Numerical and Experimental Advances in Innovative Manufacturing Processes

Journal Name	Impact Factor	CiteScore	Launched Year	First Decision (median)	APC
Alloys alloys	-	-	2022	22.5 Days	CHF 1000
Applied Sciences applsci	2.5	5.3	2011	18.4 Days	CHF 2400
Journal of Manufacturing and Materials Processing jmmp	3.3	5.1	2017	16.5 Days	CHF 1800
Materials materials	3.1	5.8	2008	13.9 Days	CHF 2600
Metals metals	2.6	4.9	2011	17.8 Days	CHF 2600

21 pages, 5551 KiB

Open AccessArticle

Neural Networks Applied for Predictive Parameters Analysis of the Refill Friction Stir Spot Welding Process of 6061-T6 Aluminum Alloy Plates

by Dan Cătălin Bîrsan, Viorel Păunoiu and Virgil Gabriel Teodor

Materials 2023, 16(13), 4519; https://doi.org/10.3390/ma16134519 - 21 Jun 2023

Cited by 5 | Viewed by 1783

Abstract

Refill friction stir spot welding (RFSSW) technology is a solid-state joint that can replace conventional welding or riveting processes in aerospace applications. The quality of the new welding process is directly influenced by the welding parameters selected. A finite element analysis was performed [...] Read more.

Refill friction stir spot welding (RFSSW) technology is a solid-state joint that can replace conventional welding or riveting processes in aerospace applications. The quality of the new welding process is directly influenced by the welding parameters selected. A finite element analysis was performed to understand the complexity of the thermomechanical phenomena during this welding process, validated by controlled experiments. An optimization model using neural networks was developed based on 98 parameter sets resulting from changing 3 welding parameters, namely pin penetration depth, pin rotation speed, and retention time. Ten parameter sets were used to verify the learning results of the optimization model. The 10 results were drawn to correspond to a uniform distribution over the training domain, with the aim of avoiding areas that might have contained distortions. The maximum temperature and normal stress reached at the end of the welding process were considered output data. Full article

(This article belongs to the Topic Numerical and Experimental Advances in Innovative Manufacturing Processes)

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15 pages, 6406 KiB

Open AccessArticle

Effect of Peel Ply on Resin Flow during Vacuum Infusion

by Sehun An, Jung-soo Kim, Hyung Doh Roh, Wie-Dae Kim, Jungwan Lee and Moon-Kwang Um

Materials 2023, 16(12), 4421; https://doi.org/10.3390/ma16124421 - 15 Jun 2023

Cited by 1 | Viewed by 1885

Abstract

Although various simulations have been conducted for the vacuum infusion process, most of the studies have considered only fabrics and flow medium and ignored the effect of peel ply. However, peel ply can affect resin flow because it is placed between the fabrics [...] Read more.

Although various simulations have been conducted for the vacuum infusion process, most of the studies have considered only fabrics and flow medium and ignored the effect of peel ply. However, peel ply can affect resin flow because it is placed between the fabrics and flow medium. To verify this, permeability of two types of peel plies was measured, and it was found that the permeability between the peel plies differed significantly. Moreover, the permeability of the peel plies was lower than that of the carbon fabric; thus, peel ply can cause a bottleneck in the flow in the out-of-plane direction. Some 3D flow simulations were conducted in cases of no peel ply and for two types of the peel plies to confirm the effect of peel ply, and experiments were also conducted for two types of the peel plies. It was observed that filling time and flow pattern were highly dependent on the peel plies. The smaller permeability of peel ply has, the greater effect of peel ply is. These results indicate that the permeability of peel ply is one of the dominant factors and should be considered in process design in vacuum infusion. Additionally, by adding one layer of peel ply and applying permeability, the accuracy of flow simulations can be improved for filling time and pattern. Full article

(This article belongs to the Topic Numerical and Experimental Advances in Innovative Manufacturing Processes)

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16 pages, 9606 KiB

Open AccessArticle

Hot Forging Die Design Optimization Using FEM Analysis for Near-Net Forming of 18CrNiMo7-6 Steel Pinion Shaft

by Nijenthan Rajendran, Charles Chemale Yurgel, Wojciech Z. Misiolek and Ricardo Alves de Sousa

Metals 2023, 13(4), 815; https://doi.org/10.3390/met13040815 - 21 Apr 2023

Cited by 5 | Viewed by 3554

Abstract

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 scrap; [...] Read more.

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 scrap; enhance specific properties; increase productivity. Near-net forged products have good dimensional accuracy and continuous metal flow lines, which are characteristic of improved mechanical properties. To avoid the traditional trial-and-error experimental method, the process and tool design were accomplished with a careful and detailed numerical simulation approach. In the present work, the Finite Element Method was used to develop a process model for the existing hot forging process of the 18CrNiMo7-6 steel pinion shaft used in a wind turbine. The developed numerical process model was validated via experiment including a comparison of the metal flow lines from the FEM model with the metallography results of the forged part. Two new die designs were proposed, and the simulation results were compared to the actual process to achieve improved geometry. The results for the new geometries showed improvements in terms of the die cavity filling for the new proposed dies and better results in grain flow orientation. Compared to the initial non-optimized die, the new designs improved the mechanical properties and savings associated with the lower volume of required raw material and fewer finishing operations. Considering the applied stresses and wear in the new near-net shape, the die geometry shall be updated to accommodate more severe solicitations. Naturally, all the improvements carried out are dependent on other factors such as the conditions of the equipment, operator skills, lubrication, and other variables. A surface heat treatment is also suggested for stress relief as a reliability improvement. Full article

(This article belongs to the Topic Numerical and Experimental Advances in Innovative Manufacturing Processes)

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21 pages, 121699 KiB

Open AccessArticle

Impact of Submerged Entry Nozzle (SEN) Immersion Depth on Meniscus Flow in Continuous Casting Mold under Electromagnetic Brake (EMBr)

by Alexander Vakhrushev, Ebrahim Karimi-Sibaki, Jan Bohacek, Menghuai Wu, Andreas Ludwig, Yong Tang, Gernot Hackl, Gerald Nitzl, Josef Watzinger and Abdellah Kharicha

Metals 2023, 13(3), 444; https://doi.org/10.3390/met13030444 - 21 Feb 2023

Cited by 5 | Viewed by 2368

Abstract

Complex multi-phase phenomena, including turbulent flow, solidification, and magnetohydrodynamics (MHD) forces, occur during the continuous casting (CC) under the applied electromagnetic brake (EMBr). The results of the small-scale experiment of the liquid metal model for continuous casting (mini-LIMMCAST) at the Helmholtz-Zentrum Dresden-Rossendorf (HZDR), [...] Read more.

Complex multi-phase phenomena, including turbulent flow, solidification, and magnetohydrodynamics (MHD) forces, occur during the continuous casting (CC) under the applied electromagnetic brake (EMBr). The results of the small-scale experiment of the liquid metal model for continuous casting (mini-LIMMCAST) at the Helmholtz-Zentrum Dresden-Rossendorf (HZDR), investigating MHD flow with a deep immersion depth of 100 mm, are supplemented by newly presented numerical studies with the shallow position of the submerged entry nozzle (SEN) at 50 mm below the meniscus. Herein, the focus is on the MHD effects at the meniscus level considering (i) a fully insulating domain boundary, (ii) a perfectly conductive mold, or (iii) the presence of the solid shell. The volume-of-fluid (VOF) approach is utilized to model a Galinstan flow, including free surface behavior. A multiphase solver is developed using conservative MHD formulations in the framework of the open-source computational fluid dynamics (CFD) package OpenFOAM^®. The wall-adapting local eddy-viscosity (WALE) subgrid-scale (SGS) model is employed to model the turbulent effects on the free surface flow. We found that, for the deep immersion depth, the meniscus remains calm under the EMBr for the conductive and semi-conductive domain. For the insulated mold disregarding the SEN position, the self-inducing MHD vortices, aligned with the magnetic field, cause strong waving of the meniscus and air bubble entrapment for shallow immersion depth. Secondary MHD structures can form close to the meniscus under specific conditions. The influence of the EMBr and immersion depth on the flow energy characteristics is analyzed using power spectral density (PSD). Full article

(This article belongs to the Topic Numerical and Experimental Advances in Innovative Manufacturing Processes)

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19 pages, 6048 KiB

Open AccessArticle

Design Optimization of Hot Isostatic Pressing Capsules

by Samaneh Sobhani, Marc Albert, David Gandy, Ali Tabei and Zhaoyan Fan

J. Manuf. Mater. Process. 2023, 7(1), 30; https://doi.org/10.3390/jmmp7010030 - 25 Jan 2023

Cited by 6 | Viewed by 3624

Abstract

Power metallurgy hot isostatic pressing (PM-HIP) is a manufacturing technique capable of producing net shape or near-net shape components with complicated geometries from materials that are difficult to melt and cast, mechanically deform or weld. However, the process and soundness of the outcome [...] Read more.

Power metallurgy hot isostatic pressing (PM-HIP) is a manufacturing technique capable of producing net shape or near-net shape components with complicated geometries from materials that are difficult to melt and cast, mechanically deform or weld. However, the process and soundness of the outcome are extremely sensitive to the geometric design of the capsule (also known as the die or can) that is used in the process. The capsule design for each new component involves several trial–error iterations to achieve the desired geometry and shape of the component. For each iteration, costly HIP experiments need to be conducted and new capsules need be manufactured with small modifications. In this study, a robust finite element analysis (FEA) model of the HIP process is developed, then wrapped in a multi-objective genetic algorithm (MOGA) optimization framework to obtain the optimal pre-HIP capsule design, which yields the desired post-HIP component geometry in one HIP run. The FEA-based optimization algorithm is validated by HIP experiments, showing excellent agreement between the experiment and the model. Full article

(This article belongs to the Topic Numerical and Experimental Advances in Innovative Manufacturing Processes)

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9 pages, 1081 KiB

Open AccessArticle

Experimental Investigation of the Effects of Process Parameters on the Radius of Curvature in Laser Forming Process of Cylindrical Surfaces

by Mehdi Safari, Seyed Mohammad Miralaa and Ricardo Alves de Sousa

Metals 2023, 13(1), 56; https://doi.org/10.3390/met13010056 - 25 Dec 2022

Cited by 2 | Viewed by 1532

Abstract

In this work, the laser forming process of cylindrical surfaces is studied experimentally. For this purpose, the effects of process parameters such as laser power, laser scanning scheme, and distance between irradiation lines on the radius of curvature of the laser-formed cylindrical surfaces [...] Read more.

In this work, the laser forming process of cylindrical surfaces is studied experimentally. For this purpose, the effects of process parameters such as laser power, laser scanning scheme, and distance between irradiation lines on the radius of curvature of the laser-formed cylindrical surfaces are examined. The design of experiment (DOE) method based on the Box–Behnken algorithm is also employed for investigations. To produce the cylindrical surfaces from flat sheets, parallel lines are used as the irradiation scheme. The results show that by increasing the laser power, the radius of curvature for a laser-formed cylindrical surface can be decreased. Additionally, the radius of curvature of the cylindrical surface increases when the scanning speed increases. In addition, it is concluded that the radius of curvature decreases when the distance between irradiation lines increases. Full article

(This article belongs to the Topic Numerical and Experimental Advances in Innovative Manufacturing Processes)

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14 pages, 3788 KiB

Open AccessArticle

A Study on the Acquirement Method of Mechanical Property Parameters in the Different Base Materials Composite Region of Clad Rebar

by Zecheng Zhuang, Zhen Li, Xuehai Qian, Jianping Tan, Lei Zeng, Yang Zhao and Yong Xiang

Materials 2022, 15(24), 8929; https://doi.org/10.3390/ma15248929 - 14 Dec 2022

Cited by 2 | Viewed by 1513

Abstract

Clad rebar is one of the key structures of marine and construction services. Therefore, it is of great importance to acknowledge the mechanical property parameters of the composite region in the structural integrity evaluation of clad rebar. The different base materials of clad [...] Read more.

Clad rebar is one of the key structures of marine and construction services. Therefore, it is of great importance to acknowledge the mechanical property parameters of the composite region in the structural integrity evaluation of clad rebar. The different base materials of clad rebar (20MnSiV/316L steel, 35#/316L steel, 45#/316L steel, and 55#/316L steel) are researched in this study. The composite area is further refined, and simultaneously, a refinement model of the composite region of clad rebar is established. In view of the fact that a surface hardness experiment is quite easy to conduct, a proposed method consists of obtaining the mechanical property parameters of materials using the surface hardness test. The mechanical property parameters are acquired; moreover, the relationship between yield stress and surface hardness of the stainless steel clad rebar is set up. We used this method to acquire the mechanical parameters of a composite surface uneven area of clad rebar, and we established a mechanical parameters mathematics model of clad rebar, it is a significant basis for a structural integrity evaluation of cladding materials. Full article

(This article belongs to the Topic Numerical and Experimental Advances in Innovative Manufacturing Processes)

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19 pages, 9298 KiB

Open AccessArticle

Mechanical Wave Propagation in Solidifying Al-Cu-Mn-Ti Alloy and Its Effect on Solidification Feeding

by Wei Chen, Shiping Wu and Rujia Wang

Metals 2022, 12(12), 2001; https://doi.org/10.3390/met12122001 - 22 Nov 2022

Cited by 2 | Viewed by 1591

Abstract

The wave field in solidifying metals is the theoretical basis for analyzing the effects of mechanical vibration on solidification, but there is little research on this topic. This study investigated the wave field and its effect on the solidification feeding in the low-pressure [...] Read more.

The wave field in solidifying metals is the theoretical basis for analyzing the effects of mechanical vibration on solidification, but there is little research on this topic. This study investigated the wave field and its effect on the solidification feeding in the low-pressure sand casting (LPSC) of Al-Cu-Mn-Ti alloy through experimental and numerical investigation. The solidification temperature field was simulated by Anycasting^TM, and the wave field was simulated by the self-developed wave propagation software. The shrinkage defect detection showed that applying vibration had a greater promotional effect on feeding than increasing the holding pressure. The predicted defects under vibration coincided with the detections. The displacement field showed that the casting vibrated harmonically with an inhomogeneous amplitude distribution under the continuous harmonic vibration excitation, and the vibration energy was mainly concentrated in the feeding channel. With solidification, the

u_{x}

amplitude reduced rapidly after the overlapping of dendrites, finally reducing slowly to a certain level; the

u_{y}

amplitude reduced dramatically after the occurrence of a quasi-solid phase, finally reducing slowly to near zero. Mechanical vibration produced a severe shear deformation in the quasi-liquid phase—especially in the lower feeding channel—reducing the grain size to promote mass feeding. The feeding pressure and feeding gap were changed periodically under vibration, causing the vibration-promoting interdendritic feeding rate to fluctuate and eventually stabilize at about 13.4%. The mechanical vibration can increase the feeding pressure difference and change the blockage structure simultaneously, increasing the formation probability of burst feeding. Full article

(This article belongs to the Topic Numerical and Experimental Advances in Innovative Manufacturing Processes)

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15 pages, 5064 KiB

Open AccessArticle

Calibration of Finite Element Model of Titanium Laser Welding by Fractional Factorial Design

by Ruben Escribano-García, Pedro Álvarez and David Marquez-Monje

J. Manuf. Mater. Process. 2022, 6(6), 130; https://doi.org/10.3390/jmmp6060130 - 26 Oct 2022

Cited by 4 | Viewed by 2252

Abstract

This paper focuses on the calibration of heat source parameters to reproduce temperatures and distortions in welded joints. Specifically, the proposed methodology, which combines the Finite Element Method and Design of Experiments, is applied to calibrate a T-joint dissimilar titanium laser welding process. [...] Read more.

This paper focuses on the calibration of heat source parameters to reproduce temperatures and distortions in welded joints. Specifically, the proposed methodology, which combines the Finite Element Method and Design of Experiments, is applied to calibrate a T-joint dissimilar titanium laser welding process. The thermal problem is addressed using a 3D transient model with a Conical Gaussian heat flux, and the mechanical problem is tackled using a 3D elastic-plastic model. A Fractional-Factorial Design is performed to define a set of thermo-mechanical uncoupled models. Finally, optimal parameter combinations that replicate experimental data are identified. This methodology allows automation that replaces the traditional trial and error process, which frequently does not provide good results, is an exhausting task and requires a dubious amount of time. Full article

(This article belongs to the Topic Numerical and Experimental Advances in Innovative Manufacturing Processes)

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23 pages, 5294 KiB

Open AccessSystematic Review

Response Surface Methodology Using Observational Data: A Systematic Literature Review

by Mochammad Arbi Hadiyat, Bertha Maya Sopha and Budhi Sholeh Wibowo

Appl. Sci. 2022, 12(20), 10663; https://doi.org/10.3390/app122010663 - 21 Oct 2022

Cited by 35 | Viewed by 6213

Abstract

In the response surface methodology (RSM), the designed experiment helps create interfactor orthogonality and interpretable response models for the purpose of process and design optimization. However, along with the development of data-recording technology, observational data have emerged as an alternative to experimental data, [...] Read more.

In the response surface methodology (RSM), the designed experiment helps create interfactor orthogonality and interpretable response models for the purpose of process and design optimization. However, along with the development of data-recording technology, observational data have emerged as an alternative to experimental data, and they contain potential information on design/process parameters (as factors) and product characteristics that are useful for RSM analysis. Recent studies in various fields have proposed modifications to the standard RSM procedures to adopt observational data and attain considerable results despite some limitations. This paper aims to explore various methods to incorporate observational data in the RSM through a systematic literature review. More than 400 papers were retrieved from the Scopus database, and 83 were selected and carefully reviewed. To adopt observational data, modifications to the procedures of RSM analysis include the design of the experiment (DoE), response modeling, and design/process optimization. The proposed approaches were then mapped to capture the sequence of the modified RSM analysis. The findings highlight the novelty of observational-data-based RSM (RSM-OD) for generating reproducible results involving the discussion of the treatments for observational data as an alternative to the DoE, the refinement of the RSM model to fit the data, and the adaptation of the optimization technique. Future potential research, such as the improvement of factor orthogonality and RSM model modifications, is also discussed. Full article

(This article belongs to the Topic Numerical and Experimental Advances in Innovative Manufacturing Processes)

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