Search Results (138)

In recent decades, the automotive industry has faced challenges around improving energy efficiency, reducing pollutant emissions, increasing occupant safety, and reducing production costs. To solve these challenges, it is necessary to reduce the weight of vehicle bodies. In this way, the steel industry has developed more efficient metal alloys. To combine vehicle mass reduction with improved performance in deformations in cases of impact, a new family of advanced steels is present, AHSS (Advanced High-Strength Steels). However, this family of steels has lower formability and greater springback compared to conventional steels; if it is not properly controlled, it will directly affect the accuracy of the product and its quality. Different regions of a stamped component, such as the flange, the body wall, and the punch pole, are subjected to different states of stress and deformation, determined by numerous process variables, such as friction/lubrication and tool geometry, in addition to blank holder force and drawbead geometry, which induce the material to different deformation modes. Thus, it is understood that the degree of work hardening in each of these regions can be evaluated by grain morphology and material hardening, defining critical regions of embrittlement that, consequently, will affect the material’s stampability. This work aims to study the formability of the cold-formed DP600 steel sheets in the die radius region using a Modified Nakazima test, varying drawbead geometry, followed by a nanohardness evaluation and material characterization through the electron backscatter diffraction (EBSD). The main objective is to analyze the work hardening in the critical blank regions by applying these techniques. The nanoindentation evaluations were consistent in die radius and demonstrated the hardening influence, proving that the circular drawbead presented the most uniform hardness variation along the profile of the stamped blank and presented lower hardness values in relation to the other geometries, concluding that the drawbead attenuates this variation, contributing to better sheet formability, which corroborates the Forming Limit Curve results. Full article

A new concept of a 3D volumetric module, made up of six plane stiffened self-compacting fiber-reinforced concrete (SFRC) panels, is here studied. Experimental campaigns are carried out on SFRC material and on the thin-slab structures used for this modular concept. The high volume of steel fibers (80 kg/m³) used in the formulation of this concrete allow a positive strain hardening to be obtained in the post-cracking regime observed on the bending characterization tests. The high mechanical material characteristics, obtained both in tension and compression, allow a significant decrease in the module slabs’ thickness. The tests carried out on the 7 cm thick slab demonstrate a high load-bearing capacity and ductility under bending loading; this is also the case for shear loading configuration, although without any shear reinforcements. Numerical simulations of the material mechanical tests were conducted using Abaqus code; the results corroborate the experimental findings. Then, simulations were also conducted at the structural level, mainly to evaluate the behavior and the bearing capacity of the thin 3D module stiffened slabs. Finally, knowing that the concrete module truck transport can be a weak point, the decelerations induced during transportation were characterized and the integrity of the largest 3D module was demonstrated. Full article

This article deals with drilling, the most common and simultaneously most important traditional machining operation, and which is significantly influenced by the properties of the machined material itself. To fully understand this process, both from a theoretical and practical perspective, it is essential to examine the influence of technological and tool-related factors on its various parameters. Based on the evaluation of experimentally obtained data using advanced statistical methods and machine learning decision trees, we present a detailed analysis of the effects of technological factors (f_n, v_c) and tool-related factors (D, ε_r, α₀, ω_r) on variations in torque (M_c) during drilling of two types of engineering steels: carbon steel (C45) and case-hardening steel (16MnCr5). The experimental verification was conducted using CTS20D cemented carbide tools coated with a Triple Cr SHM layer. The analysis revealed a significant influence of the material on torque variation, accounting for a share of 1.430%. The experimental verification confirmed the theoretical assumption that the nominal tool diameter (D) has a key effect (53.552%) on torque variation. The revolution feed (f_n) contributes 36.263%, while the tool’s point angle (ε_r) and helix angle (ω_r) influence torque by 1.189% and 0.310%, respectively. No significant effect of cutting speed (v_c) on torque variation was observed. However, subsequent machine learning analysis revealed the complexity of interdependencies between the input factors and the resulting torque. Full article

This paper presents an extended method for determining flow curves under shear loading using torsion tests, a technique often used to characterize plastic behavior in metal forming. Torsion tests are advantageous due to their ability to achieve flow curves up to large strains (~3) while maintaining stable specimen geometry during deformation. However, the strain and strain rate distribution across the specimen are non-uniform, increasing radially from the rotation axis. Traditional analytical methods, such as the Fields and Backofen approach, address this non-uniformity by considering average strain and strain rates. Conversely, inverse approaches, which rely on fitting constitutive equations through iterative procedures, are more sensitive to the choice of empirical equations and can be computationally expensive. To address these issues, this study adapts an inverse piecewise flow curve determination method from compression tests for use in torsion tests. A stepwise methodology is proposed to calculate constant strain rates and isothermal flow curves, where flow curves for the lowest strain rates are first determined and subsequently used to derive flow curves at higher strain rates. The proposed approach was applied to the case-hardened steel 16MnCrS5, with tests conducted at temperatures ranging from 900 °C to 1100 °C and strain rates from 0.01 s⁻¹ to 1 s⁻¹. The experimental data obtained were successfully replicated by the flow curves with a maximum deviation of only 1%. The results demonstrate the efficiency and accuracy of the stepwise inverse approach for determining flow curves in torsion tests, making it appropriate for characterizing material behavior for metal-forming applications. Full article

Steel and aluminum alloys are used to manufacture the bodies of bulk material handling machines. The aluminum body enables a higher load mass and thus reduces transport costs. However, the greater abrasion of aluminum alloys leads to more frequent repairs to the underside of the body, as the abrasion parameters of aluminum are lower. This study, which used three different methods to evaluate abrasive wear (erosive/impact wear, abrasive wear in the mass of the free abrasive and abrasion test according to ASTM G65), showed that the most significant influence on the wear of 3004 series aluminum is the grain size of the abrasive. Only under erosive/impact wear conditions with abrasive particles of 2.0–5.0 and 5.0–8.0 mm is aluminum competitive with Hardox 450 in terms of volumetric wear, with aluminum exhibiting 1.3–1.4 times the wear rate of steel. Tests on the abrasive mass of the grinding fraction in question have shown that the volumetric wear of aluminum is 0.2–2.3 times higher at very low contact loads. In contrast, aluminum wears 7.5 and 4 times more than steel in the ASTM G65 test (0.1–0.4 mm fraction) at low and medium contact loads. Only in exceptional cases is the aluminum floor of bulk material handling equipment competitive with hardened steel in terms of wear intensity. Full article

Understanding the volume fractions of microstructure constituents such as ferrite, pearlite, bainite, and martensite in low-alloy steels is critical for tailoring mechanical properties to specific engineering applications. To address the complexity of these relationships, this study explores the use of artificial neural networks (ANNs) as a robust tool for predicting these microstructure constituents based on alloy composition, specific Jominy distance, and heat treatment parameters. Unlike previous ANN-based predictions that rely on the hardness after quenching as an input parameter, this study excludes hardness. The developed model relies on readily available input parameters, enabling accurate estimation of microstructure composition prior to heat treatment, which significantly improves its practicality for process planning, optimization, and reducing trial-and-error on industrial applications. Three different input configurations were tested to evaluate the predictive capabilities of ANNs, with results showing that the use of specific Jominy distance as an input variable enhances model performance. Furthermore, the findings suggest that specific Jominy distance could serve as a practical alternative to detailed chemical composition data in industrial applications. The predictions for ferrite, pearlite, and martensite were more accurate than those for bainite, which can be attributed to the complex nature of bainite formation. Full article

The backfill binder material is the key to the cost and performance of cemented paste backfill. This study aims to understand the current situation of metal ore backfill binders, identify industry challenges, inspire research ideas, and explore development directions. Current research investigates trends and developments of backfill binders through literature review, experience summary, field research, statistical analysis, and other methods. Firstly, the main backfill binder types are summarized, including cement, metallurgical slag, thermal slag, chemical slag, and tailings binders. Secondly, the research progress regarding reactivity activation, hydration mechanism, harmful ion solidification, energy conservation, and carbon reduction is summarized. Thirdly, three industrial applications of new backfill binders are introduced and summarized. Cement is still the most common, followed by slag powder binder. The cases of steel slag binder and semi-hydrated phosphogypsum backfill have shown significant effects. Solid waste-based backfill binder materials are gradually replacing cement, which is a trend. Finally, further research is discussed, including hydration modeling and simulation, material properties under extreme environments, hardening process control, and technical standards for backfill binders. This work provides a reference and basis for promoting green and efficient paste backfill and sustainable industry development. Full article

Arc quenching has many advantages, including generating large amounts of heat in a short time, a self-quenching ability, and simple equipment. The electric arc energy from a TIG welding machine was used to modify the surface properties of S45C Carbon Steel Cylinders. The study focuses on the impact of arc length, current intensity, travel speed, gas flow rate, heating angle, and pulse on surface hardness after arc quenching an S45C steel tube with a cylinder surface. The study found that the hardness reduces from 45.1 HRC to 41.2 HRC as the current intensity increases from 125 A to 140 A. According to Taguchi’s results, the ranking of factors which have the greatest impact on surface hardness are pulse time, travel speed, intensity, gas flow rate, arc length, and heating angle. The pulse time has the highest impact because it directly influences the heating input, followed by the travel speed. Arc length and heating angle, on the other hand, have the least effect. The base metal, heat-affected area, and hardened area are the three distinct areas that make up the microstructure structure. After the arc quenching process, the case hardening depth is represented by the heat-affected zone at 1536 μm. A highly colored residual austenite and a needle-shaped martensite phase make up the hardened region. The hardened region is 1200 μm thick and has a hardness of more than 300 HV0.3. The study’s findings may improve the application and understanding of the arc quenching treatment procedure in the industrial sector. Full article

This article deals with a mutual comparison of indexable cutting inserts of the CNMG 120408 type from two different manufacturers during the machining of hardened steel AISI 4337 and austenitic stainless steel AISI 316 L. The main goal is to analyse the different wear processes depending on the difference in the manufacturer’s design and also depending on the properties of the different machined materials. The progress of the wear of the main spine of the tool, the types of wear and the service life of the cutting edge were monitored, with the achievement of the critical value VB_max = 300 µm being the standard. In addition to the wear of the inserts, the production of chips was monitored in terms of their shape, average size and number of chips per 100 g of chips produced. In order to understand the relationships arising from the obtained data, an SEM equipped with an elemental analyser was used to analyse the coating layers and the substrate of the unworn inserts and the types of wear and the intensity of the surface damage of the worn inserts. A several-fold difference in the lifetime of the cutting edge was found, both in terms of design and in terms of the selected machined material, while in both cases the cutting edge with Al₂O₃ and TiCN layers of half thickness achieved a better result in liveness. From the point of view of chip formation, very similar results in shape and average length were observed despite the different designs of chip breakers. Cutting inserts with half the thickness of the coating layers achieved longer cutting edge life in the non-primary material application compared to the target workpiece material. At the same time, it was observed that a thinner coating layer has a positive effect on chip formation in terms of its length and shape. Full article

The building and construction sector is the largest emitter of greenhouse gases, accounting for 37% of global emissions. The production and use of materials such as cement, steel, and aluminum contribute significantly to this carbon footprint. Utilizing valorized agricultural by-products, such as hemp shiv and sunflower pith, in construction can enhance the insulating properties of materials and reduce their environmental impact by capturing CO₂. Additionally, during the formulation process, molecules such as polyphenols and sugars are released, depending on process parameters like pH and temperature. In some cases, these releases can cause issues, such as delaying the hardening of agro-based concrete or serving as binding agents in binderless particle boards. This study focuses on the molecules released during the processing of these materials, with particular attention to the effects of pH and temperature, and the modifications to the plant particles resulting from these conditions. Physical, chemical, and morphological analyses were conducted on the treated hemp shiv particles (HS1 and HS2). No physical or morphological differences were observed between the samples. However, chemical differences, particularly in the lignin and soluble compound content, were noted and were linked to the release of plant substances during the process. Full article

This paper introduces an innovative approach that enables the automated and precise prediction of steel’s chemical composition based on the desired Jominy curve. The microstructure, and in fact the presence of martensite, is decisive for the hardness of the steel, so the study considered the occurrence of this phase at particular distances from the quenched end of the Jominy sample. Steels for quenching and tempering and case hardening were investigated. With the representative collected dataset of hardness values from the quenched end of the Jominy specimen, microstructure and chemical composition of steels, the complex regression model was made using supervised artificial neural networks. The balance between cost and required hardenability can be achieved through optimizing the chemical composition of steel. This model of designing steel with required hardenability can be of great benefit in the mechanical engineering and manufacturing industry. The model is verified experimentally. Full article

The paper investigates the feasibility of plasma electrolytic treatment (PET) of 90CrSi tool steel to enhance hardness and wear resistance. The influence of electrophysical parameters of PET (polarity of the active electrode, chemical-thermal treatment, and polishing modes) on the composition, structure, morphology, and tribological properties of the surface was studied. Tribological tests were carried out under dry friction conditions according to the shaft-bushing scheme with fixation of the friction coefficient and temperature in the friction contact zone, measurements of surface microgeometry parameters, morphological analysis of friction tracks, and weight wear. The formation of a surface hardened to 1110–1120 HV due to the formation of quenched martensite is shown. Features of nitrogen diffusion during anodic PET and cathodic PET were revealed, and diffusion coefficients were calculated. The wear resistance of the surface of 90CrSi steel increased by 5–9 times after anodic PET followed by polishing, by 16 times after cathodic PET, and up to 32 times after subsequent polishing. It is shown that in all cases, the violation of frictional bonds occurs through the plastic displacement of the material, and the wear mechanism is fatigue wear during dry friction and plastic contact. Full article

In this work emphasis was given to determine the evolution of the retained austenite phase fraction via X-ray diffractometry technique in the as-hardened AISI 440C martensitic stainless steel surface subjected to cavitation for increasing test times. Scanning electron microscopy results confirmed the preferential carbide phase removal along the prior/parent austenite grain boundaries for the first cavitation test times on the polished sample surface during the incubation period. Results suggest that the strain-induced martensitic transformation of the retained austenite would be assisted by the elastic deformation and intermittent relaxation action of the harder martensitic matrix on the austenite crystals through the interfaces between both phases. In addition, an estimation of the stacking fault energy value on the order of 15 mJ m⁻² for the retained austenite phase made it possible to infer that mechanical twinning and strain-induced martensite formation mechanisms could be effectively presented in the studied case. Finally, incubation period, maximum erosion rate, and erosion resistance on the order of 7.0 h, 0.30 mg h⁻¹, and 4.8 h μm⁻¹, respectively, were determined for the as-hardened AISI 440C MSS samples investigated here. Full article

In general, formed components are lightweight as well as highly economic and resource efficient. However, forming-induced ductile damage, which particularly affects the formation and growth of pores, has not been considered in the design of components so far. Therefore, an evaluation of forming-induced ductile damage would enable an improved design and take better advantage of the lightweight nature as it affects the static and dynamic mechanical material properties. To quantify the amount, morphology and distribution of the pores, advanced scanning electron microscopy (SEM) methods such as scanning transmission electron microscopy (STEM) and electron channeling contrast imaging (ECCI) were used. Image segmentation using a deep learning algorithm was applied to reproducibly separate the pores from inclusions such as manganese sulfide inclusions. This was achieved via layer-by-layer ablation of the case-hardened steel 16MnCrS5 (DIN 1.7139, AISI/SAE 5115) with a focused ion beam (FIB). The resulting images were reconstructed in a 3D model to gain a mechanism-based understanding beyond the previous 2D investigations. Full article

Current research studies devoted to cutting forces in drilling are oriented toward predictive model development, however, in the case of mechanistic models, the material effect on the drilling process itself is mostly not considered. This research study aims to experimentally analyze how the machined material affects the feed force (Ff) during drilling, alongside developing predictive mathematical–statistical models to understand the main effects and interactions of the considered technological and tool factors on Ff. By conducting experiments involving six factors (feed, cutting speed, drill diameter, point angle, lip relief angle, and helix angle) at five levels, the drilling process of stainless steel AISI1045 and case-hardened steel 16MnCr5 is executed to validate the numerical accuracy of the established prediction models (AdjR = 99.600% for C45 and AdjR = 97.912% for 16MnCr5). The statistical evaluation (ANOVA, RSM, and Lack of Fit) of the data proves that the drilled material affects the F_f value at the level of 17.600% (p < 0.000). The effect of feed represents 44.867% in C45 and 34.087% in 16MnCr5; the cutting speed is significant when machining C45 steel only (9.109%). When machining 16MnCr5 compared to C45 steel, the influence of the point angle (lip relief angle) is lower by 49.198% (by 22.509%). The effect of the helix angle is 163.060% higher when machining 16MnCr5. Full article