Springback and longitudinal bow are two major shape defects in gradual forming processes like chain-die forming and roll forming. In this study, the springback and longitudinal bow of AHSS in chain-die forming of hat and U profiles are investigated through experiment and finite element simulation. The disparity of springback along the longitudinal direction and longitudinal bow signifies complex deformation

Plane strain compression of cylindrical billets with flat dies has been studied in this paper. A deformation model has been proposed and the dimensions of the deformed billet cross-section for a given press stroke have been determined. To analyze the process, two types of theoretical approaches, i.e., the upper bound technique and the slab method of analysis have been applied and the required forming

Ultrasonic assisted grinding (UAG) is one of the most suitable methods for the processing of hard and brittle materials such as silicon carbide (SiC). During UAG of SiC, the machining quality is directly determined by the material removal mechanism. However, the research on the material removal mechanism for UAG of SiC is still not sufficiently developed. To achieve better comprehension of the material

Finite element (FE) technique has been used extensively to have a deeper understanding on the mechanics of metal cutting and for process optimization. The accuracy of the model is dependent on both the highly non-linear material plasticity model and the simulated friction condition between contacting surfaces. Hence, majority of the predicted results were validated from direct or indirect experimental

Ti-6Al-4V alloy has been widely used in industrial fields. Electrical discharge machining (EDM) is a commonly used technology for machining Ti-6Al-4V alloy. During EDM of Ti-6Al-4V alloy, the thermal and physical characteristics of tool electrode have an important influence on processing characteristics. In order to study the influence of different electrode materials on the processing characteristics

The nickel alloy has good mechanical strength and corrosion resistance at high temperature; it is extensively used in aerospace and biomedical and energy industries, as well as alloy designs of different chemical compositions to achieve different mechanical properties. However, for high mechanical strength, low thermal conductivity, and surface hardening property, the nickel alloy has worse cutting

A novel 3D model was developed to study the effects of process parameters on the friction stir welding (FSW) of Al-SiC composites with regards to residual stresses and peak temperatures. An arbitrary Lagrangian–Eulerian formulation and remeshing were employed to account for large plastic deformations. The thermal history of the workpiece was used to define a coupled thermo-mechanical model. Al-SiC

In this paper, we demonstrate the fabrication of S-shaped micron-sized constrictions on steel (Fe3CII) surface using the femtosecond laser ablation technique. The femtosecond laser used has a wavelength of 775 nm, a power range of 0–1000 mW, a pulse duration of 130 fs, and a pulse repetition rate of 1–2 kHz. The ultra-low-pulse duration of 130 fs enables ablation of material surfaces without excessive

This paper proposes a new method to simultaneously calibrate the milling force coefficients and the cutter runout parameters in helical end milling. The linear cutting force model is utilized with the consideration of the runout of the cutter, and the mathematical relationships between the instantaneous milling forces and the milling force coefficients are expressed by an underdetermined system of

Collaborative robots can be a proper solution to improve the throughput of manual systems without reducing their flexibility. To effectively use cobots in productive systems, it is fundamental to develop a suitable task allocation model that considers collaboration. Hence, we present a model for collaborative assembly line balancing (C-ALB) which considers paralleling tasks and collaboration in the

In this study, a new cost-effective and high-precision process chain for the fabrication of large-scale infrared (IR) diffractive lens arrays on chalcogenide glass is proposed. First, a positive diffractive lens array is fabricated on a polymethylmethacrylate (PMMA) master substrate by employing a step-and-repeat hot imprinting process. The direct hot imprinting can transfer microstructures from a

In this paper, possibility of improving high-speed reciprocating wire electrical discharge machine (HS-WEDM) machining performances using SiC nanofluids was studied. The performances of SiC nanofluid high-speed WEDM and conventional emulsion dielectric high-speed WEDM were compared. An extra dielectric circulating system was used to satisfy requirement of adding SiC nanofluids. Type of operation, dielectric

Although Inconel 718 is an important material for modern aircraft and aerospace, it is a kind material, which is known to have low machinability. Especially, while these types of materials are machined, high cutting temperatures, BUE on cutting tool, high cutting forces, and work hardening occur. Therefore, in recent years, instead of producing new cutting tools that can withstand these difficult conditions

A novel platform for remote collaboration is proposed in this paper. This platform makes it possible for an expert to assist a worker for industrial assembly task in different places. Our goal is to compare the effect of sharing head pointer in a SAR remote collaboration with AR annotations in manufacturing. First, we develop an AR remote collaborative platform. This platform implements sharing a remote

Ultrasonic-assisted machining is an advanced method which could improve the process of machining. Besides, simulation modeling process is a method to help the researchers analyze different aspects of the process with more details in a shorter time. Simulation of ultrasonic-assisted machining is also a field of research that is of interest to researchers working in the field of machining processes.

The calibration of areal surface topography measuring instruments is of high relevance to estimate the measurement uncertainty and to guarantee the traceability of the measurement results. Calibration structures for optical measuring instruments must be sufficiently small to determine the limits of the instruments. Besides other methods, micro-milling is a suitable process for manufacturing areal material

The recent step towards “Sustainable Manufacturing (SM)” and efforts to reduce the consumption of cutting fluids have become the hot topic of research these days. Various efforts and strategies have been employed in the modern manufacturing sector to control the environmental pollutions generated from the application of cutting fluids. Therefore, in this holistic work, one such effort of reducing the

This paper proposes a new measurement method based on a single probe scanning to measure the roundness error of the artifact. The presented method simplifies the mathematical processing. There is no need for complex forward and inverse Fourier transforms. The probe is installed on a micro-stage platform, and a voice coil motor drives the micro-stage platform. In this paper, a precise mathematical model

Hot cracking susceptibility and the formation of brittle martensite phase are the main factors that limit the weldability of a dissimilar joint between carbon steel (CS) and austenitic stainless steel (SS). In this study, the self-constraint finger test was used to correlate the welding thermo-mechanical field with the crack susceptibility of a dissimilar weld between the CS ASTM A36 and SS AISI 304L

Taking the specific geometry and gesture of the diamond grains into consideration, a novel simulation model to predict the machined surface topography in grinding of superalloy (GH4169) is presented, where the arrangements of abrasive grains and the plowing induced pile-up ridges are also integrated. Based on the designed surface topography of the grains arrayed brazed diamond wheels, the grinding

This study aims to investigate the formability of the AA2198-T3 Al-Li alloy in hydro-mechanical deep drawing (HMDD), through experimentation and finite element simulation. The effects of the most critical factors were studied: die cavity pressure and forming temperature; the forming temperature is selected at 298K and 423K. The Gurson−Tvergaard−Needleman model (GTN model) was employed to analyze the

Pitting and wear often appear on heavy-duty-axle gears due to their harsh working conditions, such as high torques, high loads, and poor lubrication. Shot peening is a popular surface strengthening method for gears. In order to ensure complete coverage during shot peening, 100~200% coverage is usually prescribed for most gears. However, it is difficult to effectively improve the contact fatigue and

The gap discharge state monitoring system for wire electrical discharge machining (WEDM) has an important impact on machining performance. Due to sampling noise and the slight differences between different types of discharge pulses in reciprocating traveling WEDM, it is easy to misjudge discharge pulse types based solely on the gap voltage and current in the conventional discharge state monitoring

Surface properties play a critical role in the structural integrity of any component and this becomes even more critical for weld joints. Laser shock peening (LSP) is one of the non-contact methods which is getting popular in industries to enhance surface properties for improving service life, mainly fatigue of engineering components. In the present study, electron beam welding (EBW) of commercially

The spindle system is the key component of the CNC (computer numerical control) grinding machine. In order to explore the factors affecting the reliability of the CNC grinding machine spindle system and find out measures to improve the reliability of the CNC grinding machine, this paper proposed a reliability evaluation algorithm based on fault data. Five common distribution functions are used to establish

In order to improve the uniformity of the flow field, the processing stability, and the machining accuracy of the electrochemical machining (ECM) of cross groove structure, in this work, the flow field simulation model of the ECM of cross groove was established, and a flow field analysis was carried out based on the cathodes with different holes. Further, an experimental device was designed for the

Utilization of laser powder deposition (LPD) as an innovative repair tool for damaged steel components is increasingly growing in recent years. This paper investigates repairing a standard US light rail using LPD. No study has focused on repairing standard US rails thus far. Besides, this is the first time that a three-dimensional finite element model is developed where element-birth-and-kill technique

Computer-controlled ultra-precision polishing technology is widely used for high-quality surface processing. However, its polishing tool has some shortcomings, such as limited adaptability and more surface damage to the complex surface. Therefore, a new smart material-based abrasive tool named magnetorheological elastic polishing composites (MREPCs) and its flexible polishing method is proposed. This

In this paper, the subject of research is the AZ31B magnesium alloy. Aiming at the poor formability of magnesium alloys at room temperature, we have introduced isothermal local loading technology to improve the formability of magnesium alloys. We combined finite element simulations and experiments to study the effects of forming parameters on the forming limit angle and thinning rate of single-point

The distribution characteristics of machining errors in high energy efficiency milling are an important index to evaluate the surface geometry parameters, cutting stability, and dynamic cutting efficiency. The existing methods for machining errors focus on the overall level of the parameters of a machined surface and the degree of deviation from the index and ignore the influence of the instantaneous

The ultrasonic elliptical vibration cutting (UEVC) technique has been found to be a promising technique for ultra-precision machining of microstructural functional surfaces. However, the current UEVC technique can not achieve higher frequency ultrasonic cutting due to its rigid orthogonal vibration transmission. To further study the characteristics in high-frequency UEVC of microstructural surface

In machining processes, cutting tools reach temperatures higher than 900 °C, thus deteriorating their mechanical properties. To reduce this problem, cutting tools are coated with materials possessing thermal insulation characteristics. Such coatings benefit machining, providing faster cutting speeds and tool life. However, the heating of the tools is still present. Therefore, in this work, an analysis

To reduce the thermal stress at the clad layer and further reduce the crack generation in the laser cladding process, a method of controlling the cracks at the clad layer by changing the laser energy density is proposed. Comparative thermal–mechanical coupling finite element analysis was performed on the uniform rectangular and convex shape beam spot cladding processes on plasma-sprayed MCrAlY coating

Springs are mechanical devices which are used quite extensively in different industries and mechanisms. Traditionally, springs have been manufactured by wrapping a hot wire around a rotating mandrel. This process has certain limitations because it is difficult to vary the spring parameters such as pitch and wire diameter. However, through the use of AM processes, with the complexity-for-free approach

The effects of deep rolling parameters, particularly, work speed and cooling conditions (dry and cryogenic) on the surface integrity of AISI 304L machined samples and their further impact on uniform and localized corrosion behavior in chloride environment were experimentally investigated in this work. The electrochemical behavior of machined and deep rolled samples was assessed using cyclic potentiodynamic

In this paper, a finite element (FE) cutting model for particle-reinforced metal matrix composites (PRMMCs) considering material damage was developed to predict SiC particle failure, cutting forces, and machined surface topography in SiCp/Al composite machining, and to analyze the dynamic mechanisms of chip formation and particle failure evolution. The validity of the simulation model was verified

The present study examined the effects of drilling parameters such as spindle speed (N), feed rate (f), diameter of the tools (d) and drill geometry such as twist drills (HSS-TiN) and brad and spur drills (BSD) used on delamination damage in a biosandwich structure consisting of an epoxy matrix reinforced with bidirectional jute fibres and cork (JFCE). Response surface methodology (RSM) and artificial

Stainless steel is a kind of difficult-to-machine material, and the work hardening in milling easily leads to high energy consumption and poor surface quality. Thus, the influence of machined surface hardness on energy consumption and surface quality cannot be ignored. To solve this problem, the prediction models for machine tool specific energy consumption and surface roughness are developed with

Centrifugal compressor impeller is one of the main parts in supercharger of the diesel engines to increase the engine power. Because the blade profile is complex and its thickness is generally thin as 0.7~2.0mm, it is important to ensure the precision for the enhancement of the quality of product. In order to prevent the formation of shrinkage defects, optimal gating systems were designed to examine

Forging dies are crucial in forging to manufacture accurate workpieces. These dies are generally made of AISI H steel series and hardened and tempered medium carbon alloy steel. Dies are processed by using high-speed milling + polishing or electrical discharge machining + polishing. The surface quality of the workpiece depends on the surface properties of these dies, where surface roughness, material

Manufacturability without supports in design studies for additive manufacturing (AM) brings many advantages such as time, cost, part surface quality, and design freedom. It is thought that the geometries that can be produced without support will help the more widespread use of AM technologies. In this study, the unsupported manufacturability and efficiency research of conformal cooling channel (CCC)

This paper focuses on predicting regenerative chatter onset conditions in machining stainless steel. To establish a credible regenerative chatter model, the mass and flexibility of the workpiece are considered and modeled for lateral deformations using the Timoshenko beam theory; the motion of the cutting tool is modeled as a mass-spring-damper system. The varying natural frequencies and dynamic stiffness

Surface machined by high-speed wire electrical discharge machining (HS-WEDM) at super-high thickness (more than 1000 mm) cutting suffers from uneven surface, a major problem that has been investigated in this paper. According to the analysis, as wire frame span increases, the rigidity of the wire electrode decreases, and under the action of discharge explosive force, wire electrode vibration intensifies

To establish the dynamic model of machine tool structure is an important means to assess the performance of the machine tool structure during the cutting process. It is necessary to study the dynamics of the machine tools in different configurations for the sake of analyzing the dynamic behavior of the machine tools in the entire workspace. In this paper, a robust approach is presented to build an

In order to achieve the grindability of super abrasive grinding wheels, a new kind of electroplated CBN grinding wheel has been designed based on the phyllotaxis theory of biology, and fabricated by the use of ultraviolet lithography and electroplating technology. With the help of grinding experiments, the grinding performances of the cylindrical wheels with different abrasive configurations, including

Titanium alloy is widely used for manufacturing structural parts of high-end equipment due to its excellent mechanical properties, despite difficulty in being machined. Nowadays, titanium alloy parts are mostly machined by ball-end milling cutters (BEMC), but the cutting edge structure of the BEMC limits the improvement in machining efficiency and surface quality of the parts. In this paper, a circular-arc

FEA-based Gaussian density heat source models were developed to study the effect of convective and radiative heat sinks on the transient temperature field predicted by the available analytical solution of the purely conduction-based Goldak’s heat source. A new complex 3D Gaussian heat source model, incorporating all three modes of heat transfer, i.e. conduction, convection and radiation, has been developed

To improve the efficiency of complex assemblies in large-scale assembly sequence planning, an intelligent sequence planning method for constructing an assembly hybrid G-diagram model to realize the hierarchy of assembly structures is proposed. The assembly hybrid G-diagram model is constructed according to the assembly relationship semantics, and the assembly relationship semantics can be transformed

To avoid degradation of material properties, high equipment investment, low efficiency, and potential safety issues caused by conventional technologies like line heating, multi-point plate forming, and explosive forming, a new die-less single-tool multi-point plate forming (DS-MPF) technology is proposed. In DS-MPF, a moving bar is used as a single forming tool and combined with horizontal and vertical

A Correction to this paper has been published: https://doi.org/10.1007/s00170-021-07508-2

An Correction to this paper has been published: https://doi.org/10.1007/s00170-021-07458-9

An Correction to this paper has been published: https://doi.org/10.1007/s00170-021-07449-w

A correction to this paper has been published https://doi.org/10.1007/s00170-021-07310-0

Often, surface mechanical treatment (SMT) or heat (quenching, tempering) is used to improve the surface condition and mechanical characteristics such as impact resistance and tensile strength. Hence the objective of this experimental work, where ball burnishing (BB) as well as quenching and tempering were applied on S355 JR steel specimens, is to evaluate the surface hardness Hv, the rupture strength

This work describes the effect of newly introduced faying surfaces on the microstructure and the mechanical properties of dissimilar weld joints of AA6063 and AISI304L alloys that are fabricated through the rotary friction welding process (RFW). The experiments were done as six different experimental methods (‘A’ to ‘F’) at 1300 rpm rotation, 18 MPa friction pressure (FP), 24 MPa upset pressure (UP)

This article establishes a finite element method (FEM) model to characterize and classify the chip morphologies of Inconel 718, which tends to form shear localized chips. Orthogonal cutting simulations in a wide range of speeds with three uncut chip thicknesses are carried out to model the plastic deformation of Inconel 718 and thus the formation of the serrated chips by utilizing the Johnson-Cook

A tangential ultrasonic vibration-assisted gear grinding (TUVAGG) system was proposed in this paper to enhance the machining accuracy and performance of gears. Firstly, the longitudinal resonant vibration system of the TUVAGG was designed based on the non-resonant theory. The frequency equation and the displacement characteristics for the vibration system were obtained for the particular boundary conditions

Recent years have witnessed the rapid development of electromagnetic flanging of tubes, which uses coils to generate electromagnetic forces to achieve the deformation with high speed but without contact. However, the electromagnetic force decays dramatically with the increase of distance, resulting in strict requirements of geometrical matching between the coils and the tubes. Usually, new coils should

Tube-to-tubesheet welding is widely used in manufacturing of heat exchangers, steam turbines, condensers, boilers, etc. It has evolved from manual arc welding, automatic welding to digital welding. In the future, it will be toward intelligent welding. However, the key technologies related to tube-to-tubesheet welding are seldom summarized. This paper presents the sensing, positioning, and control methods

Variation propagation modeling of multistage machining processes enables variation reduction by making an accurate prediction on the quality of a part. Part quality prediction through variation propagation models, such as stream of variation and Jacobian-Torsor models, often focus on a 3-2-1 fixture layout and do not consider form errors. This paper derives a mathematical model based on dual quaternion