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Journal of Manufacturing and Materials Processing, Volume 3, Issue 2

2019 June - 23 articles

Cover Story: This paper introduces a fracture-based finite element model, the embedded cohesive zone finite element method (ECZ-FEM), for machining simulation of brittle materials. In ECZ-FEM, a network of cohesive zone (CZ) elements are embedded in the material body of regular elements to capture multiple randomized cracks during a cutting process. The material damage can then be defined by the fracture energy in CZ elements rather than the conventional stress-strain failure. This work presents several simulation results from orthogonally cutting a dense polyurethane foam, which is a brittle bone-mimicking material. Various chip forms, such as dusty debris and irregular fragmented pieces that are observed in the experiment, can be seen in the simulations. View this paper.
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Articles (23)

  • Article
  • Open Access
68 Citations
7,053 Views
15 Pages

The quality and reliability in additive manufacturing is an emerging area. To ensure process quality and reliability, the influence of all process parameters and conditions needs to be understood. The product quality and reliability characteristics,...

  • Article
  • Open Access
4 Citations
3,464 Views
9 Pages

In this work, we introduce an analytical expression for approximating the transient melting radius during powder melting in Selective Laser Melting (SLM) assumed with a stationary laser heat source. The purpose of this work is to evaluate the suggest...

  • Article
  • Open Access
1 Citations
4,636 Views
18 Pages

Laser Powder Bed Fusion (LPBF) is a predominant Additive Manufacturing (AM) process. While metallic LPBF is gaining popularity, one of the barriers facing its wider industrial use is the current relatively limited knowledge with respect to its dimens...

  • Article
  • Open Access
35 Citations
8,753 Views
12 Pages

Manufacturing of Metallic Bipolar Plate Channels by Rolling

  • Alexander Bauer,
  • Sebastian Härtel and
  • Birgit Awiszus

Producing metallic bipolar plates for Proton Exchange Membrane (PEM) fuel cells by forming is still a topic of research. So far, it has mainly been applied for small batches, but it offers substantial advantages regarding both costs and installation...

  • Article
  • Open Access
3 Citations
5,632 Views
15 Pages

Resistance spot welding of aluminum (Al5754) to magnesium (AZ31B) alloys results in the formation of a variety of solidification microstructures and intermetallic compounds that may affect the in-service performance of the weld. This study evaluates...

  • Article
  • Open Access
19 Citations
6,834 Views
12 Pages

In-Situ Fretting Wear Analysis of Electrical Connectors for Real System Applications

  • Arpith Siddaiah,
  • Ashish K. Kasar,
  • Vishal Khosla and
  • Pradeep L. Menezes

The tribological behavior of electrical contacts, especially separable type electrical connectors at low contact loads, are considered. The reliability of these connectors has been a major concern due to the fretting phenomenon that can lead to an un...

  • Article
  • Open Access
63 Citations
7,975 Views
15 Pages

Machining Chatter Prediction Using a Data Learning Model

  • Harish Cherukuri,
  • Elena Perez-Bernabeu,
  • Miguel Selles and
  • Tony Schmitz

Machining processes, including turning, are a critical capability for discrete part production. One limitation to high material removal rates and reduced cost in these processes is chatter, or unstable spindle speed-chip width combinations that exhib...

  • Article
  • Open Access
6 Citations
4,985 Views
11 Pages

The effect of micro patterning of cemented carbide surface using nanosecond diode pumped solid-state pulsed laser on the strength of induction brazed carbide and steel joints has been investigated. Surface patterns increase the total surface area of...

  • Article
  • Open Access
18 Citations
5,853 Views
15 Pages

Effect of SLM Build Parameters on the Compressive Properties of 304L Stainless Steel

  • Okanmisope Fashanu,
  • Mario F. Buchely,
  • Myranda Spratt,
  • Joseph Newkirk,
  • K. Chandrashekhara,
  • Heath Misak and
  • Michael Walker

Selective laser melting (SLM) is well suited for the efficient manufacturing of complex structures because of its manufacturing methodology. The optimized process parameters for each alloy has been a cause for debate in recent years. In this study, t...

  • Article
  • Open Access
14 Citations
5,173 Views
13 Pages

Friction stir welding (FSW) provides users with many advantages over fusion welding techniques. Nevertheless, it is not widely employed in current industry mainly due to high equipment costs and royalties. To overcome these issues, a low-cost FSW tec...

  • Article
  • Open Access
5 Citations
3,671 Views
14 Pages

The efficiency of laser beam processes basically depends on the efficiency of the laser beam source and the efficiency of the irradiated material’s energy absorption. This absorptivity can be influenced by the surface condition. Besides coating...

  • Article
  • Open Access
6 Citations
3,424 Views
9 Pages

Prediction of Ground Surfaces by Using the Actual Tool Topography

  • Rolf Hockauf,
  • Volker Böß,
  • Thilo Grove and
  • Berend Denkena

This paper presents a prediction model for ground surfaces that uses the actual grinding wheel topography to perform a grinding simulation. Precise knowledge of expected machined surfaces plays an important role in process planning. Here, the main cr...

  • Article
  • Open Access
17 Citations
5,816 Views
18 Pages

Prediction of weld bead geometry is critical for any welding process, since several mechanical properties of the weldment depend on this. Researchers have used artificial neural networks (ANNs) to predict the bead geometry based on the input paramete...

  • Article
  • Open Access
58 Citations
6,158 Views
23 Pages

Friction Stir Welding of T-Joints: Experimental and Statistical Analysis

  • Ibrahim Sabry,
  • Ahmed M. El-Kassas,
  • Abdel-Hamid I. Mourad,
  • Dinu Thomas Thekkuden and
  • Jaber Abu Qudeiri

T-welded joints are commonly seen in various industrial assemblies. An effort is made to check the applicability of friction stir welding for producing T-joints made of AA6063-T6 using a developed fixture. Quality T-joints were produced free from any...

  • Article
  • Open Access
19 Citations
6,522 Views
11 Pages

Preparation of Maleic Anhydride Grafted Poly(trimethylene terephthalate) (PTT-g-MA) by Reactive Extrusion Processing

  • Natália F. Braga,
  • Henrique M. Zaggo,
  • Thaís L. A. Montanheiro and
  • Fabio R. Passador

Maleic anhydride (MA) grafted with poly(trimethylene terephthalate) (PTT)—abbreviated as PTT-g-MA—can be used as a compatibilizing agent to improve the compatibility and dispersion of nanofillers and a dispersed polymer phase into PTT mat...

  • Article
  • Open Access
11 Citations
5,404 Views
14 Pages

Machining of brittle materials is common in the manufacturing industry, but few modeling techniques are available to predict materials’ behavior in response to the cutting tool. The paper presents a fracture-based finite element model, named em...

  • Article
  • Open Access
18 Citations
6,110 Views
17 Pages

Development of an Additive Manufacturing System for the Deposition of Thermoplastics Impregnated with Carbon Fibers

  • Miguel Reis Silva,
  • António M. Pereira,
  • Nuno Alves,
  • Gonçalo Mateus,
  • Artur Mateus and
  • Cândida Malça

This work presents an innovative system that allows the oriented deposition of continuous fibers or long fibers, pre-impregnated or not, in a thermoplastic matrix. This system is used in an integrated way with the filamentary fusion additive manufact...

  • Article
  • Open Access
6 Citations
4,026 Views
10 Pages

Thin-Rib and High Aspect Ratio Non-Stochastic Scaffolds by Vacuum Assisted Investment Casting

  • Vitor H. Carneiro,
  • Hélder Puga,
  • Nuno Peixinho and
  • José Meireles

Cellular structures are a classic route to obtain high values of specific mechanical properties. This characteristic is advantageous in many fields, from diverse areas such as packaging, transportation industry, and/or medical implants. Recent studie...

  • Article
  • Open Access
12 Citations
4,347 Views
10 Pages

High Speed Roll-to-Roll Printable Transistor Enabled by a Pulsed Light Curable CNT Ink

  • Peter Mack Grubb,
  • Farzad Mokhtari Koushyar,
  • Travis Lenz,
  • Aref Asghari,
  • Gongwen Gan,
  • Wenlong Xia,
  • Hamed Dalir,
  • Harish Subbaraman and
  • Ray T. Chen

This paper reports the first high speed roll-to-roll printable transistor using a carbon nanotube (CNT) semiconducting layer. The transistor is made possible through the development of a pulsed light curable CNT ink compatible with typical drop on de...

  • Article
  • Open Access
63 Citations
8,219 Views
19 Pages

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 (relat...

  • Article
  • Open Access
14 Citations
4,277 Views
11 Pages

Cadaveric decellularized bone tissue is utilized as an allograft in many musculoskeletal surgical procedures. Typically, the allograft acts as a scaffold to guide tissue regeneration with superior biocompatibility relative to synthetic scaffolds. Tra...

  • Article
  • Open Access
19 Citations
5,751 Views
22 Pages

The aim of this study is to analyze the co-relation between the geometrical accuracy of parts formed by single-point incremental forming (SPIF) and the resulting distribution of the residual stresses induced in the material as a function of the diffe...

  • Article
  • Open Access
14 Citations
4,898 Views
18 Pages

This paper investigates the underlying interplay between the key process parameters of magnetic abrasive finishing (MAF) in improving surface quality. The five process parameters considered were the working gap, rotational speed, feed rate, abrasive...

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J. Manuf. Mater. Process. - ISSN 2504-4494