148 Results Found

Metalworking is an essential process for the manufacture of machinery and equipment components. The design of the die geometry is an essential aspect of metalworking, and directly affects the resultant product’s quality and cost. As a matter of...

The formability of aluminum alloy sheet in electromagnetic impaction deformation has attracted the attention of numerous researchers for the past decades. However, the influences of die geometry and high-speed impaction electromagnetic deformation on...

The main challenge in a polymer coextrusion process is to have a good die design prior to the process, which can minimize the geometric errors that are caused by extrusion swell and interface motion. For this purpose, a coupling method of optimizatio...

Electromagnetic riveting (EMR) is a high-speed solid-state joining technique with growing relevance in aerospace manufacturing, particularly for titanium alloys such as Ti-6Al-4V. Although the mechanical behavior of EMR joints has been previously stu...

The paper presents the results of FEM computer simulations of the drawing process on a cylindrical journal of thin-walled CuSn8 alloy tubes. This study demonstrates through FEM simulations that the drawing angle significantly affects the state of str...

The efforts to increase the operating speed of the wire drawing process play a crucial role regarding the industrial productivity. The problem is closely related to various features such as heat generation, material plastic deformation, as well as th...

The presented research focuses on assessing the impact of the geometry of the compaction channel on the quality of pellets produced from giant miscanthus, silphium, and sida. Geometry refers to parameters such as L, D, α, and the diameter of th...

Quality regulation of extruded expanded foods represents a critical technological challenge in this field. Current research has predominantly focused on the impact of extrusion processing parameters, largely overlooking the regulatory role of die str...

As a result of conventional wire-forming processes, the residual stress distribution in wires is frequently unfavorable for subsequent forming processes such as bending operations. High tensile residual stresses typically occur in the near-surface re...

Extrusion welding of AlZnMg alloys encounters great technological difficulties in practice associated with high shaping forces and the low quality of longitudinal welds. Three different chemical compositions of 7021 aluminum alloy, differing in terms...

Coat-hanger die design aims for optimization of the die geometry of the body and the flow distribution manifold, such that through the exit at the die lip homogeneous distribution of the polymer melt is achieved. This paper proposes a novel methodolo...

The optimization of polymer extrusion processes is crucial for improving product quality and manufacturing efficiency in plastic industries. This study aims to investigate the viscoelastic flow behavior of high-density polyethylene (HDPE) through an...

Traditional methods for wrinkled tubes involve welding processes and additional elements, such as plates, screws, rivets, and guides. Considering all the limitations of these processes, this work aims to propose a methodology that allows for maximisi...

A coupled surface response optimization method with a three-dimensional finite volume method is adopted in this study to identify five independent geometric variables of the die interior that provides a design with the lowest velocity variance at the...

The availability of tools for predicting quality in high pressure die casting is a challenging issue since a large amount of defects is detected in components with a consequent worsening of the mechanical behavior. In this paper, a tool for predictin...

This study investigates the influence of die design parameters on forging forces and thermomechanical responses during near-solidus forging (NSF) of complex steel components. Finite element simulations using Forge NxT analyzed six die configurations...

The paper presents a method for checking the geometry of stamped car body parts using a 3D optical measurement system. The analysis focuses on the first forming operation due to the deformation and material flow associated with stall thresholds. An e...

Increasing the durability of trimming dies used to clean anodes is a very important goal in order to reduce the costs involved in obtaining aluminum. The research focused both on choosing an optimal material for the execution of trimming dies and on...

A review of the different coextrusion processes and the related processing problems is presented. A one-dimensional bilayer coextrusion Poiseuille flow model is first developed with Newtonian and shear-thinning rheological behaviors. A transitory com...

This work presents a novel fully automated computational framework for optimizing profile extrusion dies, aiming to achieve balanced flow at the die flow channel outlet while minimizing total pressure drop. The framework integrates non-isothermal, no...

The wire drawing process, used for both ferrous and non-ferrous metals, employs different machines depending on the material and wire diameter: breakdown, single- or multi-wire machines for non-ferrous, and bull block machines for ferrous and non-fer...

The effects of tool wear on the accuracy of complex geometry in thin-sheet blanking are examined. Two illustrative examples are given. The first example considers the effect of tool wear when using a cutting die with a 5% clearance value. The second...

This paper presents a wear analysis of tungsten carbide drawing dies in the process of steel wire drawing. The finite element method (FEM) analysis showed a significant correlation between drawing die geometry, single reduction size and drawing speed...

In this study, porthole die used for extrusion of a solid heatsink profile with wall thickness variation ratio up to 15.3 was designed using finite element (FE) simulations. To improve the flow balance in the die, a design approach was introduced to...

Hollow tubes are generally manufactured using porthole die extrusion. A finite element software QForm is used to analyze the material flow of aluminum alloy A6061 tubes inside a specially designed porthole die during tube extrusion. High welding pres...

The article presents a comprehensive review of key issues and challenges related to enhancing the durability of hot forging tools. It discusses modern strategies aimed at increasing tool life, including modifications to tool materials, heat treatment...

This manuscript presents an advanced modeling methodology developed to accurately simulate the temperature field evolution in the die and wheel in an industrial low-pressure die casting (LPDC) machine employed in the production of A356 automotive whe...

The objective of the presented work was to develop a new forging process for a pinion shaft as a component of a wind turbine. A study of near-net-shape forming using Deform 3D software was performed to reduce operational cost, time, and material scra...

An investigation has been carried out into the microstructures developed during the early stages of equal channel angular extrusion (ECAE) in a polycrystalline single-phase Al-0.13Mg alloy, with emphasis on the substructural alignment with respect to...

This work focuses on the extrusion foaming under CO2 of commercial TPV and how the process influences the final morphology of the foam. Moreover, numerical modelling of the cell growth of the extrusion foaming is developed. The results show how a pre...

The formability of the drawn part in the deep drawing process depends not only on the material properties, but also on the equipment used, metal flow control and tool parameters. The most common defects can be the thickening, stretching and splitting...

Internal die cooling during forging can reduce thermal loads, counteracting surface softening, plastic deformation and abrasive die wear. Additive manufacturing has great potential for producing complex geometries of the internal cooling channels. In...

In the V-bending of sheet metals using a pair of plastic punch and die manufactured by a 3D printer, the effects of two different dimensions designed with the same tool geometry on the deformation behaviors of the punch, die, and sheet were evaluated...

In order to not only produce an open-die forged part with the desired final geometry but to also maintain economic production, precise process planning is necessary. However, due to the incremental forming of the billet, often with several hundred st...

High-pressure die casting (HPDC) can produce precise geometries in a highly productive manner. In this paper, the failure location and cycles were identified by analyzing the fatigue behavior of the die subjected to repeated thermal stress. An energy...

The use of coat-hanger dies is prevalent in the plastic film and sheet extrusion industry. The product quality and the power of the extrusion machine depend on the uniformities of the fluid velocity at the exit and the pressure drop. Die manufacturer...

The extrusion of hollow profiles from hard-deformable AlZnMg alloys by using porthole dies encounters great technological difficulties in practice. High extrusion force accompanies the technological process, which is caused by high deformation resist...

On the way toward MEMS miniaturization, the quantification of geometric uncertainties stands as a primary challenge. In this paper, an approach that combines genetic algorithms and proper orthogonal decomposition with kriging surrogate modeling was p...

In the last decades, the application of automatic control techniques in freeform bending processes was limited to the motion control of the bending die, i.e., the workpiece itself was not considered inside the closed-loop control system. In a previou...

Modern optical fiber required a double-layer resin coating on the glass fiber to provide protection from signal attenuation and mechanical damage. The most important plastics resin used in coating of fiber optics are plasticized polyvinyle (PVC), low...

In the polymer sheet processing industry, the primary objective when designing a coat-hanger die is to achieve a uniform velocity distribution at the exit of the extrusion die outlet. This velocity distribution depends on the internal flow channels o...

Embossing is a functional and strategic process for creating high-quality multi-sensory tissue-paper products. Embossing modifies the sheet surface by generating hill and/or valley designs, changing the third-dimension z with a compressive die. This...

The use of 3D printing has proven to have significant benefits to manufacture components with complex geometries with several types of materials and reinforcements for a wide variety of uses including structural applications. The focus of this study...

The growing demand for precision and consistency in the forging industry has heightened the need for predictive simulation tools. While extensive research has focused on parameters such as flow stress, die wear, billet fracture, and residual stresses...

Innovative approaches in hot forging, such as the use of floating dies, which aim to minimise burr formation by controlling material flow, require precise management of die geometry distortions. These distortions, primarily caused by thermal gradient...

This study investigates the melt-flow behavior of the AlSi9Cu3 alloy during high-pressure die casting using a combined experimental and numerical approach. A transparent die and a high-speed camera were used to capture the transient motion of the mel...

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 weig...

This paper investigates the critical plunger velocity in high-pressure die casting during the slow phase of the piston motion and how it can be determined with computational fluid dynamics (CFD) in open source software. The melt-air system is modelle...

This study presents a comprehensive evaluation of a novel spinneret design to enhance polymer melt extrusion performance in fibre spinning production. Computational fluid dynamics (CFD) simulations using ANSYS Polyflow 2024 R2 are employed to analyse...

A closed die forging process was developed to successfully forge an automotive suspension component from AZ80 Mg at a variety of different forging temperatures (300 °C, 450 °C). The properties of the forged component were compared and contrasted with...