Papers by Keyword: Cellular Metals

Abstract: The selection of an adequate friction model is an important aspect inthe finite element modeling of machining. Previously, different friction modelshave been compared, but the influence of the constitutive model or theworkpiece material have not been considered. This article focuses on theinfluence of the material and the constitutive model on the evaluation of thefriction model in machining. Numerical experiments are performed on threedifferent materials using different constitutive models. For every combinationof material and constitutive model, several simulations using different Coulombcoefficients, but the same cutting parameters, are performed. Several variablesare evaluated: cutting force, shear plane angle, chip-tool contact length,maximum temperature and maximum stress. The results reveal that the workpiecematerial plays an important role in the evaluation of the friction model. Theyalso show that there is significant influence from the constitutive models oncontact length, curvature ratio and chip thickness.

Abstract: Heat conductivity is a well-known energy transfer method and it is here applied to the study of metal foams and laser processing. Metallic hollow sphere structures (MHSS), a relatively new group of advanced composite materials, combine the advantages of cellular metals without major scattering of their material parameters. They are characterised by high geometry reproduction leading to relatively constant mechanical and physical properties.The laser processing technology provides not only a laser cutting but also a laser soldering procedure. Within this work a laser cutting process is applied to MHSS. Laser beam cutting is a highly efficient technique to cut materials, because the relatively small amount of heat affects only a small heating zone.Numerical simulation is used in order to define proper process parameters for a large variety of MHSS. The finite element method based simulation covers material parameters as well as process parameters like the cutting velocity. Heat conduction and convection are taken into account and the phase change from solid to liquid state as well. Within the simulations the concept of representative volume element (RVE) is applied. The temperature distribution is the fundamental result.

Abstract: The dynamic crushing behavior of cellular metals is closely related to their microstructure. Two types of random defects by randomly thickening/removing cell walls are investigated in this paper. Their influences on the deformation modes and plateau stresses of honeycombs are studied by finite element simulation using ABAQUS/Explicit code. Three deformation modes, i.e. the Homogeneous Mode, the Transitional Mode and the Shock Mode, are used to distinguish the deformation patterns of honeycombs under different impact velocities. The critical impact velocity for mode transition between the Homogeneous and Transitional modes is quantitatively determined by evaluating a stress uniformity index, defined as the ratio between the plateau stresses on the support and impact surfaces. It is found that the critical impact velocity decreases with increasing thickening ratio but increases with increasing removing ratio. The plateau stress on the impact surface heavily depends on the impact velocity due to the inertia effect. The random defects lead to a weakening effect on the plateau stress. For the honeycombs with randomly removing cell walls, the weakening effect is especially obvious at a moderate impact velocity. For the honeycombs with randomly thickening cell walls, the weakening effect is particularly severe at a low impact velocity, but this effect almost disappears when the impact velocity is high enough.

Abstract: This paper investigates the structural properties of sintered hollow sphere struc- tures. First of all, the packing density is analysed using three different methods: namely, liquid infiltration, Archimedes' principle, and image processing of micrographs. In addition, the pore fraction in the metallic sphere shells is characterised based on micrographs and the density of the structure and the base material is determined. In the final part, the geometrical characteristics of the sphere structure and the material composition of the base material are analysed.

Abstract: The paper investigates the mechanical properties of sintered hollow sphere struc- tures. First of all, the Young's modulus, plastic modulus, initial flow stress, initial flow strain, plateau stress and densifcation strain are derived from compressive tests. In addition, the material behaviour during the compressive testing is described. Furthermore, the influence of different specimen shapes on the results is discussed.

Abstract: In this paper, the increase of the effective thermal conductivity of paraffin based heat sinks is investigated by making use of cellular metallic matrixes with open cells which are introduced in the thermal low conductive paraffin wax. Lattice Monte Carlo analyses are conducted on different model geometries of such composites composed of a cellular matrixes and paraffin wax. The dependence of the effective thermal conductivity on the cell geometry and the metal foam matrix material is analysed. Furthermore, a diamond coating is simulated in order to estimate its influence on the effective thermal conductivity.

Abstract: inno.zellmet is a large funded project which aims at the commercialisation of new, non-foam types of cellular metals. The project focuses on porous structures made from metallic short fibers and structures made from metallic hollow spheres, which are both chararacterised by multifunctionality and low specific weight. Six research institutes and 17 partners from industry constitute a local network that jointly develops solutions based on these "constructed materials". Target applications are situated in industrial sectors such as light-weight construction, decentralised energy generation, medical and biotechnology, as well as sound absorption and explosion protection for stationary machinery. inno.zellmet has started in March 2005 and will run for 3 years. During this time, it receives 3.9 Mio. EUR in funding from the German Federal Ministry of Education and Research under the "Unternehmen Region" initiative. This paper highlights some of the results obtained so far.