2024 August - 56 articles
The fabrication of welded joints in steel sheets has become a focal point, especially in meeting the demands for interconnections within battery packs for electric vehicles (EVs). This study delves into the impact arising from the initiation arc duri...
This research investigates the correlation between polymer melt viscosity, tensile properties, and injection molding energy consumption for three grades of polypropylene: a virgin grade, a recycled grade, and a modified recycled grade. Cold runner an...
To satisfy the requirements of five-axis processing quality, this article improves and optimizes the machine tool structure design to produce improved dynamic characteristics. This study focuses on the investigation of five-axis machine tools’...
This paper delves into the formability of material deposited by wire arc additive manufacturing. It presents a novel dieless Nakajima testing procedure that offers a practical solution for obtaining strain loading paths up to failure directly from th...
The joining of AA6082-T6 and polyamide 6 using pinless friction stir spot welding was investigated in this study. The influence of the clamping frame geometry was studied and the welds produced were characterized based on their morphology and mechani...
By combining the ring rolling and roll bonding processes, the product spectrum can be additionally expanded. Since a successful composite ring rolling process requires a higher growth tendency for the inner ring, previous publications commonly includ...
Additive friction stir deposition (AFSD) is a solid-state metal additive manufacturing technique, which utilizes frictional heating and plastic deformation to create large deposits and parts. Much like its cousin processes, friction stir welding and...
Laser powder bed fusion allows the production of complex geometries and eases the shaping of difficult-to-transform materials, such as near-equiatomic Ti-Ni shape memory alloys. In this study, a numerical model was used to select 11 sets of printing...
The real-time, full-field simulation of the tube hydroforming process is crucial for deformation monitoring and the timely prediction of defects. However, this is rather difficult for finite-element simulation due to its time-consuming nature. To ove...
In milling processes in which material removal is performed periodically from solid material, dynamic effects are generally considered to be responsible for instabilities and subsequent productivity limits. Usually, in such applications, the process-...
This paper introduces a complete real-time algorithm, where the chatter is detected and eliminated by spindle speed manipulation via the chatter energy feedback calculated from the axis encoder measurement. The proposed method does not require profou...
Conventional aluminum recycling consumes a substantial amount of energy and has a negative impact on secondary alloys. To address this challenging topic, Friction Stir Extrusion has been patented, which represents an innovative solid-state recycling...
This study investigates the complex relationships between process parameters and material properties in FDM-based 3D-printed biocomposites using explainable AI techniques. We examine the effects of key parameters, including biochar content (BC), laye...
In tool and mold making, components are typically first pre-machined in a soft state with residual stock allowance, as economical production is not possible in a hardened state due to the enormous tool wear. This extends the process chain and therefo...
The milling of thin-wall geometries has been a challenge due to inherent chatter vibrations and workpiece deflections. Moreover, tool path generation strategies in CAD-CAM systems are not able to fully address all such concerns. The objective of this...
In the context of low-pressure casting, an excessive inlet velocity may result in the introduction of an oxide film and air into a liquid metal, leading to the formation of a two-layer film structure within the casting. Such defects can significantly...
Chip morphology is an intrinsic characteristic of the machining process that determines the quality of the process. When machining low machinability materials, the chips formed are usually long, continuous, and difficult to break. Due to the negative...
The thermal conductivity of components manufactured using Laser Powder Bed Fusion (LPBF), also called Selective Laser Melting (SLM), plays an important role in their processing. Not only does a reduced thermal conductivity cause residual stresses dur...
Virtual commissioning (VC), defined as the simulation and testing of systems in a virtual environment before physical implementation, plays a key role in addressing the challenges of integrating and validating complex systems efficiently and effectiv...
Nowadays, additive manufacturing technologies have impacted different engineering sectors. Three- and four-dimensional printing techniques are increasingly used in soft and flexible electronics thanks to the possibility of working contemporarily with...
This study employs friction stir processing to create a surface alloy using Al1050 aluminum as the base material, with Cu powder applied to enhance surface properties. Various parameters, including tool rotation speed, feed rate, and the number of pa...
This paper presents a comprehensive analysis of the utilization of 3D printing technology for the fabrication of ceramic shells in the context of investment casting. This study encompasses an exploration of various 3D printing techniques such as bind...
Automated industrial Visual Inspection Systems (VIS) are predominantly designed for specific use cases, resulting in constrained adaptability, high setup requirements, substantial capital investments, and significant knowledge barriers. This paper ex...
Industrial robots are increasingly prevalent due to their large workspace and cost-effectiveness. However, their limited static and dynamic stiffness can lead to issues like mode coupling chatter and regenerative chatter in robotic milling processes,...
This work discusses challenges in conventional grinding wheels: heat-induced tool wear and workpiece thermal damage. While textured abrasive wheels improve heat dissipation, the current surface-only methods, such as those based on laser and machining...
The additive manufacturing technology powder bed fusion of metal with a laser beam (PBF-LB/M) is industrially established for tool-free production of complex and individualized components and products. While the in-processing is based on a layer-by-l...
Similar to bulk metal forming, clinch joining is characterised by large plastic deformations and a variety of different 3D stress states, including severe compression. However, inherent to plastic forming is the nucleation and growth of defects, whos...
The rapid tooling of mold inserts for injection molding allows for very fast product development, as well as a highly customized design. For this, a combination of rapid prototyping methods with suitable polymer materials, like the high-performance t...
Composite materials, such as aluminum alloy FGMs, provide advantageous weight reduction properties compared to homogenous pure structures while still preserving sufficient stiffness for diverse applications. Despite various research on drilling simul...
This paper evaluates the design and fabrication of a thermoplastic polyurethane (TPU) shape memory polymer (SMP) using fused deposition modeling (FDM). The commercially available SMP filament was used to create parts capable of changing their shape f...
Aluminum alloy–graphene metal matrix composite is largely used for structural applications in the aerospace and space exploration sector. In this work, the preprocessed powder particles (AA 2014 and graphene) were used as a reinforcement materi...
The mechanical properties of woven jute fiber-reinforced PLA polymer laminates additively manufactured through Laminated Object Manufacturing (LOM) technology are simulated using the finite element method in this work. Woven jute fiber reinforcements...
Laser-based powder bed fusion of metals (PBF-LB/M) is the most used additive manufacturing (AM) technology for metal parts. Nevertheless, challenges persist in effectively managing metal powder, particularly in blending methodologies in the choice of...
The laser welding of magnesium alloys presents challenges attributed to their low laser-absorbing efficiency, resulting in instabilities during the welding process and substandard welding quality. Furthermore, the complexity of signals during laser w...
Twin-roll casting is a technology for the production of thin strips directly from liquid metal by combining continuous casting with hot rolling in a single step. The thermo-mechanical cyclic interaction with the solidifying strip causes fatigue crack...
This paper reports on an experimental investigation that used a full factorial design to study the main effects and the interaction effect of layer thickness and compaction thickness on the green part density in the binder jetting additive manufactur...
Fused granular fabrication (FGF) is used in industrial applications to manufacture complex parts in a short time frame and with reduced costs. Recently, the overprinting of continuous fibre-reinforced laminates has been discussed to produce high-perf...
Additive manufacturing has witnessed significant growth in recent years, revolutionizing the automotive and aerospace industries amongst others. Despite the use of additive manufacturing for creating complex geometries and reducing material consumpti...
The trade-off between resolution and speed represents a significant challenge when extrusion-based additive manufacturing (AM) is used for large-format additive manufacturing (LFAM). This paper presents an analysis of a new material extrusion process...
This paper details the utilization of the focused ion beam digital image correlation (FIB-DIC) technique for measuring in-plane displacements and the employment of the height digital image correlation (hDIC) technique as a two-step DIC method for det...
This study investigated the impact of temperature, time, and homogenisation on the transient liquid phase bonding of Inconel 617 to stainless steel 310, employing AWS BNI2 foil as an interlayer. Nine test series were conducted at temperatures of 1050...
Additive manufacturing (AM) is increasingly used for fabricating parts directly from digital models, usually by depositing and bonding successive layers of various materials such as polymers, metals, ceramics, and composites. The design freedom and r...
Information on the flyer deformation during laser impact welding (LIW) is an important aspect to consider when high reliability of the welded components is required. For this reason, accurate numerical models simulating thermal and mechanical aspects...
Melt track width can vary in a wire-arc-directed energy-deposited material (DED) using a constant set of process parameters, leading to a lower-quality build. In this work, a novel framework is proposed that uses the data from the process parameter d...
Polymeric resins are becoming increasingly popular in medical and engineering applications due to their properties, such as their low weight, high strength, corrosion resistance, non-allergenicity, and extended service life. The grinding process is u...
Precise electrochemical machining (PECM) is being used increasingly to produce turbine blades (high-pressure compressors) from difficult-to-machine materials such as Inconel. However, the challenges associated with PECM are particularly pronounced fo...
Friction stir welding (FSW) is a widely employed welding process, in which advancing and rotational speeds consitute critical parameters shaping the welding outcome and affecting the temperature evolution. This work develops an experimental methodolo...
In the context of directed energy deposition (DED), the production of complex components necessitates precise control of all processing parameters while mitigating undesirable factors like heat accumulation. This research seeks to explore and validat...
In this study, the effects of the δ phase and annealing twins on the hardness, tensile properties, and Charpy impact toughness of Inconel 718 fabricated using L-PBF were investigated. The as-printed components underwent two stages of heat treat...
Dissimilar welds between ferritic and austenitic stainless steels are widely used in industrial applications. Taking into account the issues inherent to arc welding, such as the high heat input and the need to carry out multiple passes in the case of...
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