2021 June - 38 articles
The use of the welding process on an industrial scale has become significant over the years and is currently among the main processes for joining metallic materials. Along the weld, structural changes occur in the vicinity of the joint. These thermal...
During magnetic pulsed welding (MPW), a wavy interface pattern can be observed. However, this depends on the specific material combination being joined. Some combinations, e.g., steel to aluminum, simply provide undulating waves, while others, e.g.,...
Collision welding is a joining technology that is based on the high-speed collision and the resulting plastic deformation of at least one joining partner. The ability to form a high-strength substance-to-substance bond between joining partners of dis...
Ultrasonic welding of titanium alloy Ti6Al4V to carbon fibre reinforced polymer (CFRP) at 20 kHz frequency requires suitable welding tools, so called sonotrodes. The basic function of ultrasonic welding sonotrodes is to oscillate with displacement am...
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 directio...
This paper reports on a dual-axial tool servo diamond turning method for the one-step fabrication of hierarchical micro-nano-structured surfaces. With respect to the dual-axial servo motion (XZ), the z-axis motion can generate the primary surface wit...
The emerging multi-axis fused deposition modeling (FDM) printing process is a powerful technology for fabricating complicated 3D models that otherwise would require extensive support structures or suffer the severe stair-case effect if printed on a c...
The increasing demand for high-performance components is leading to a greater use of advanced alloys such as DA718, which is, e.g., used in engine parts due to its high-temperature strength. The strict quality requirements pose major challenges for t...
The constitutive model and its pertinent set of parameters are important input data in finite element modeling to define the behavior of Ti6Al4V during machining process. The present work focusses on comparing different constitutive models and the pa...
The ability to produce metal matrix nanocomposites via pressing and infiltration was validated. Al/TiC nanocomposite was used as the model material. Pressing the powder in a die yielded cylindrical specimens with a green density of 1.98 ± 0.05 g/cm3,...
Knowledge of the relationships between thermomechanical process loads and the resulting modifications in the surface layer enables targeted adjustments of the required surface integrity independent of the manufacturing process. In various processes w...
The filament drive is a key part of the extrusion assembly of a Fused Filament Fabrication printer. This investigation examines the maximum feed force and the slip of different driving rollers using a filament made of polylactic-acid (PLA) on a test...
Vacuum drying can dehydrate materials further than dry heat methods, while protecting sensitive materials from thermal degradation. Many industries have shifted to vacuum drying as cost- or time-saving measures. Small-scale vacuum drying, however, ha...
A cubic-machining test has been proposed to evaluate the geometric errors of rotary axes in five-axis machine tools using a 3 × 3 zone area in the same plane with different tool postures. However, as only the height deviation among the machining zone...
Due to rising demands regarding the functionality and load-bearing capacity of functional components such as synchronizer rings in gear systems, conventional forming operations are reaching their limits with respect to formability and efficiency. One...
In this paper, the tool wear mechanisms for low-frequency vibration-assisted drilling (LF-VAD) of carbon fiber-reinforced polymer (CFRP)/Ti6Al4V stacks are investigated at various machining parameters. Based on the kinematics analysis, the effect of...
Electro-Hydraulic Forming (EHF) is a high rate sheet metal forming process based on the electrical discharge of high voltage capacitors in a water-filled chamber. During the discharge, the pulsed pressure wave propagates from the electrodes and forms...
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 wo...
This study aimed at the investigation of the effect of substrate temperature on residual stress in laser powder bed fusion using a physics-based analytical model. In this study, an analytical model is proposed to predict the residual stress through t...
Multiturn coils are required for manufacturing sheet metal parts with varying depths and special geometrical features using electromagnetic forming (EMF). Due to close coil turns, the physical phenomena of the proximity effect and Lorentz forces betw...
Single-lip deep hole drilling (SLD) is characterized by a high surface quality and compressive residual stress in the subsurface of the drill hole. These properties are strongly dependent on the cutting parameters of the SLD process and the actual ge...
Nickel-base alloys are proven materials in the fields of the aerospace and oil industry, which is due to their characteristic material properties of high temperature strength, high toughness and good oxidation resistance. These properties are benefic...
Minimum Quantity Lubrication nanofluid (MQL-nanofluid) is a viable sustainable alternative to conventional flood cooling and provides very good cooling and lubrication in the machining of difficult to cut materials such as titanium and Inconel. The c...
Drag finishing is a widely used superfinishing technique in the industry to polish parts under the action of abrasive media combined with an active surrounding liquid. However, the understanding of this process is not complete. It is known that pyram...
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 challeng...
The shot peening process is a common procedure to enhance fatigue strength on load-bearing components in the metal processing environment. The determination of optimal process parameters is often carried out by costly practical experiments. An effici...
Additive manufacturing (AM) technology has rapidly evolved with research advances related to AM processes, materials, and designs. The advantages of AM over conventional techniques include an augmented capability to produce parts with complex geometr...
Some manufacturing companies now use recycled aluminum alloys. It is important that they have the necessary data relating to the control of the machinability of these alloys. Thus, this study on the machinability in the turning of two recycled alumin...
In contrast to other cutting processes, adiabatic blanking typically features high blanking velocities (>3 m/s), which can lead to the formation of adiabatic shear bands in the blanking surface. The produced surfaces have excellent properties, suc...
Tools are of strategic importance for industrial manufacturing processes. Their behaviour has a great influence on the productivity of the process and the quality of the product. A material saving and efficient technique for processing metallic workp...
Polycrystalline diamond (PCD) tools are widely used in industry due to their outstanding physical properties. However, the ultra-high hardness of PCD significantly limits the machining efficiency of conventional abrasive grinding processes, which are...
This article develops and demonstrates a set of design-focused manufacturability constraints for the fused deposition modeling/fused filament fabrication (FDM/FFF) process. These can be mapped from the basic behavior and process characteristics and f...
The article refers to an analysis of the multi-operation process of manufacturing a hub type forging used to transmit power in motorcar gear boxes, by way of die forging on a crank press. The investigations were performed in order to improve the curr...
This review focuses on the current state of the art in liquid metal additive manufacturing (AM), an emerging and growing family of related printing technologies used to fabricate near-net shape or fully free-standing metal objects. The various printi...
Hybrid structures are important for the automotive and aeronautical industry as they have the potential to reduce vehicle or aircraft weight and to improve fuel efficiency. Continuous ultrasonic metal welding is a promising technique for hydraulic ap...
In sheet metal forming, free deformation of the sheet takes place frequently without contact with forming tools. The pre-straining resulting from the free deformation leads to a surface roughening of the sheet metal. It is assumed that the roughening...
The influence of yield function parameters on hole-expansion (HE) predictions are investigated for an anisotropic AA6022-T4 aluminum sheet. The HE experiment is performed in a fully-instrumented double-action hydraulic press with a flat-headed punch....
The importance of functional surfaces is continuously growing in the context of increasing demands on the sustainability of performance, resource efficiency and manufacturing costs of technical systems. For example, microstructured substrate surfaces...
