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Journal of Manufacturing and Materials Processing, Volume 5, Issue 1

2021 March - 26 articles

Cover Story: The manufacture of thin walls with sharp corners has been optimized by adjusting the limits of a 3-axis Cartesian kinematics through data recorded and analyzed offline, such as axis speed, acceleration, and the positioning of the X and Y axes. The study was carried out with SS316L and IN718 alloys using the directed energy deposition process with laser. Thin walls were obtained with 1 mm thickness, and only one bead per layer and straight/sharp corners at 90. After adjusting the in-position parameter G502 for positioning precision on the FAGOR 8070 CNC system, it was possible to obtain walls with minimal material accumulation in the corner, and practically constant layer thickness and height, with adequate radii of internal curvature. View this paper.
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Articles (26)

  • Feature Paper
  • Article
  • Open Access
5 Citations
3,490 Views
14 Pages

Condition Monitoring of Manufacturing Processes under Low Sampling Rate

  • Gabriel Bernard,
  • Sofiane Achiche,
  • Sébastien Girard and
  • René Mayer

Manufacturing processes can be monitored for anomalies and failures just like machines, in condition monitoring and prognostic and health management. This research takes inspiration from condition monitoring and prognostic and health management techn...

  • Article
  • Open Access
13 Citations
5,909 Views
20 Pages

Due to stricter emission targets in the mobility sector and the resulting trend towards lightweight construction in order to reduce weight and consequently emissions, multi-material systems that allow a material to be placed in the right quantity and...

  • Communication
  • Open Access
9 Citations
3,841 Views
13 Pages

Synthesis of Bulk Zr48Cu36Al8Ag8 Metallic Glass by Hot Pressing of Amorphous Powders

  • Tianbing He,
  • Nevaf Ciftci,
  • Volker Uhlenwinkel and
  • Sergio Scudino

The critical cooling rate necessary for glass formation via melt solidification poses inherent constraints on sample size using conventional casting techniques. This drawback can be overcome by pressure-assisted sintering of metallic glass powders at...

  • Article
  • Open Access
15 Citations
4,130 Views
13 Pages

This work deals with the optimization of crucial process parameters related to the abrasive flow machining applications at micro/nano-levels. The optimal combination of abrasive flow machining parameters for nano-finishing has been determined by appl...

  • Article
  • Open Access
36 Citations
10,740 Views
16 Pages

Turbine Blade Tip Repair by Laser Directed Energy Deposition Additive Manufacturing Using a Rene 142–MERL 72 Powder Blend

  • Mohsen K. Keshavarz,
  • Alexandre Gontcharov,
  • Paul Lowden,
  • Anthony Chan,
  • Devesh Kulkarni and
  • Mathieu Brochu

Laser directed energy deposition (LDED) was used with a powder blend comprising 75 wt.% Rene 142 and 25 wt.% of Merl 72 (4275M72) for turbine blade tip repair applications. Sound samples could be deposited at ambient temperature on Haynes 230. The mi...

  • Article
  • Open Access
2 Citations
5,741 Views
12 Pages

Edge Grinding Characteristics of Display Glass Substrate

  • Dennis Wee Keong Neo,
  • Kui Liu,
  • Rui Huang and
  • Hu Wu

Display glass substrate as a brittle material is very challenging to machine due to its excellent physical, mechanical, electrical, and optical properties such as high hardness, high strength, high wear resistance, good fracture toughness, good chemi...

  • Article
  • Open Access
7 Citations
3,686 Views
14 Pages

Manufacturing Concept and Prototype for Train Component Using the FSW Process

  • Elizabeth Hoyos,
  • Santiago Escobar,
  • Jeroen De Backer,
  • Jonathan Martin and
  • Mauricio Palacio

Friction stir welding (FSW) is a process originally developed for joining light materials, such as aluminum and magnesium, as an answer to their poor weldability by conventional fusion processes. In Colombia, the technique has been studied but its in...

  • Article
  • Open Access
11 Citations
3,314 Views
14 Pages

In electromagnetic forming of thin sheet metal, the die is located within the effective range of the electromagnetic wave. Correspondingly, a current is induced not only in the sheet metal, but also in the die. Like the current in the workpiece, also...

  • Article
  • Open Access
3 Citations
4,505 Views
25 Pages

The Shielded Active Gas Forge Welding (SAG-FW) method is a solid-state welding technique in which the mating surfaces are heated by induction heating or direct electrical heating before being forged together to form a weld. In this article, an API 5C...

  • Article
  • Open Access
16 Citations
4,878 Views
15 Pages

Fabricating micro-structures on optical materials has received great interest in recent years. In this work, micro-grooving experiments were performed on polycrystalline zinc selenide (ZnSe) to investigate the feasibility of surface micro-structuring...

  • Article
  • Open Access
7 Citations
5,489 Views
18 Pages

Die Material Selection Criteria for Aluminum Hot Stamping

  • Maider Muro,
  • Ines Aseguinolaza and
  • Garikoitz Artola

The aim of this work is to develop a die material selection criterion for aluminum hot stamping applications. The criterion has been based on the back-to-back comparison of a set of reciprocating friction and wear tests. Three representatives belongi...

  • Article
  • Open Access
5 Citations
3,353 Views
14 Pages

Investigation of Mechanical Loads Distribution for the Process of Generating Gear Grinding

  • Patricia de Oliveira Teixeira,
  • Jens Brimmers and
  • Thomas Bergs

In grinding, interaction between the workpiece material and rotating abrasive tool generates high thermo-mechanical loads in the contact zone. If these loads reach critically high values, workpiece material properties deteriorate. To prevent the mate...

  • Article
  • Open Access
3,668 Views
10 Pages

Micro-Injection Molding of Diffractive Structured Surfaces

  • Ann-Katrin Boinski,
  • Barnabas Adam,
  • Arne Vogelsang,
  • Lars Schönemann,
  • Oltmann Riemer and
  • Bernhard Karpuschewski

In recent years, the use of highly functional optical elements has made its way into our everyday life. Its applications range from use in utility items such as cell phone cameras up to security elements on banknotes or production goods. For this pur...

  • Article
  • Open Access
10 Citations
3,707 Views
12 Pages

Ultraprecision machining is required in many advanced fields. To create precise parts for realizing their high performance, the whole machining process is usually conducted on the same ultraprecision machine tool to avoid setting errors by reducing s...

  • Article
  • Open Access
6 Citations
3,651 Views
13 Pages

In recent years, increasing automotive safety by improving crashworthiness has been a focal point in the automotive industry, employing high-strength steel such as press hardenable steel (PHS). In addition to the improved strength of individual parts...

  • Article
  • Open Access
11 Citations
4,378 Views
20 Pages

Prediction of Shearing and Ploughing Constants in Milling of Inconel 718

  • Chi-Jen Lin,
  • Yu-Ting Lui,
  • Yu-Fu Lin,
  • Hsian-Bing Wang,
  • Steven Y. Liang and
  • Jiunn-Jyh Junz Wang

The present study proposes an integrated prediction model for both shearing and ploughing constants for the peripheral milling of Inconel 718 by using a preidentified mean normal friction coefficient. An equation is presented for the identification o...

  • Article
  • Open Access
10 Citations
6,257 Views
12 Pages

Dexel-Based Simulation of Directed Energy Deposition Additive Manufacturing

  • Volker Böß,
  • Berend Denkena,
  • Marc-André Dittrich,
  • Talash Malek and
  • Sven Friebe

Additive manufacturing is typically a flexible alternative to conventional manufacturing processes. However, manufacturing costs increase due to the effort required to experimentally determine optimum process parameters for customized products or sma...

  • Review
  • Open Access
13 Citations
4,128 Views
23 Pages

Kinematic Fields Measurement during Orthogonal Cutting Using Digital Images Correlation: A Review

  • Haythem Zouabi,
  • Madalina Calamaz,
  • Vincent Wagner,
  • Olivier Cahuc and
  • Gilles Dessein

Understanding the mechanism of chip formation during orthogonal cutting requires a local measurement of the displacement and strain fields in the cutting zone. These measurements can then be used in order to enhance/validate numerical simulation of m...

  • Article
  • Open Access
5 Citations
3,617 Views
15 Pages

Continuous generating gear grinding with vitrified grinding worms is an established process for the hard finishing of gears for high-performance transmissions. Due to the increasing requirements for gears in terms of power density, the required surfa...

  • Article
  • Open Access
17 Citations
5,357 Views
17 Pages

Optimization of Thin Walls with Sharp Corners in SS316L and IN718 Alloys Manufactured with Laser Metal Deposition

  • Juan Carlos Pereira,
  • Herman Borovkov,
  • Fidel Zubiri,
  • Mari Carmen Guerra and
  • Josu Caminos

In this work, the manufacture of thin walls with sharp corners has been optimized by adjusting the limits of a 3-axis cartesian kinematics through data recorded and analyzed off-line, such as axis speed, acceleration and the positioning of the X and...

  • Article
  • Open Access
3 Citations
3,504 Views
25 Pages

Equal-channel angular pressing (ECAP) is known to induce significant grain refinement and formation of tangled dislocations within the grains. These are induced to evolve to form low-angle boundaries (i.e., cell boundaries) and eventually high-angle...

  • Article
  • Open Access
17 Citations
4,883 Views
16 Pages

While deep drawing of sheet metals is economical at high volumes, it can be very costly for manufacturing prototypes, mainly due to high tooling costs. Additively manufactured polymer tools have the potential to be more cost-efficient for small serie...

  • Article
  • Open Access
21 Citations
4,968 Views
12 Pages

Milling tools with a large length–diameter ratio are widely applied in machining structural features with deep depth. However, their high dynamic flexibility gives rise to chatter vibrations, which results in poor surface finish, reduced produc...

  • Article
  • Open Access
7 Citations
4,307 Views
17 Pages

Validation of a Coupled Simulation for Machine Tool Dynamics Using a Linear Drive Actuator

  • Michael Wiesauer,
  • Christoph Habersohn and
  • Friedrich Bleicher

In order to ensure high productivity capabilities of machine tools at a low cost but at increased geometric accuracy, modeling of their static and dynamic behavior is a crucial task in structure optimization. The drive control and the frictional forc...

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