| 1. |
- Adane, Tigist Fetene, et al.
(författare)
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Towards a Generic Framework for the Performance Evaluation of Manufacturing Strategy : An Innovative Approach
- 2018
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Ingår i: JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING. - : MDPI AG. - 2504-4494. ; 2:2
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Tidskriftsartikel (refereegranskat)abstract
- To be competitive in a manufacturing environment by providing optimal performance in terms of cost-effectiveness and swiftness of system changes, there is a need for flexible production systems based on a well-defined strategy. Companies are steadily looking for methodology to evaluate, improve and update the performance of manufacturing systems for processing operations. Implementation of an adequate strategy for these systems' flexibility requires a deep understanding of the intricate interactions between the machining process parameters and the manufacturing system's operational parameters. This paper proposes a framework/generic model for one of the most common metal cutting operations-the boring process of an engine block machining system. A system dynamics modelling approach is presented for modelling the structure of machining system parameters of the boring process, key performance parameters and their intrinsic relationships. The model is based on a case study performed in a company manufacturing engine blocks for heavy vehicles. The approach could allow for performance evaluation of an engine block manufacturing system condition. The presented model enables a basis for other similar processes and industries producing discrete parts.
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| 2. |
- da Silva, Leandro Joao, et al.
(författare)
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Work Envelope Expansion and Parametric Optimization in WAAM with Relative Density and Surface Aspect as Quality Constraints : The Case of Al5Mg Thin Walls with Active Cooling
- 2021
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Ingår i: JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING. - : MDPI. - 2504-4494. ; 5:2
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Tidskriftsartikel (refereegranskat)abstract
- The successful and efficient production of parts with specific features by Wire + Arc Additive Manufacturing (WAAM) strongly depends on the selection of proper and typically interrelated deposition parameters. This task might be particularly challenging in the making of thin walls, which might be highly impacted by processing conditions and heat accumulation. In this context, this study aims at expanding the work envelope and optimizing the parametric conditions in WAAM with relative density and surface aspects of the preforms as quality constraints. The experimental approach was based on the deposition of thin Al5Mg walls by the CMT process on its standard welding setup and with an active cooling technique to enhance the deposition robustness. Internal voids were estimated by Archimedes’ method. The surface quality of the walls was assessed through the visual aspect and the surface waviness by cross-section analysis. All the conditions presented relative density higher than 98%. The upgrade of the standard welding hardware to WAAM purposes through the addition of a supplementary shielding gas nozzle to the torch and the intensity of the heat sinking from the part significantly expanded the process work envelope, with its applicability being successfully demonstrated with multi-objective optimization. To sum up, a decision-making procedure is presented towards achieving intended preform quality.
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| 3. |
- Dahat, Shubham, 1996-, et al.
(författare)
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A Methodology to Parameterize Wire + Arc Additive Manufacturing : A Case Study for Wall Quality Analysis
- 2020
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Ingår i: Journal of Manufacturing and Materials Processing. - : MDPI. - 2504-4494. ; 4:1
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Tidskriftsartikel (refereegranskat)abstract
- The objective of this work was the development of a methodology to parametrize wire + arc additive manufacturing (WAAM), aiming dimension repeatability, and tolerances. Parametrization of WAAM is a difficult task, because multiple parameters are involved and parameters are inter-dependent on each other, making overall process complex. An approach to study WAAM would be through operational maps. The choice of current (Im) and travel speed (TS) for the desirable layer width (LW) determines a parametrization that leads to either more material or less material to be removed in post-operations, which is case study chosen for this work. The work development had four stages. First stage, named ‘mock design’, had the objective of visualizing the expected map and reduce further number of experiments. At the second stage, ‘pre-requisite for realistic operational map’, the objective was to determine the operating limits of TS and Im with the chosen consumables and equipment. Within the ‘realistic operational map’ stage, a design for the experiments was applied to cover a parametric area (working envelope) already defined in the previous stage and long and tall walls were additively manufactured. Actual values of LW (external and effective layer width) were measured and an actual operating envelope was reached. According to the geometry-oriented case study, a surface waviness index (SWindex) was defined, determined, and overlapped in the envelope. It was observed that the walls with parameters near the travel speed limits presented higher SWindex. This operational map was further validated (fourth stage) by selecting a target LW and finding corresponding three parametric set (covering the whole range of operational map) to produce walls on which geometry characterization was carried out. After geometry characterization, obtained LW was compared with the target LW (the maximum values were very tied, with deviations from +0.3 to 0.5 mm), with a SWindex deviation at the order of 0.05. Both results evidence high reproductivity of the process, validating the proposed methodology to parametrize WAAM.
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| 4. |
- Holmberg, Jonas, 1976-, et al.
(författare)
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Surface integrity investigation to determine rough milling effects for assessment of machining allowance for subsequent finish milling of alloy 718
- 2021
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Ingår i: Journal of Manufacturing and Materials Processing. - : MDPI AG. - 2504-4494. ; 5:2
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Tidskriftsartikel (refereegranskat)abstract
- The planned material volume to be removed from a blank to create the final shape of a part is commonly referred to as allowance. Determination of machining allowance is essential and has a great impact on productivity. The objective of the present work is to use a case study to investigate how a prior rough milling operation affects the finish machined surface and, after that, to use this knowledge to design a methodology for how to assess the machining allowance for subsequent milling operations based on residual stresses. Subsequent milling operations were performed to study the final surface integrity across a milled slot. This was done by rough ceramic milling followed by finish milling in seven subsequent steps. The results show that the up-, centre and down-milling induce different stresses and impact depths. Employing the developed methodology, the depth where the directional influence of the milling process diminishes has been shown to be a suitable minimum limit for the allowance. At this depth, the plastic flow causing severe deformation is not present anymore. It was shown that the centre of the milled slot has the deepest impact depth of 500 µm, up-milling caused an intermediate impact depth of 400 µm followed by down milling with an impact depth of 300 µm. With merged envelope profiles, it was shown that the effects from rough ceramic milling are gone after 3 finish milling passes, with a total depth of cut of 150 µm. © 2021 by the authors.
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| 5. |
- Khodaee, Alireza, 1984-, et al.
(författare)
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Numerical and Experimental Analysis of the Gear Size Influence on Density Variations and Distortions during the Manufacturing of PM Gears with an Innovative Powder Processing Route Incorporating HIP
- 2018
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Ingår i: Journal of manufacturing and material processing. - : MDPI AG. - 2504-4494. ; 2:3, s. 49-
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Tidskriftsartikel (refereegranskat)abstract
- The paper is the result of research intended to develop a process route for the manufacturing of powder metallurgical (PM) gears for application in transmissions units for heavy duty powertrain applications. The main problem of PM for such applications is that the generated pores that occur through conventional pressing and sintering processes reduce the gear strength, which reduces the capacity for power transmission by the gear. In prior work, removing the pores and reaching 100% density by adding Hot Iso-static Pressing (HIP) after two times pressing and two times sintering steps in the process route was suggested to solve the mentioned problem. During the investigations of this work it was revealed that the gear dimensions could influence the process results with respect to geometrical distortions. In this paper we have presented a finite element (FE) model based analysis on how the gear geometrical parameters influenced the distortions occurring in HIP. The simulation model is validated with experiments. Furthermore, the simulation model is used to create a prediction model for further investigations. The research showed that PM gears with different sizes during the proposed process route behaved differently in terms of distortions. This was illustrated with a series of simulations with different gear geometries. A regression model was developed based on the FE results for further practical predictive use. The distortions caused by HIP should be considered in the process design to prevent expensive post processes afterwards to reach the gear with accurate geometry and keep the costs of manufacturing low. It is concluded that it is possible to use the innovative process route including HIP to reach the full density and close all the open pores but not for all kind of gear geometries.
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| 6. |
- Law, Madeleine, et al.
(författare)
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Assessment of Mechanisms for Particle Migration in Semi-Solid High Pressure Die Cast Aluminium-Silicon Alloys
- 2020
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Ingår i: Journal of manufacturing and materials processing. - Basel, Switzerland : MDPI AG. - 1042-6914 .- 1532-2475 .- 2504-4494. ; 4:51
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Tidskriftsartikel (refereegranskat)abstract
- In semi-solid metal high pressure die casting and in conventional high pressure die casting, it is common to find a defect band just below the surface of the component. The formation of these bands is not fully understood. However, there are several theories as how they occur, and it has been suggested that segregation is caused by the migration of aluminium-rich externally solidified crystals. In the present work the formation of these bands is investigated theoretically by reviewing suitable potential mechanisms for the migration of such crystals. Two mechanisms are identified as the most probable: Saffman lift force and the Mukai-Lin-Laplace effect. However, it was not possible to identify which of these two mechanisms acted in the case studies. Further testing is required to identify the mechanism that is causing the migration of the aluminium globules and suitable tests are proposed.
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| 7. |
- Liu, Zhibo, et al.
(författare)
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Research on Tool Wear Based on 3D FEM Simulation for Milling Process
- 2020
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Ingår i: JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING. - : MDPI AG. - 2504-4494. ; 4:4
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Tidskriftsartikel (refereegranskat)abstract
- In the process of metal cutting, the anti-wear performance of the tool determines the life of the tool and affects the surface quality of the workpiece. The finite element simulation method can directly show the tool wear state and morphology, but due to the limitations of the simulation time and complex boundary conditions, it has not been commonly used in tool life prediction. Based on this, a tool wear model was established on the platform of a finite element simulation software for the cutting process of titanium alloy TC4 by end milling. The key technique is to embed different types of tool wear models into the finite element model in combination with the consequent development technology. The effectiveness of the tool wear model was validated by comparing the experimental results with the simulation results. At the same time, in order to quickly predict the tool life, an empirical prediction formula of tool wear was established, and the change course of tool wear under time change was obtained.
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| 8. |
- Torkamani, Hadi, et al.
(författare)
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Effect of Rotation Speed and Steel Microstructure on Joint Formation in Friction Stir Spot Welding of Al Alloy to DP Steel
- 2022
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Ingår i: Journal of Manufacturing and Materials Processing. - : MDPI. - 2504-4494. ; 6:1
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Tidskriftsartikel (refereegranskat)abstract
- In this work, friction stir spot welding of 5754 aluminum alloy to dual phase steel was investigated using two different ratios of martensite and ferrite (0.38 and 0.61) for steel sheet initial microstructure and varying tool rotation speed (800, 1200 and 2000 rpm). The effect of these parameters on the joint formation was evaluated by studying the plunging force response during the process and the main characteristics of the joint at (i) macrolevel, i.e., hook morphology and bond width, and (ii) microlevel, i.e., steel hook and sheet microstructure and intermetallic compounds. The plunging force was reduced by increased tool rotation speed while there was no significant effect from the initial steel microstructure ratio of martensite and ferrite on the plunging force. The macrostructural characterization of the joints showed that the hook morphology and bond width were affected by the steel sheet initial microstructures as well as by the tool rotation speed and by the material flow driver; tool pin or shoulder. At microstructural level, a progressive variation in the ratio of martensite and ferrite was observed for the steel hook and sheet microstructure. The zones closer to the tool presented a fully martensitic microstructure while the zones away from the tool showed a gradual increase in the ferrite amount until reaching the ratio of ferrite and martensite of the steel sheet initial microstructure. Different types of FexAly intermetallic compounds were found in three zones of the joint; the hook tips, in the hooks close to the exit hole and in the corner of the exit hole. These compounds were characterized by a brittle behavior with hardness values varying from 456 to 937 HV01.
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| 9. |
- Tsagkir Dereli, Tountzer, et al.
(författare)
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Simulation based prediction of compliance induced shape deviations in internal traverse grinding
- 2021
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Ingår i: Journal of Manufacturing and Materials Processing. - : MDPI AG. - 2504-4494. ; 5:2
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Tidskriftsartikel (refereegranskat)abstract
- Internal traverse grinding (ITG) using electroplated cBN tools in high-speed grinding conditions is a highly efficient manufacturing process for bore machining in a single axial stroke. However, process control is difficult. Due to the axial direction of feed, changes in process normal force and thus radial deflection of the tool and workpiece spindle system, lead to deviations in the workpiece contour along the length of the bore, especially at tool exit. Simulations including this effect could provide a tool to design processes which enhance shape accuracy of components. A geometrical physically-based simulation is herein developed to model the influence of system compliance on the resulting workpiece contour. Realistic tool topographies, obtained from measurements, are combined with an FE-calibrated surrogate model for process forces and with an empirical compliance model. In quasistatic experimental investigations, the spindle deflection is determined in relation to the acting normal forces by using piezoelectric force measuring elements and eddy current sensors. In grinding tests with in-process force measurement technology and followed by measurement of the resulting workpiece contours, the simulation system is validated. The process forces and the resulting characteristic shape deviations are predicted in good qualitative accordance with the experimental results.
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| 10. |
- Xu, Dongdong, et al.
(författare)
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Investigation of the influence of tool rake angles on machining of inconel 718
- 2021
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Ingår i: Journal of Manufacturing and Materials Processing. - : MDPI AG. - 2504-4494. ; 5:3
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Tidskriftsartikel (refereegranskat)abstract
- It is essential for superalloys (e.g., Inconel 718) to obtain an anticipated surface integrity after machining, especially for safety critical areas (e.g., aerospace). As one of the main characteristics for cutting tools, the rake angle has been recognized as a key factor that can significantly influence the machining process. Although there are large research interests and outcomes in the machining of nickel-based superalloys, most of them focus on the surface integrity and macroscale temperature observation, whereas the temperature distribution in the tool rake face is not clear. Thus, it is necessary to investigate the basic role of rake angles and the tool–workpiece interaction mechanism to determine the machining condition variations and surface integrity. In the present study, both experimental and numerical methods are employed to explore the cutting force, thermal distribution, and shear angles during the process and the metallurgy characteristics of the subsurface after machining, as well as the mechanical properties. The research has emphasized the importance of rake angles on both the cutting process and machined surface integrity, and has revealed the microscale temperature distribution in the tool rake face, which is believed to have a close relationship with the tool crater wear. In addition, it is clearly presented that the surface generated with positive rake angle tools generates the minimum subsurface deformation and less strain hardening on the workpiece.
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| 11. |
- Yacob, Filmon, et al.
(författare)
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Octree-Based Generation and Variation Analysis of Skin Model Shapes
- 2018
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Ingår i: Journal of Manufacturing and Material Processing. - : MDPI AG. - 2504-4494. ; (3):52
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Tidskriftsartikel (refereegranskat)abstract
- The concept of Skin Model Shape has been introduced as a method for a close representation of manufactured parts using a discrete geometry representation scheme. However, discretized surfaces make irregular polyhedra, which are computationally demanding to model and process using the traditional implicit surface and boundary representation techniques. Moreover, there are still some research challenges related to the geometrical variation modelling of manufactured products; specifically, methods for geometrical data processing, the mapping of manufacturing variation sources to a geometric model, and the improvement of variation visualization techniques. To provide steps towards addressing these challenges this work uses Octree, a 3D space partitioning technique, as an aid for geometrical data processing, variation visualization, variation modelling and propagation, and tolerance analysis. Further, Skin Model Shapes are generated either by manufacturing a simulation using a non-ideal toolpath on solid models of Skin Model Shapes that are assembled to non-ideal fixtures or from measurement data. Octrees are then used in a variation envelope extraction from the simulated or measurement data, which becomes a basis for further simulation and tolerance analysis. To illustrate the method, an industrial two-stage truck component manufacturing line was studied. Simulation results show that the predicted Skin Model Shapes closely match to the measurement data from the manufacturing line, which could also be used to map to manufacturing error sources. This approach contributes towards the application of Octrees in many Skin Model Shape related operations and processes.
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| 12. |
- Yehorov, Yuri, et al.
(författare)
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Balancing WAAM Production Costs and Wall Surface Quality through Parameter Selection : A Case Study of an Al-Mg5 Alloy Multilayer-Non-Oscillated Single Pass Wall
- 2019
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Ingår i: Journal of Manufacturing and Materials Processing. - : MDPI. - 2504-4494. ; 3:2, s. 1-19
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Tidskriftsartikel (refereegranskat)abstract
- The purpose of the study was to propose a strategy to assess the potential reduction of the production cost during wire+arc additive manufacturing (WAAM) based on the combination of wire feed speed (related to deposition rate) and travel speed (related to deposition time). A series of experiments, using a multilayer-non-oscillated single pass wall made of an Al-Mg alloy, was conducted. The quality of the wall was assessed through the lateral surface waviness and top layer undulation. The concepts of Surface Waviness and Buy-to-Apply indices were introduced. Initially, the range of travel speed (TS) that provided layers with acceptable quality was determined for a given wire feed speed (WFS), corresponding to a constant current. Then, the effect of the increase of production capacity of the process (though current raising, yet maintaining the ratio WFS/TS constant) on the wall quality for a given condition within the TS range was assessed. The results showed that the useful range of TS prevents too rough a waving surface below the lower limit and top surface undulation over the higher limit. However, inside the range, there is little quality variation for the case under study. Finally, simulations of deposition time were developed to demonstrate the weight of the TS on the final deposition time and wall quality as a function of a target wall width. This respective weight showed the existence of a complex and unpredictable, yet determined, power of a combination of TS, target wall geometry, and dead time between subsequent layers. It was verified to be possible to find optimized TS as a function of different target geometries.
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| 13. |
- Zhou, Jinming, et al.
(författare)
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Comparative assessment of the surface integrity of AD730® and IN718 superalloys in high-speed turning with a CBN tool
- 2019
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Ingår i: Journal of Manufacturing and Materials Processing. - : MDPI AG. - 2504-4494. ; 3:3
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Tidskriftsartikel (refereegranskat)abstract
- Nickel-based superalloys are typical materials used in components of aeroengines and gas turbine machinery. The strength properties of these alloys at high temperatures are crucial not only to the performance (e.g., power generation efficiency, energy consumption, and greenhouse gas emissions) of aeroengines and industrial gas turbines, but also to machinability during component manufacturing. This study comparatively evaluated the surface integrity of two superalloys, AD730® and Inconel 718 (IN718), during high-speed finishing turning using cubic boron nitride (CBN) tools. IN718 is a conventional superalloy used for the hot section components of aeroengines and industrial gas turbines, while AD730® is a novel superalloy with enhanced high-temperature mechanical properties and good potential as a next-generation superalloy for these components. High-speed turning tests of two superalloys were conducted using a CBN cutting tool and jet stream cooling. The achieved surface integrity of the AD730® and IN718 superalloys was characterized and analyzed to assess the comparability of these alloys.
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| 14. |
- Ahlsell, Levin, et al.
(författare)
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Additive Manufacturing of Slow-Moving Automotive Spare Parts: A Supply Chain Cost Assessment
- 2023
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Ingår i: Journal of Manufacturing and Materials Processing. - : MDPI AG. - 2504-4494. ; 7:1
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Tidskriftsartikel (refereegranskat)abstract
- This study develops a cost model for the additive manufacturing (AM)-produced spare parts supply chain in the automotive industry. Moreover, we evaluate the economic feasibility of AM for slow-moving automotive spare parts by comparing the costs of the traditional manufacturing (TM) spare parts supply chain (SPSC) with centralized, outsourced AM SPSC. Data from a multiple case study of an OEM in the automotive industry regarding SPSC is utilized. The supply chain costs of 14 individual spare parts were analyzed, and the total SPSC cost for the AM and TM, were compared. Three of the fourteen parts showed potential for cost-savings, if they were produced with AM instead of TM. In this context, AM polymer parts showed greater potential than metal to replace TM as the more economical option of manufacturing from a total supply chain cost perspective. This study shows that the AM competitiveness to TM, from a financial perspective, increases for spare parts with low demand, high minimum order quantity, and high TM production price. The SPSC cost model included: cost of production, transport, warehousing, and service costs. This study contributes to the emerging field of part identification for AM and the existing literature regarding cost modeling in SPSCs.
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| 15. |
- Holmberg, Jonas, 1976-, et al.
(författare)
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Abrasive Water Jet Milling as An Efficient Manufacturing Method for Superalloy Gas Turbine Components
- 2022
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Ingår i: Journal of Manufacturing and Materials Processing. - : MDPI. - 2504-4494. ; 6:5
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Tidskriftsartikel (refereegranskat)abstract
- In order to improve efficiency when manufacturing gas turbine components, alternative machining techniques need to be explored. In this work, abrasive water jet (AWJ) machining by milling has been investigated as an alternative to traditional milling. Various test campaigns have been conducted to show different aspects of using AWJ milling for the machining of superalloys, such as alloy 718. The test campaigns span from studies of individual AWJ-milled tracks, multi-pass tracks, and the machining of larger components and features with complex geometry. In regard to material removal rates, these studies show that AWJ milling is able to compete with traditional semi/finish milling but may not reach as high an MRR as rough milling when machining in alloy 718. However, AWJ milling requires post-processing which decreases the total MRR. It has been shown that a strong advantage with AWJ milling is to manufacture difficult geometries such as narrow radii, holes, or sharp transitions with kept material removal rates and low impact on the surface integrity of the cut surface. Additionally, abrasive water jet machining (AWJM) offers a range of machining possibilities as it can alter between cutting through and milling. The surface integrity of the AWJM surface is also advantageous as it introduces compressive residual stress but may require post-processing to meet similar surface roughness levels as traditional milling and to remove unwanted AWJM particles from the machined surface. © 2022 by the authors.
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| 16. |
- Law, Madeleine, 1972-, et al.
(författare)
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Assessment of Mechanisms for Particle Migration in Semi-Solid High Pressure Die Cast Aluminium-Silicon Alloys
-
Ingår i: Journal of Manufacturing and Materials Processing. - 2504-4494 .- 2504-4494.
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Tidskriftsartikel (refereegranskat)abstract
- Abstract: In semi-solid metal high pressure die casting, as well as in conventional high pressure die casting, it is common to find a defect band just below the surface of the component. The formation of these bands are not yet fully understood. However, there are several theories as how they occur. Previous research by the lead author suggested that aluminium globules migrate toward the centre of the component, leaving a band behind. In the present work the formation of these bands is investigated theoretically by reviewing suitable potential mechanisms from literature. It was found that it is not possible to positively identify the mechanism responsible for the observed banding using theoretical considerations alone. However, from the mechanisms examined there are two that are identified as the most probable: Saffman lift force and the Mukai-Lin-Laplace effect. Further testing is required to identify the mechanism that is causing the migration of the aluminium globules and suitable tests are proposed.
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| 17. |
- Sridhar, Praveen, et al.
(författare)
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Modeling Grinding Processes-Mesh or Mesh-Free Methods, 2D or 3D Approach?
- 2022
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Ingår i: Journal of Manufacturing and Materials Processing. - : MDPI. - 2504-4494. ; 6:5
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Tidskriftsartikel (refereegranskat)abstract
- The objectives of this study are mainly two: (1) to validate whether a single grain scratch process can be modeled in two dimensions under the assumption of plane strain, and (2) to select the best discretization approach to model a single grain scratch process. This paper first focuses on the simulation of the orthogonal cutting process (aluminum alloy A2024 T351) using two mesh-based discretization approaches, the pure Lagrangian method (LAG) and the arbitrary Lagrangian-Eulerian method (ALE), and two particle-based approaches, the particle finite element method (PFEM) and smooth particle hydrodynamics (SPH), for both positive and negative rake angles. Benchmarking of the orthogonal cutting models at a rake angle of gamma = 20 degrees is performed with the results of the process forces (cutting and passive forces) of a turning experiment from the literature. It is shown that all models are able to predict the cutting forces, but not the passive force. The orthogonal cutting model is further extended to simulate the cutting mechanism with negative rake tool geometries typically found in grinding and single grit scratching processes. The effects of the negative rake angles on the discretization approaches are studied. The calculated process forces are also compared to the measurements of the single grit scratch process performed at our laboratory. The 2D orthogonal cutting models significantly overestimate the process forces. One of the reasons why the orthogonal 2D cutting model is inadequate is that it cannot describe the complex mechanisms of material removal such as rubbing, plowing, and cutting. To account for these phenomena in LAG, ALE, and SPH discretization approaches, a 3D scratch model is developed. When comparing the process forces of the 3D model with the experimental measurements, all three discretization approaches show good agreement. However, it can be seen that the ALE model most closely matches the process forces with the experimental results. Finally, the ALE 3D scratch model was subjected to sensitivity analysis by changing the cutting speed, the depth of cut and the tool geometry. The results clearly show that the ALE method not only predicts the process forces and form the trends observed in the scratching experiments, but also predicts the scratch topography satisfactorily. Hence, we conclude that a 3D model is necessary to describe a scratch process and that the ALE method is the best discretization method.
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