1,721,182 research outputs found
On the Choice of Tool Material in Friction Stir Welding of Titanium Alloys
No full textFriction Stir Welding (FSW) is a solid state welding process patented in 1991 by TWI; initially adopted to weld aluminum alloys, is now being successfully used also for magnesium alloys, copper and steels. The wide diffusion the process is having is due to the possibility to weld both materials traditionally considered difficult to be welded or "unweldable" by traditional fusion welding processes due to peculiar thermal and chemical material properties, and complex geometries as sandwich structures and straightening panels. Recently, research is focusing on titanium alloys thanks to the high interest that such materials are getting from the industry due to the extremely high strength-weight ratio together with good corrosion resistance properties. At the moment, the main limit to the industrial applicability of FSW to titanium alloys is the tool life, as ultra wear and deformation resistant materials must be used. In this paper a, experimental study of the tool life in FSW of titanium alloys sheets at the varying of the main process parameters is performed. Numerical simulation provided important information for the fixture design and analysis of results. Tungsten and Rhenium alloy W25Re tools are found to be the most reliable among the ones considered
Wear Modeling in Mild Steel Orthogonal Cutting when using Uncoated Carbide Tools
No full textWear prediction in machining has been recently studied by FEM although the use of numerical methods for such applications is still a very challenging research issue. In fact, wear phenomenon involves many aspects related to process mechanics which require a very accurate modelling. In other words, only a very punctual code set-up can help the researchers in order to obtain consistent results in FE analysis. The high relative velocity between chip and tool requires effective material models as well as friction modelling at the interface. Moreover the prediction of temperature distribution is another critical task; in the paper some different procedures are discussed. Subsequently a wear model is presented and calibrated in order to obtain a suitable tool to be implemented in a FE code with the aim to describe the wear evolution during the simulation process. A proper designed experimental campaign supplied some reference data for model set-up and verify in the practical application. All these aspects are carefully discussed in the pape
Design and development of a new machine tool for continuous friction stir extrusion
No full textIn the present paper the Continuous Friction Stir Extrusion process (CFSE), derived from the already known Friction Stir Extrusion (FSE), is proposed for effective solid-state recycling of metal scraps. A new dedicated machine tool was designed and developed. A Lagrangian implicit thermomechanical numerical model was set up and used to determine the proper ranges of the most relevant process parameters. An effective case study is proposed, involving the actual extrusion of a recycled wire in a continuous way. Metallurgical observations and mechanical characterization tests were carried out on the obtained specimen showing the potential of the process and its industrial feasibility.(c) 2023 CIRP
Multi-directional vs. mono-directional multi-step strategies for single point incremental forming of non-axisymmetric components
No full textMulti Stage approach is used in Single Point Incremental Forming (SPIF) to overcome one of the main forming limitations, namely the maximum wall angle, characterizing the single stage process. In this paper, different multi-path strategies for the production of parts with flat edges are considered in order to evaluate the best solution in terms of feasibility and geometrical accuracy of the final part: A) mono-directional incremental draw angle; B) mono-directional incremental draw angle with increasing part side; C) Multi-directional approach with non-horizontal path planes. Strain evaluation by means of CGA (Circular Grid Analysis) and defect analysis have been carried out in order to identify the main limitations of each approach. A defect-free part has been obtained with Strategy C. The developed numerical analysis, showing good agreement with experimental thickness distribution, highlighted the peculiar material redistribution from the thicker zones to the thinner ones occurring using Strategy C
Finite Element Analysis of the Thermo-Mechanical Behaviour of Coated Tools in Mild Steel Machining
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