of this difficult-to-cut alloy.
IRJET- Manufacturing of Mould Die for Nut Ring and Process Cycle OptimizationIRJET Journal
This document describes research on optimizing the compression molding process for manufacturing nitrile rubber nut rings. A mold die was designed and fabricated. Nut ring samples were produced using various temperature (165, 175, 185°C) and curing time (2, 3, 5 minutes) combinations. Finite element analysis of the mold die was performed in ANSYS to analyze deformation, stresses, and strains. Hardness testing found the 185°C, 2 minute and 185°C, 3 minute combinations produced samples closest to the optimum 75 Shore A hardness. Simulation results matched the experimental findings and showed maximum deformation, stresses, and strains increased with higher temperatures.
Multiresponse optimization of surface grinding operation of en19 alloy steel ...IAEME Publication
This document describes an experimental study that used grey relational analysis to optimize surface grinding parameters for EN19 alloy steel using water-based nanofluids. The study considered nanofluid type (Al2O3 and CuO), nanofluid concentration (2-6%), depth of cut (5-10um), and feed rate (1000-2500mm/min) as process parameters. Multiple responses including surface roughness, temperature, grinding wheel wear, and material removal rate were measured. Grey relational analysis was used to convert the multi-response optimization into a single response problem to simplify the optimization. Analysis of variance was conducted to determine significant process parameters affecting the grey relational grade. The optimal levels of parameters were selected and a confirmation
Multi-Response Optimization of WEDM Process Parameters of Monel 400 using Int...ijceronline
Non-traditional machining processes such as Wire Electric Discharge Machining (WEDM) are increasingly been employed to machine difficult-to-machine materials. Monel 400 an alloy of Nickel and Copper is taken in this study and it is cut through Wire Electric Discharge Machining process. It is utilized mainly in corrosion resistant applications. Further, the process parameters are optimized to get the desired machining conditions which can improve the quality of machining. Design of Experiments is done through Central Composite Design (CCD). Response Surface Methodology (RSM) and Genetic Algorithm (GA) which is an evolutionary algorithm are the techniques employed for the optimization of parameters in WEDM. The multi response optimization for achieving maximum material removal rate (MRR) and minimum surface roughness, the optimum process parameters are found to be ‘Current’ of 2.031 A, ‘T-On’ of 3 µs, ‘T-Off’ of 10 µs, the obtained maximum MRR is 6.339 mm 3 /min and minimum surface roughness is 1.846 µm.
International Journal of Computational Engineering Research (IJCER) ijceronline
International Journal of Computational Engineering Research(IJCER) is an intentional online Journal in English monthly publishing journal. This Journal publish original research work that contributes significantly to further the scientific knowledge in engineering and Technology
Investigation of significance in phase transformation of powder metallurgy steelIAEME Publication
This document summarizes research on modeling and simulating the heat treatment of powder metallurgy steel components. It describes developing a database of material properties including heat transfer coefficients, mechanical properties, and phase transformation kinetics for different porosity levels. A commercial simulation software called DANTE was modified to include porosity and used to predict dimensional changes, residual stresses, and microstructure of a test component during heat treatment. The model predictions matched well with measurements on industrial parts, demonstrating the model's ability to simulate heat treatment of porous powder metallurgy steels.
Analysis Of The Structure Of A Material Used In The Manufacture Of Thermal Ch...IJERA Editor
The dynamic stability of machine has its own importance in the quality of the machined product. With the development of new technologies for cutting tools, as the geometries and materials, cutting speeds used today reach values inconceivable for two decades. In the automotive industry steel and cast iron are gradually being replaced by lower density material and even lower costs. In complex shapes tools, heterogeneous material removal in roughing, sudden changes of sections, etc. Stress relieving treatment should be carried out to minimize dimensional variations of form during quenching and tempering. Materials for manufacture of thermal fixing most appropriate for that operating system still needs to be further investigated. Therefore, this study investigated the elastic behavior of the material used in the manufacture of tooling systems for cutting tools. Has been evaluated In fastening system, the temperature variation exerted on the mandrel body region and the thermal expansion where H13 steel can withstand the assembly process by thermal interference. This method can determine the amount of number of cycles until the onset of fatigue that material.
The document presents a study that aims to optimize welding variables and predict weld bead geometry in gas metal arc welding (GMAW) process. Experiments were conducted using a central composite design to study the relationship between input process parameters (current, speed, angle, distance, pinch) and output parameters (bead width, height, depth, dilution). Mathematical models were developed using regression analysis. A neural network was then used to predict welding outputs, and a simulated annealing algorithm was applied to optimize the process parameters to achieve optimum dilution.
Experimental investigation of tool wear in turning of inconel718 material rev...EditorIJAERD
This document summarizes an experimental investigation into tool wear during turning of Inconel718 material. It reviews the effects of various cutting conditions, tool geometries, and tool treatments on tool wear and other output parameters like cutting force, temperature, vibration, power consumption, surface roughness, and material removal rate. The goal is to analyze tool wear based on literature to optimize machining of Inconel718 using a CNC machine. Various studies investigating factors like cutting speed, feed rate, depth of cut, tool material, and cooling conditions are summarized to reduce tool wear during machining of this difficult-to-cut alloy.
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.
Analysis of Double Pipe Heat Exchanger With Helical FinsIRJET Journal
This document analyzes a double pipe heat exchanger with helical fins through computational fluid dynamics (CFD). It aims to study the flow and temperature fields inside the tubes for different helical fin angles. The geometry of the double pipe heat exchanger is modeled in CATIA V5 and meshed in Hypermesh. CFD simulations are performed in ANSYS Fluent to analyze the flow and temperature distributions for fin angles of 0, 5, 10, 15, 20, and 25 degrees. The results determine that heat transfer rate and overall heat transfer coefficient increase with helical fins compared to a smooth tube, with fins providing additional surface area to enhance heat transfer.
Finite Element Simulation of Serrated Chip Formation in High Speed CuttingIJRES Journal
The description of high speed cutting process with simulation based on finite element method provides huge superiorities compared to analytical and experimental models. This work focused on the study of high speed cutting process with finite element method, using commercial software ABAQUS/Explicit. The chip morphology is predicted, and the stress, strain and temperature in the chip are all simulated vividly when cutting stably. The serrated chip formation is explained by the adiabatic shear theory. The results showed that it is better to use the adiabatic shear theory to explain the formation of serrated chip.
IRJET- Experimental Investigation of Wear Behaviour of Aluminium Metal Matrix...IRJET Journal
The document experimentally investigates the wear behavior of an aluminum metal matrix composite reinforced with titanium carbide (TiC) particulate. Aluminum LM6 was reinforced with 4%, 6%, 8%, and 10% TiC by weight using stir casting. Pin-on-disc tests were conducted to determine the wear rate of the composites under dry sliding conditions at varying loads, sliding velocities, and temperatures. Scanning electron microscopy showed an even distribution of TiC particles in the aluminum matrix. The results showed that wear resistance increased with higher TiC content and lower load, sliding velocity, and temperature. Statistical analysis using Taguchi design of experiments indicated that load had the greatest influence on wear rate, followed by TiC content, sliding
IRJET- Improving the Performance of M42 Twist Drill ToolIRJET Journal
This document summarizes an experiment to optimize the heat treatment process and improve the performance of M42 twist drill tools. The experiment tested different materials, heat treatment cycles, spindle speeds, and point angles. Testing found that M42 material exhibited the lowest wear and temperature, making it the best material. Further testing determined that a point angle of 118 degrees and spindle speed of 750 RPM provided the best performance. In total, the experiment aimed to optimize the drill tool design and heat treatment process to improve tool life, hardness, and reduce costs.
The Vibration Impact on the Surface Roughness Which are Made for Ck35 Steel D...theijes
The vibrations have negative impact in the processing process by chip removal because they damage the quality of the processed surface, accelerate the cutting tool and machine wear; they can also lead to the cutting tool destruction or the parts of the machine and reduce the productivity of the cutting process.
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.
Optimalization of Parameters for 3D Print for Acrylonitrile-Butadiene-Styrene...IRJET Journal
This document discusses optimizing parameters for 3D printing acrylonitrile-butadiene-styrene (ABS) plastic using fused deposition modeling (FDM) to achieve high quality production. Samples were printed at various nozzle temperatures from 245°C to 285°C and tested for mechanical and thermal properties. Tensile strength was highest for samples printed at 285°C while flexibility was best for those at 245°C. Impact toughness was similar across temperatures. Thermal analysis found no material degradation from the printing process. Overall, the study determined the optimal temperature range for ABS printing with FDM based on achieving desired mechanical properties and print quality.
IRJET- Optimisation Technique for Design and Fabrication of ASTM Based Multit...IRJET Journal
This document describes the design and optimization of a die for manufacturing parts of varying thicknesses according to ASTM standards. Key points:
1) The multi-thickness die has three sections - a male part, holding plate, and female part. Variable thickness parts can be made by inserting shims of different thicknesses between the male and female parts.
2) The die design was optimized to reduce costs by machining cavities directly into the core plate, eliminating the need for a separate cavity plate.
3) Total manufacturing cost, material cost, tooling cost, and processing cost formulas were developed and optimized to reduce the cost per part. Process optimization focused on streamlining machining steps.
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
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.
Computational Fluid Dynamic Analysis and Structural Analysis of Ribbed Panel ...IRJET Journal
This document summarizes a computational fluid dynamics (CFD) analysis and structural analysis of a ribbed panel structure using finite element analysis (FEA). The analysis involved: 1) CFD to determine maximum pressure and velocity, 2) calculations to determine required plate thickness, 3) geometric modeling and meshing of the structure, and 4) static and transient structural analyses. The results showed the structure was safe under the applied pressure and impact loads with stresses and deflections within allowable limits, demonstrating the design was structurally sound. Section optimization also showed the same structural rigidity could be achieved with less weight.
This document summarizes a study that used Taguchi experimental design to optimize process parameters for friction stir welding of aluminum alloy 6063. Experiments varied tool rotational speed, welding speed, and axial force. Tensile testing found the highest strength (92 MPa) at a rotational speed of 1400 rpm, welding speed of 1.2 mm/sec, and axial force of 7 KN. Welding speed had the greatest influence on strength. Analysis of variance identified statistically significant parameters affecting strength. The optimal parameters achieved a joint efficiency of 70%.
IRJET- AODV and DSR Routing Protocol Performance Comparison in MANET using Ne...IRJET Journal
This document compares the performance of two mobile ad hoc network (MANET) routing protocols: Ad hoc On-Demand Distance Vector (AODV) and Dynamic Source Routing (DSR). The protocols were evaluated using the Network Simulator 2 (NS2) across three simulation scenarios with varying time durations. The results showed that AODV had lower initial packet loss compared to DSR. However, at longer simulation times both protocols performed similarly with comparable packet delivery ratios. In conclusion, AODV is more suitable when the MANET needs to be established quickly, while both protocols can be used for longer-term MANETs as their performance converges over time.
Designing, Fabricating, and Controlling of Shaped Metal Deposition System in ...Hassan Alwaely
This document summarizes Hassan Jasib Khudhair's master's thesis on designing, fabricating, and controlling a shaped metal deposition system for additive manufacturing. The research aims to develop a computer-aided double wire deposition machine controlled by a robotic arm. Experimental results show that process parameters like current, travel speed, and wire feed ratios influence bead geometry, hardness, and residual stress of deposited stainless steel parts. Finite element analysis of the system also shows that the design parameters allow for safe operation within specified stress limits. Overall, the study evaluates a new technique for additive manufacturing of metal parts using a cold wire feed method.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
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.
Conceptual design of laser assisted fixture for bending operationeSAT Publishing House
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
IRJET- Multi-Objective Optimization of WEDM Process Parameters of Ti-Ni S...IRJET Journal
The document discusses optimization of wire electrical discharge machining (WEDM) process parameters for machining titanium-nickel (Ti-Ni) shape memory alloy for biomedical applications. Eighteen experiments were conducted using Taguchi's L18 orthogonal array to evaluate the effects of five process parameters (pulse on time, pulse off time, servo voltage, wire feed, and wire tension) on material removal rate, surface roughness, and dimensional deviation as response variables. Grey relational analysis was used to determine the optimal parameter set that offers the maximum material removal rate and minimum surface roughness and dimensional deviation. Pulse on time was found to be the most influential parameter based on analysis of variance.
Die forging is a manufacturing process that shapes metal using localized compressive forces. It is classified by the temperature at which it occurs - cold, warm, or hot forging. Forged parts can range in weight from under a kilogram to 580 metric tons and usually require further processing. Forging produces stronger parts than casting or machining because the grain deforms to follow the shape, resulting in continuous grain and better strength. It involves shaping heated metal between top and bottom dies by hammering or pressing. Close die forging uses two engraved dies to form complex parts.
Forging processes involve shaping metals by applying compressive forces. There are four main types: hammer/drop forging uses gravity impacts, press forging uses hydraulic or mechanical presses, and open-die and closed-die forging differ in whether dies fully contain the metal. Forging increases strength by working the metal and altering its microstructure. Proper die and process design are needed to control metal flow, fill dies completely, and minimize flash and defects. Die materials must withstand thermal and mechanical stresses, while coatings can extend die life.
This document discusses various types of forging processes including hot forging, press forging, swaging, and cold forging. It describes how each process uses compressive forces and dies to shape metal at different temperatures. Examples of specific forging techniques are provided like hammer forging, drop forging, and upset forging. The document also outlines common forging tools, defects that may occur, and applications in small tools and automotive manufacturing.
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.
Analysis of Double Pipe Heat Exchanger With Helical FinsIRJET Journal
This document analyzes a double pipe heat exchanger with helical fins through computational fluid dynamics (CFD). It aims to study the flow and temperature fields inside the tubes for different helical fin angles. The geometry of the double pipe heat exchanger is modeled in CATIA V5 and meshed in Hypermesh. CFD simulations are performed in ANSYS Fluent to analyze the flow and temperature distributions for fin angles of 0, 5, 10, 15, 20, and 25 degrees. The results determine that heat transfer rate and overall heat transfer coefficient increase with helical fins compared to a smooth tube, with fins providing additional surface area to enhance heat transfer.
Finite Element Simulation of Serrated Chip Formation in High Speed CuttingIJRES Journal
The description of high speed cutting process with simulation based on finite element method provides huge superiorities compared to analytical and experimental models. This work focused on the study of high speed cutting process with finite element method, using commercial software ABAQUS/Explicit. The chip morphology is predicted, and the stress, strain and temperature in the chip are all simulated vividly when cutting stably. The serrated chip formation is explained by the adiabatic shear theory. The results showed that it is better to use the adiabatic shear theory to explain the formation of serrated chip.
IRJET- Experimental Investigation of Wear Behaviour of Aluminium Metal Matrix...IRJET Journal
The document experimentally investigates the wear behavior of an aluminum metal matrix composite reinforced with titanium carbide (TiC) particulate. Aluminum LM6 was reinforced with 4%, 6%, 8%, and 10% TiC by weight using stir casting. Pin-on-disc tests were conducted to determine the wear rate of the composites under dry sliding conditions at varying loads, sliding velocities, and temperatures. Scanning electron microscopy showed an even distribution of TiC particles in the aluminum matrix. The results showed that wear resistance increased with higher TiC content and lower load, sliding velocity, and temperature. Statistical analysis using Taguchi design of experiments indicated that load had the greatest influence on wear rate, followed by TiC content, sliding
IRJET- Improving the Performance of M42 Twist Drill ToolIRJET Journal
This document summarizes an experiment to optimize the heat treatment process and improve the performance of M42 twist drill tools. The experiment tested different materials, heat treatment cycles, spindle speeds, and point angles. Testing found that M42 material exhibited the lowest wear and temperature, making it the best material. Further testing determined that a point angle of 118 degrees and spindle speed of 750 RPM provided the best performance. In total, the experiment aimed to optimize the drill tool design and heat treatment process to improve tool life, hardness, and reduce costs.
The Vibration Impact on the Surface Roughness Which are Made for Ck35 Steel D...theijes
The vibrations have negative impact in the processing process by chip removal because they damage the quality of the processed surface, accelerate the cutting tool and machine wear; they can also lead to the cutting tool destruction or the parts of the machine and reduce the productivity of the cutting process.
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.
Optimalization of Parameters for 3D Print for Acrylonitrile-Butadiene-Styrene...IRJET Journal
This document discusses optimizing parameters for 3D printing acrylonitrile-butadiene-styrene (ABS) plastic using fused deposition modeling (FDM) to achieve high quality production. Samples were printed at various nozzle temperatures from 245°C to 285°C and tested for mechanical and thermal properties. Tensile strength was highest for samples printed at 285°C while flexibility was best for those at 245°C. Impact toughness was similar across temperatures. Thermal analysis found no material degradation from the printing process. Overall, the study determined the optimal temperature range for ABS printing with FDM based on achieving desired mechanical properties and print quality.
IRJET- Optimisation Technique for Design and Fabrication of ASTM Based Multit...IRJET Journal
This document describes the design and optimization of a die for manufacturing parts of varying thicknesses according to ASTM standards. Key points:
1) The multi-thickness die has three sections - a male part, holding plate, and female part. Variable thickness parts can be made by inserting shims of different thicknesses between the male and female parts.
2) The die design was optimized to reduce costs by machining cavities directly into the core plate, eliminating the need for a separate cavity plate.
3) Total manufacturing cost, material cost, tooling cost, and processing cost formulas were developed and optimized to reduce the cost per part. Process optimization focused on streamlining machining steps.
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
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.
Computational Fluid Dynamic Analysis and Structural Analysis of Ribbed Panel ...IRJET Journal
This document summarizes a computational fluid dynamics (CFD) analysis and structural analysis of a ribbed panel structure using finite element analysis (FEA). The analysis involved: 1) CFD to determine maximum pressure and velocity, 2) calculations to determine required plate thickness, 3) geometric modeling and meshing of the structure, and 4) static and transient structural analyses. The results showed the structure was safe under the applied pressure and impact loads with stresses and deflections within allowable limits, demonstrating the design was structurally sound. Section optimization also showed the same structural rigidity could be achieved with less weight.
This document summarizes a study that used Taguchi experimental design to optimize process parameters for friction stir welding of aluminum alloy 6063. Experiments varied tool rotational speed, welding speed, and axial force. Tensile testing found the highest strength (92 MPa) at a rotational speed of 1400 rpm, welding speed of 1.2 mm/sec, and axial force of 7 KN. Welding speed had the greatest influence on strength. Analysis of variance identified statistically significant parameters affecting strength. The optimal parameters achieved a joint efficiency of 70%.
IRJET- AODV and DSR Routing Protocol Performance Comparison in MANET using Ne...IRJET Journal
This document compares the performance of two mobile ad hoc network (MANET) routing protocols: Ad hoc On-Demand Distance Vector (AODV) and Dynamic Source Routing (DSR). The protocols were evaluated using the Network Simulator 2 (NS2) across three simulation scenarios with varying time durations. The results showed that AODV had lower initial packet loss compared to DSR. However, at longer simulation times both protocols performed similarly with comparable packet delivery ratios. In conclusion, AODV is more suitable when the MANET needs to be established quickly, while both protocols can be used for longer-term MANETs as their performance converges over time.
Designing, Fabricating, and Controlling of Shaped Metal Deposition System in ...Hassan Alwaely
This document summarizes Hassan Jasib Khudhair's master's thesis on designing, fabricating, and controlling a shaped metal deposition system for additive manufacturing. The research aims to develop a computer-aided double wire deposition machine controlled by a robotic arm. Experimental results show that process parameters like current, travel speed, and wire feed ratios influence bead geometry, hardness, and residual stress of deposited stainless steel parts. Finite element analysis of the system also shows that the design parameters allow for safe operation within specified stress limits. Overall, the study evaluates a new technique for additive manufacturing of metal parts using a cold wire feed method.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
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.
Conceptual design of laser assisted fixture for bending operationeSAT Publishing House
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
IRJET- Multi-Objective Optimization of WEDM Process Parameters of Ti-Ni S...IRJET Journal
The document discusses optimization of wire electrical discharge machining (WEDM) process parameters for machining titanium-nickel (Ti-Ni) shape memory alloy for biomedical applications. Eighteen experiments were conducted using Taguchi's L18 orthogonal array to evaluate the effects of five process parameters (pulse on time, pulse off time, servo voltage, wire feed, and wire tension) on material removal rate, surface roughness, and dimensional deviation as response variables. Grey relational analysis was used to determine the optimal parameter set that offers the maximum material removal rate and minimum surface roughness and dimensional deviation. Pulse on time was found to be the most influential parameter based on analysis of variance.
Die forging is a manufacturing process that shapes metal using localized compressive forces. It is classified by the temperature at which it occurs - cold, warm, or hot forging. Forged parts can range in weight from under a kilogram to 580 metric tons and usually require further processing. Forging produces stronger parts than casting or machining because the grain deforms to follow the shape, resulting in continuous grain and better strength. It involves shaping heated metal between top and bottom dies by hammering or pressing. Close die forging uses two engraved dies to form complex parts.
Forging processes involve shaping metals by applying compressive forces. There are four main types: hammer/drop forging uses gravity impacts, press forging uses hydraulic or mechanical presses, and open-die and closed-die forging differ in whether dies fully contain the metal. Forging increases strength by working the metal and altering its microstructure. Proper die and process design are needed to control metal flow, fill dies completely, and minimize flash and defects. Die materials must withstand thermal and mechanical stresses, while coatings can extend die life.
This document discusses various types of forging processes including hot forging, press forging, swaging, and cold forging. It describes how each process uses compressive forces and dies to shape metal at different temperatures. Examples of specific forging techniques are provided like hammer forging, drop forging, and upset forging. The document also outlines common forging tools, defects that may occur, and applications in small tools and automotive manufacturing.
1) Properties of the billet material and how it deforms under different conditions of strain, strain rate, and temperature
2) Geometry and properties of the forging tools and die interface
3) Conditions within the deformation zone such as metal flow, stresses, and temperatures during forming
Forging is a metalworking process that uses localized compressive forces to shape metal. It can be done cold or hot, with the metal heated in a forge for the latter two. Forged parts range in weight from less than a kilogram to hundreds of metric tons. Basic tools used in forging include furnaces, hammers, anvils, tongs, punches, and dies. There are several types of forging including impression die forging, cold forging, and open die forging. Impression die forging uses dies to restrict metal flow into a desired shape, allowing complex geometries. Cold forging is done without heating and includes processes like bending, drawing, and heading.
TALAT Lecture 3802: Physical Mechanism of SuperplasticityCORE-Materials
This lecture describes in general the physical mechanism of superplasticity and the microstructural changes which accompany superplastic forming. General background in production engineering and material science is assumed.
The document discusses sectional views and their importance in clearly showing internal features of objects that are difficult to understand through orthographic views alone. It describes different types of sectioning including full section, half section, local section, removed section, offset section, and thin section. Guidelines are provided for hatching techniques to denote cut areas and maintain clarity between different components and sections.
The document discusses smithy work and the smithing process. It describes three types of furnaces used - rotary hearth, batch, and conveyor furnaces. It then outlines the steps to convert a mild steel rod into an L-shape through heating, hammering, and cutting processes. Key steps include heating the rod in a rotary hearth furnace, hammering it while hot to flatten it, using a chisel and hammer to cut it to size, and hammering curves and angles into it. The total estimated cost for converting 0.5kg of mild steel rod into an L-shape at the smithy shop is approximately 68 rupees.
Sheet metal is metal formed into thin, flat pieces that can be cut and bent into various shapes. Common materials used for sheet metal include steel, aluminum, copper, brass, tin, nickel, and titanium. Sheet metal has many applications and can be found in products like car bodies, roofs, and medical tables. The thickness of sheet metal can vary significantly and is referred to as its gauge, with higher gauges being thinner. Sheet metal is cut, bent, and formed using various tools and processes like shearing, punching, bending, and drawing.
Forging Lubricants For The Hot Forging Of SteelsGustavo Schiuma
Die lubrication is key for quality and productivity in hot forging processes. The right lubricant must reduce friction to allow smooth metal flow while also releasing, cooling, and protecting the die to extend its life. Proper lubricant selection and application parameters are important. Forging lubricants typically contain graphite, which helps lubricate and release the forged part from the die. Maintaining consistent lubricant concentration and application are important for optimizing the forging process.
This document discusses various metal forming processes including rolling, forging, extrusion, drawing, and shearing. It covers bulk deformation processes like rolling, forging, and extrusion which involve large plastic deformation and changing the cross-section without changing the volume. It also discusses sheet metal processes and categorizes the forming processes based on temperature into cold, warm and hot working. Key rolling processes like flat rolling, thread rolling and ring rolling are described along with forging and extrusion processes.
This document provides an overview of blacksmithing and forging processes. It discusses that blacksmiths produce objects from metal using hand tools or power tools after heating the metal. The main forging processes covered are open die forging, impression die forging, and closed forging. Key forging operations like upsetting, drawing down, punching, and bending are also summarized. The document outlines common forging materials and various heating devices used like furnaces. Important hand tools for blacksmithing like hammers, tongs, chisels, and swages are also described.
This document provides an overview of blacksmithing and forging processes. It discusses the definition of forging as the controlled deformation of metal through pressure or impact. It also covers common forging materials, types of furnaces used to heat metal for forging, and hand tools used in blacksmithing like anvils and hammers. The document describes open die forging, impression die forging, and closed forging processes. It also lists and defines common forging operations like upsetting, drawing, setting down, and discusses defects that can occur.
Furnaces are used to heat materials and change their shape or properties. There are different types of furnaces classified by their heat source (combustion or electric), how material is charged (batch or continuous), and heat recovery methods. Efficient furnaces aim to uniformly heat materials to the desired temperature using minimal fuel and labor. Common furnace types include combustion furnaces fueled by oil, gas, or coal and electric furnaces. Continuous furnaces transport material through the furnace on conveyors, pushers, or walking beams and are used for steel reheating.
The document discusses two main forging processes: open die forging and closed die forging. Open die forging uses simple flat dies and is used for large or low volume parts. Closed die forging uses carefully machined matching dies to produce parts to close tolerances. The process involves preforming billets, rough forging in blocking dies, finishing in final dies, and trimming flash. Closed die forging produces parts with good dimensions and properties but requires high die costs for small volumes.
Leading Manufacturer & Supplier of Industrial Furnace like aluminium melting furnace, Industrial Heat Treatment Furnace, Bogie hearth furnace, Pit type furnace, Rotary Furnace etc. from South India
The document discusses various fundamentals of metal forming processes including hot working, cold working, and warm working operations. It describes different metal forming techniques like forging, rolling, extrusion, and describes tools used in smithy like anvil, hammers, swages, and forging operations like upsetting, drawing, bending, and punching.
Forging is an ancient metalworking process where a metal is compressed under force into a desired shape. It can be done using a hammer and anvil and produces parts with good strength and toughness. There are different types of forging processes, including open-die forging using flat dies, impression-die forging where the workpiece takes the shape of shaped die cavities, and coining where parts are precisely forged without lubricants between dies. Forged parts often require additional heat treating for optimal properties.
This document provides information about the design of furnaces for chemical engineering plant design. It begins with contact information for the course instructor and then provides recommendations for reference books on topics like process heat transfer and plant design economics. The document outlines different types of furnaces and their basic construction. It discusses heat transfer mechanisms like radiation and convection in furnaces. Methods for designing furnaces are presented, including Lobo and Evan's method which involves calculating an overall heat transfer coefficient and radiation flux. An example application of the Lobo and Evan's method is provided to design the radiant section of a furnace given specifications like total heat duty and tube dimensions.
It is used for measuring small dimensions. It consists of a blade and a stock.
(b)
Try Square: It is used for checking the squareness and for marking lines at right angles.
(c)
Combination Square: It is used for marking lines at right angles and for measuring depth.
(d)
Steel Tape: It is used for measuring long dimensions.
Marking Tools
(a)
Pencil: It is used for marking lines on wood.
(b)
Scriber: It is used for marking lines on wood and metal surfaces.
(c)
Dividers: It is used for transferring measurements and
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.
1) The document describes a study using DEFORM 3D software to simulate the cutting process and predict cutting edge temperatures.
2) The study varied cutting speed, feed rate, and depth of cut to determine the relationship between these parameters and the friction coefficient at the tool-chip interface.
3) The simulations found that the friction coefficient decreases with increasing cutting speed but increases with greater feed rates and depth of cut. Higher speeds and depths also led to higher interface temperatures.
This document discusses metal flow simulation and design of dies for close forging. It provides an introduction to simulation and modeling of metal forging processes using finite element analysis. It describes the process modeling inputs such as geometric parameters, material properties, interface conditions, and flow chart for modeling close die forging. The document presents results from simulations run with varying die and workpiece dimensions. It discusses advantages of simulation in reducing costs and time in product development as well as limitations such as inability to model non-axisymmetric geometries and temperature effects. Future work areas include cavity filling prediction and temperature rise prediction to optimize the forging 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.
A Study on Thermo-Mechanical Analysis of Hot Rolling & Estimation of Residual...IOSR Journals
The major problem in rolling process is the defects like fire cracks, severe sticking in a billet mill,
and etc. This paper deals with the study on reducing or minimizing the defects of rolling process. The analysis
has been carried out for different temperature i.e. 100°c, 150°c, 200°c, 250°c. As the temperature goes on
increasing correspondingly the residual stresses decreases. Hot rolling process helps in reduced residual
stresses at high temperature & helps in formation of smooth granular structure of product. Due to the symmetry
of the rolling components, half the model is built & the analysis is carried out with 4 roller sizes varying from
8mm to 20mm with 4mm increment & the results were tabulated by using ANSYS. This will helps in estimation
of residual stresses.
The document discusses finite element analysis (FEA) to model temperature distribution during the turning process. It begins with an introduction to turning and FEA modeling of machining processes. It then discusses heat generation zones in turning and methods for measuring temperatures, including thermocouples and pyrometers. The literature review covers previous research using FEA to study temperature, forces, stresses and strains in machining. The goal of the research is to develop an FEA simulation model to determine temperature distributions under different cutting conditions and tool materials.
Recent advances in semiconductor technology show the improvement of fabrication on
electronics appliances in terms of performance, power density and even the size. This great achievement
however led to some major problems on thermal and heat distribution of the electronic devices. This
thermal problem could reduce the efficiency and reliability of the electronic devices. In order to minimize
this thermal problem, an optimal cooling techniques need to be applied during the operation. There are
various cooling techniques have been used and one of them is passive pin fin heat sink approach. This
paper focuses on inline pin fin heat sink, which use copper material with different shapes of pin fin and a
constant 5.5W heat sources. The simulation model has been formulated using COMSOL Multiphysics
software to stimulate the pin fin design, study the thermal distribution and the maximum heat profile.
“Thickness optimization of inclined pressure vesseleIAEME Publication
The document discusses the design and analysis of an Inclined Pressure Vessel (IPV) used for the production of nitrous oxide. Finite element analysis is used to optimize the thickness of the IPV. The analysis shows that stresses in the vessel increase with inclination angle. The minimum required thickness is determined to be 5.6 mm with a reinforcement pad at the nozzle-vessel intersection to maintain stresses below allowable levels. Experimental testing of the optimized design includes ultrasonic inspection and a hydrostatic pressure test.
The quality of the machined piece and tool life are greatly influenced by determination of
maximum temperature of the cutting tool. Numerous researchers have approached to solve this problem
with experimental, analytical and numerical analysis. There is hardly a consensus on the basics principles
of the thermal problem in metal cutting, even though considerable research effort has been made on it. It is
exceedingly difficult to predict in a precise manner the performance of tool for the machining process. This
paper reviews work on the requirements for optimization of Tool wear so that its life could easily be
predicted
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.
TENSILE BEHAVIOUR OF ALUMINIUM PLATES (5083) WELDED BY FRICTION STIR WELDING IAEME Publication
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.
The document experimentally analyzes chip-back temperature during machining at different cutting parameters. An embedded thermocouple method was used to measure the temperature at the back of the cutting tool. Tests were conducted on an AISI 1010 steel workpiece using varying cutting speeds, feed rates, and depths of cut. The results showed that increasing any of the cutting parameters led to higher measured temperatures, with cutting speed having the greatest influence. Temperatures increased more substantially at lower cutting speeds compared to higher speeds. Feed rate had a relatively smaller impact on temperature than the other parameters.
Study On The External Gas-Assisted Mold Temperature Control For Thin Wall Inj...IJERA Editor
Dynamic mold surface temperature control (DMTC) has many advantages in micro-injection molding as well as thin-wall molding product. In this paper, DMTC will be applied for the thin-wall molding part with the observation of the weldline appearance and the weldline strength. The heating step of DMTC will be achieved by the hot air flow directly to the weldline area. The results show that the heating rate could be reached to 4.5C/s, which could raising the mold surface from 30C to over 120C within 15 s. The melt filling was operated with high temperature at the weldline area; therefore, the weldline appearance was eliminated. In addition, the weldline strength was also improved. The results show that the thinner part had the higher strength of the weldline.
IRJET- Effect of Thermal Properties on Fly Ash based ConcreteIRJET Journal
This document discusses an experimental study on the effect of thermal properties of fly ash-based concrete. Fly ash is obtained from a sugar industry and sieved into two grain sizes. Concrete slabs are prepared by replacing cement with 20%, 25%, and 30% fly ash fractions. Experiments are conducted to determine the thermal conductivity, coefficient of thermal expansion, specific heat, and thermal diffusivity of the concrete slabs and compared to normal concrete. The results show that fly ash concrete has lower thermal conductivity, higher specific heat capacity, and lower thermal expansion compared to normal concrete.
Stress distribution in grinding by finite element analysisBijoy Das
This document discusses a finite element analysis of stress distribution during grinding. A model is developed to evaluate stress induced during surface grinding of titanium grade 1. Temperature distribution in the grinding zone is modeled, and heat flux entering the workpiece is calculated for dry, wet, and wet with pneumatic barrier conditions. Residual stresses are then computed based on thermal and structural loading. Results show that stress generated can be minimized by using coolant and controlling infeed rate, and that simulation of experimental findings is possible using this technique.
STRESS DISTRIBUTION IN GRINDING BY FINITE ELEMENT ANALYSISBijoy Das
This document discusses a finite element analysis of stress distribution during grinding. The analysis models the temperature distribution and resulting stresses in a titanium workpiece under different grinding conditions (dry, wet, wet with pneumatic barrier) and infeeds (10, 20, 30 microns). The model calculates heat flux, temperature, and stresses based on material properties, grinding power, and heat transfer considerations. Results show that temperature profiles and residual stresses vary significantly depending on grinding environment and infeed parameters. Wet grinding and lower infeed generate less tensile stress than dry grinding or higher infeed rates.
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.
Design and Analysis of Pressure Vessel Using Finite Element MethodIJLT EMAS
Pressure vessel is used to carry liquids such as petrol,
kerosene, aviation fuel etc and these fuel tanks are used to
transport fuel. Finite element method is a mathematical
technique used to design a fuel carrying vessel and performing
the stress analysis. In this the geometrical model is created and
the model is sub divided into smaller elements. It is subjected to
internal pressure and these Boundary conditions are applied at
specified points. The aim of this paper is to design a model and
analysis of fuel carrying tank using finite element analysis
software and also select a proper material composition for
pressure vessel.
Designing is validated according to maximum principal stress
theory and Distortion theory by taking design factor or factor of
safety. The comparisons also made between the calculation
results and software results.
The quality of the machined piece and tool life are greatly influenced by determination of
maximum temperature of the cutting tool. Numerous researchers have approached to solve this problem
with experimental, analytical and numerical analysis. There is hardly a consensus on the basics principles
of the thermal problem in metal cutting, even though considerable research effort has been made on it. It is
exceedingly difficult to predict in a precise manner the performance of tool for the machining process. This
paper reviews work on the requirements for optimization of Tool wear so that its life could easily be
predicted.
MODELING AND EXPERIMENTAL STUDY OF THERMAL/ WEAR BEHAVIOR IN CAST IRON TURNIN...IAEME Publication
The present works involves the study of thermal and wear behaviour of tool and work interface. Experiments were conducted on a precision centre lathe and cutting forces, temperature at tool tip, thickness and weight of Chips
formed during machining along with tool wear data were recorded. The influence of cutting parameters was studied.
Based on the main effects plots obtained. Finite element analysis was done using ANSYS software tool and was used to
find the tool tip deflection, counterplots. Thermal analysis was done to determine the temperature distribution over
machining interface.
2. 238 O. Brucelle, G. Bernhart / Journal of Materials Processing Technology 87 (1999) 237–246
Fig. 3. Crack network of the punch.
corresponds to what is commonly called ‘heat check-
ing’. This type of damage is the result of constraints
Fig. 1. Final and initial shape of the workpiece.
generated by high thermal gradients. During forging,
and the final shape of the part are presented in Fig. 1. the surfaces of the dies are subjected to a thermal flux
The tooling system (Fig. 2) includes several pieces; of ]1 MW m − 2, whereas, between two successive
amongst them a cemented carbide punch on which the operations, the surface temperature drops. Locally, the
present study is focused. The forging operation is per- surfaces of the tools are subjected to thermomechanical
formed with a 200 t press, with the workpiece initially fatigue (TMF) cycling which can exceed the purely
at 1000°C. The drop of the punch is done in 0.3 s and elastic-behaviour domain, and cause the initiation of
the effective contact duration between the tool and the cracks.
billet is :30 ms. Thermal fatigue is the result of a partially or com-
After a few hundred forging operations, the punch pletely constrained thermal expansion [5]. It can be the
shows [4] (Figs. 3 and 4) a circumferential crack at the result of internal constraints due to thermal gradients
fillet radius 2 and a network of cracks at the shoulder 3. or material heterogeneities, and external constraints due
After : 500 cycles, a coalescence of cracks occurs near to the mechanical loads on the surface [6]. In this
to shoulder 3 and initiates surface damages by splitting paper, the two types of constraints are superimposed;
off: the punch has to be changed at this time. moreover, this is the general case encountered in such
The crack at fillet radius 2 is a ‘mechanical induced’ type of industrial problems.
crack, in contrast to the network at shoulder 3, which
3. Methodological approach
3.1. General description of the methodology
The problem has been solved in the following way
(Fig. 5):
Fig. 2. Tooling system. Fig. 4. Details of cracking.
3. O. Brucelle, G. Bernhart / Journal of Materials Processing Technology 87 (1999) 237–246 239
Fig. 5. Methodological approach.
1. The forging process was simulated with the step 5: postprocessing of the FORGE2® results and
FORGE2® computer code. No coupling was made extraction of the temperature–time evolution laws on
intentionally between the mechanical and thermal the punch surface nodes,
loads. The results are the purely mechanical stresses step 6: punch thermal mesh generation with IDEAS®
in the punch and the evolution of the surface tem- software,
perature of the punch; step 7: ABAQUS® input data file preparation for the
2. After meshing with IDEAS® software, the thermal thermoelastic calculation of the punch thermomech-
stresses of the punch have been calculated with nical stress distribution,
ABAQUS®; step 8: validation of the thermal gradients at the
3. Validation of the two previous simulations have punch surface. For this, thermal measurements with
been performed by experimental tests. an instrumented punch have been made on the indus-
In more detail, the methodological approach com- trial facility and are compared to the calculated
bines nine steps: values. This step validates, in particular, the die/
step 1: mesh generation of the workpiece and the workpiece heat transfer coefficient.
punch with the integrated mesh generation tool of step 9: post-processing of ABAQUS® results: thermal
FORGE2® stress distribution in the punch.
step 2: tool data file definition (punch forging speed,
number of tools, geometries,…), 3.2. Forging process simulation and 6alidation
step 3: FORGE2® input data file definition (material
properties, interface properties,…) and process General description of the FORGE2® process simu-
simulation, lation tool can be found in [7]. During simulation, four
step 4: validation of step 3 through the expertise of a components are taken into account: three tooling com-
forged part. The calculated flow-line is compared to ponents and the workpiece. The elements related to the
the observed flow-line with the aim of validating the lower die and the ejector are considered as rigid bodies,
material flow during the forging operation and, as a the punch is assumed to have thermo-elastic behaviour
consequence, the process simulation step for the part and the workpiece to have thermo-elasto-viscoplastic
related to the mechanical loads. behaviour.
Table 1
Physical properties of the punch materials
Material E (GPa) 6 z (g cm−3) Cp (J kg−1 K−1) K (W m−1 K−1) h (10−6 °C−1)
WC–Co 85–15 530 0.23 14 220 100 5.8
X85WCrMoV6-5-4-2 216 0.29 8.15 439 20 12
4. 240 O. Brucelle, G. Bernhart / Journal of Materials Processing Technology 87 (1999) 237–246
Fig. 6. Flow line comparison.
|0
The physical properties of the punch materials are
~
= v · |n, if v · |n B m ·
¯
listed in Table 1.
3
The elastic behaviour of the billet material is de- |0 |
~
= m ·
¯ , if v · |n m · 0
¯
scribed by assuming that its Youngs modulus follows a
3
3
linear law with temperature in the form: with:
E =E0 · (1 −aT) where E0 and a are constants. |n =
3 · K(m,T) · (
3 · m;¯ )m
¯
A Norton–Hoff law is used to describe the visco- where m is the shear friction factor; v is the Coulomb
¯
plastic behaviour. In FORGE2® the tensorial formula- friction coefficient; |0 is the flow stress; ~ is the friction
tion is: shear stress; and |n is the normal stress at the interface.
s =2 · K(T,m ) · (
3 · m;¯ )m − 1 · m;
¯ The heat exchange at the interface boundary involves
conductive heat-transfer and dissipative energy due to
where: friction. Radiative transfer is negligible.
K(T,m )= K0 · (m +m0)n · e − i · T
¯ ¯ ¯ A comparison was made between the predicted work-
piece flow-line and the observed flow-line on a sec-
i, K0 and m0 are constants, T is temperature, K is
¯ tioned airbag part, after etching. The similarity of the
consistency, m is the strain-rate exponent, s is the stress two figures (Fig. 6) validates the material constitutive
deviator, m is the effective strain, m;¯ is the effective
¯ laws and tribological laws used for simulation.
strain-rate and n is the hardening coefficient. As a consequence, the purely mechanical stresses in
The corresponding AISI 316L material parameters the punch are available.
are listed in Table 2 [7].
The interface description between the tool and the 3.3. Thermal stress analysis
workpiece takes into account the three following as-
pects: contact, friction and heat transfer. The friction The thermomechanical stress analysis is only focused
law used during simulation is the Coulomb law limited on the punch and is performed with ABAQUS® soft-
by Tresca shear stress: ware to obtain a more precise analysis of the thermal
Table 2
AISI 316L material parameters
E0 (GPa) a (°C−1)1 i (°C−1) n K (kg m−1 s−1.936) m
216 −3.773×10−4 0.215×10−2 0.205 0.1777×107 0.6400 ×10−1
5. O. Brucelle, G. Bernhart / Journal of Materials Processing Technology 87 (1999) 237–246 241
3.4. Experimental punch temperature monitoring
It is of prime importance to be confident with the
temperature distribution inside the punch during suc-
cessive forging operations. The calculated surface tem-
peratures are directly linked to the heat-transfer
coefficient at the tool/workpiece interface. It is known
that the heat-transfer coefficient is affected by numer-
ous factors [8]; amongst them the more important being
contact pressure, the surface topography, duration of
contact and temperature difference level.
A punch was instrumented with type K thermocou-
ples; for practical and economical reasons, a tool steel
(X85WCrMoV6-5-4-2) was used for the manufacture of
the test punch. After preliminary simulations (with
thermal properties of this type of material, see Table 1),
Fig. 7. Punch meshing. five thermocouples were located in the test punch as
shown in Fig. 8, some of them at 1 mm beneath the
gradient and the induced thermal stresses. For this, a surface. The tests were been performed on an industrial
special mesh, refined near to the surface, has been press without any lubricant.
generated with IDEAS® software (Fig. 7). The punch is Data acquisition during testing was performed with a
considered as thermo-elastic, and only a thermal load computer system at a rate of 100 Hz. Typical experi-
case analysis is performed. This load case is defined by mental evolution of the thermal response at the various
the thermal evolution at the surface nodes: tempera- locations in the test punch are presented in Fig. 9. It
ture –time profiles during forging, derived from the can be noted that in the punch itself, the thermal wave
process simulation, and a low convective flux during is smoothed and shifted in time, in comparison with the
the waiting periods. 30 ms duration of contact.
Fig. 8. Thermocouple location.
6. 242 O. Brucelle, G. Bernhart / Journal of Materials Processing Technology 87 (1999) 237–246
Fig. 9. Experimental temperature evolution.
Successive numerical iterations have been per- was identified as heat transfer coefficient for the defi-
formed changing the value of the heat-transfer coeffi- nition of the cemented carbide punch thermal load
cient, until the calculated temperature evolution was case. Reference [9] reports such a value for high con-
in agreement with the experimental thermocouple re- tact pressure and high temperature difference
sponse. As a result, a value of 15 kW m − 1 K − 1 (1000°C).
Fig. 10. Von Mises mechanical stress (MPa).
7. O. Brucelle, G. Bernhart / Journal of Materials Processing Technology 87 (1999) 237–246 243
Fig. 11. Simulated temperature evolution.
4. Results and discussion from the thermal stress); and (ii) at shoulder 3, the
maximum stresses are compressive in the circonferential
4.1. Mechanical and thermomechanical stress direction (along the outer diameter of the punch),
distribution reaching a level of − 2300 MPa ( − 700 MPa from the
mechanical and − 1600 MPa from the thermal stress).
The purely mechanical stresses in the punch are
compressive stresses, and the equivalent Von Mises 4.2. Discussion
stress distribution in the punch as shown in Fig. 10, for
the maximum forging load. Near to the surface, the 4.2.1. Cemented carbide beha6iour
stresses are generally low (:200 – 300 MPa), except in Cemented carbide material properties are linked
fillet radius 2 and at the end of shoulder 3, where they closely to the Co content and the WC particle size. In
reach a level of 600 –700 MPa. tension and compression, the WC–Co composite ex-
Temperature profiles on the punch surface are plot- hibits an elasto-plastic behaviour. The onset of plastic
ted for different points in Fig. 11. These temperatures deformation depends on the material composition, as
can reach 700°C at shoulder 3 (point 4) and shoulder 1 shown in [10]. The punch is manufactured with a 85–15
(point 2), with the evolution versus time being different WC–Co material. SEM investigations have shown that
at each location. The temperature distribution in the the mean particle size is close to 2.5 mm (Fig. 14).
punch at the end of the forging step is illustrated in Fig. For such compositions, reference [10] reports a true
12. The sharp thermal gradient induces high thermal elastic limit (at 0.002%) of 1050 MPa and a conven-
stress distribution, shown in Fig. 13. The stresses are tional limit (at 0.2%) of elasticity of 3100 MPa at room
compressive on the surface, the equivalent stresses temperature. The elastic and rupture properties de-
reaching a value of 1360 MPa. crease slowly up to 600°C, whereas at higher tempera-
If the type of stresses is explores more closely, it can ture, a modification of the stress–strain curve is
be seen that the highest levels are located at the same observed [11].
places as the cracks, and that: (i) at fillet radius 2, the A stress level of 2400 MPa, as calculated previously,
maximal stresses are compressive in the zz direction corresponds to a plastic deformation as high as 0.1%
(punch motion direction) having a level of −2450 MPa when related to room temperature properties and prob-
(− 1050 MPa from the mechanical and −1400 MPa ably much higher at 700°C. As a consequence, the
8. 244 O. Brucelle, G. Bernhart / Journal of Materials Processing Technology 87 (1999) 237–246
Fig. 12. Temperature distribution (°C).
material is subjected to low cycle fatigue which is able been shown that a decrease of 50% of the heat transfer
to induce cracks after a limited number of cycles. coefficient can be reached [12]. The first option was
followed in this study.
4.2.2. Options for ser6ice life increase
Without taking into account punch material changes 4.2.3. Process parameter modification
and coatings, service life increase requires a decrease in Taking into account the capacities of the industrial
the stress and temperature level in the punch. The press, a numerical parametric study has been performed,
thermal stresses are as high as 75% of the total stress and the influence of the forging speed and the initial
field in the critical areas of the punch; as a conse- workpiece temperature on the final thermomechanical
quence, a reduction of the thermal gradient during stresses have been studied. An optimum has been found
forging must be obtained. for the following conditions: initial workpiece tempera-
Two ways may be used; the first involving a change ture, 500°C; forging speed decreased by a factor of 1.5.
of the process parameters to decrease the temperature. With these process parameters, the forging load is
This solution is based on the following points: (i) a : 140 t and the maximum punch surface temperature is
decrease of the workpiece temperature increases the close to 600°C in shoulder 3. The resulting thermal
flow stress and the related forging load. However, the stress distribution is shown Fig. 15. The maximum
capacity of the available press is much greater than equivalent Von Mises stress is close to 1000 MPa which
needed: (30 t used out of 200 t available); and (ii) a corresponds to a decrease of 30%. Circonferential and
decrease of the punch speed allows a decrease of the longidudinal zz stresses are reduced by the same
flow stress. The second way consists of using lubricat- proportion.
ing/insulating products during forging to decrease To avoid an increase of purely mechanical stresses in
workpiece/die heat transfer. The selection of an ade- fillet radius 2, further design modification of the punch
quate product remains empirical even though it has is required [13].
9. O. Brucelle, G. Bernhart / Journal of Materials Processing Technology 87 (1999) 237–246 245
Fig. 13. Thermal stress distribution (MPa).
5. Conclusions This work describes the methodological approach
that has been applied to study the reasons for the crack
The lifetime of hot forging dies is often shortened by formation and to propose a solution to increase the
surface cracking and subsequent material splitting. This lifetime.
has been observed on a punch used in a one-step A combined numerical and experimental approach is
forward/backward hot forging process. mandatory:
1. A two-step numerical simulation: first, process simu-
lation allows the calculation of purely mechanical
stresses, forging load and punch thermal boundary
conditions; second, thermo-elastic simulation for
thermal stress analysis of the punch.
2. A two-step experimental work: metallurgical obser-
vation allows the validation of workpiece material
constitutive laws and industrial tests allow punch
thermal boundary conditions.
It has been shown that thermal stresses, induced by
the sharp thermal gradient during forging, correspond
to 75% of the total stress field in the areas of surface
cracking. After a parametric analysis, a modification of
the forging process parameters (workpiece temperature
and punch velocity) has been proposed.
This work clearly shows the benefits of a methodol-
ogy based on combined numerical and experimental
Fig. 14. 85 – 15 WC–Co microstructure. approaches to determine the thermomechanical stress
10. 246 O. Brucelle, G. Bernhart / Journal of Materials Processing Technology 87 (1999) 237–246
Fig. 15. Resulting thermal stress distribution (MPa).
field in hot forging tools, and, consequently to derive [5] D.A. Spera, What is thermal fatigue? Thermal fatigue of materi-
als components, ASTM, Am. Soc. Testing Mater., Soc. Technol.
solutions for lifetime increase.
Plast. 612 (1976) 3 – 9.
[6] A.Dias, H.P. Lieurade, La fatigue thermique, mecanismes, simu-
´
lation et modelisation, Revue Bibliographique, IRSID, RFP 437,
´
Acknowledgements mai 1987.
[7] FORGE2® v.2.7 Bidimensional Forging Processes; Transvalor
SA; user manual, November 1994..
The authors would like to acknowledge Mr. Series [8] B. Snaith, S.D. Probert, P.W. O’Callaghan, Thermal resistances
from the company Mecaero for his financial and techni-
´ of pressed contacts, Appl. Energy 22 (1986) 31 – 84.
cal support to this study. [9] Z. Malinowski, J.G. Lenard, M.E. Davies, A study of the heat
transfer coefficient function of temperature and pressure, J.
Mater. Process. Technol. 41 (1994) 125 – 142.
[10] H. Doi, Elastic and Plastic Properties of WC – Co Composite
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