Papers by Keyword: Plastic Processing

Abstract: Particulate Reinforced Aluminium Matrix Composites (PRAMCs) have been widely applied in military and civilian areas such as aviation, aerospace, advanced weapon applications and electrical industries due to their good mechanical properties at elevated temperature, low thermal expansion coefficient, excellent wear resistance and low production cost. The main preparation techniques of the PRAMCs include stir casting, powder metallurgy, pressureless infiltration and spray deposition. However, the problems such as low densification and particle cluster encountered in these techniques often reduce the material properties. It has reported that the homogeneity of the distribution of particulate reinforcements in metal matrix can be improved by plastic processing, thus enhancing the material densification. This paper summarized recent progress in the plastic processing methods of the PRAMCs, with an emphasis on the spinning technique. The effects of various process parameters on the material properties were discussed in detail. A summary of research progress on the numerical simulation of plastic processing of the PRAMCs was presented. In the end, an outlook was given on the prospect of the PRAMCs’ development.

Abstract: Shape memory effects, the course and characteristic temperatures of phase transitions and mechanical properties and surface properties of NiTi alloys strongly depend on the chemical composition, the production process used and the plastic working and thermomechanical treatment as well as surface treatment. The test alloy was obtained by vacuum metallurgy by melting the components in a graphite crucible and casting into a graphite ingot mould. In order to obtain the rods in the process of hot plastic working, hot forging was applied using a smith hammer and rotary hot forging on a swaging machine. The resulting rods were subjected to an appropriate heat treatment and thermo mechanical treatment to obtain, at room temperature, a parent phase structure B2.The paper presents the results of the research of NiTi rods after hot rotary forging. The phase composition of the samples of the tested alloy after different heat treatments were determined by X-ray powder diffraction technique. It was found that at room temperature, depending upon the processing the samples had a structure parent phase with a small amount of martensite. The courses of phase transitions and the changes of the temperature characteristic were determined on the basis of the recorded DSC curves. It was found that the test rate after aging in the temperature range of 400-500 °C transitions take place involving the rhombohedral R phase. The temperature ranges of shape recovery of samples after various heat treatments were determined by recording the recovery of the shape during heating, in tests performed according to the standard ASTM 2082-06.

Abstract: 3D rolling is a novel technology for three-dimensional surface parts. In this process, by controlling the gap between the upper and lower forming rolls, the sheet metal is non-uniformly thinned in thickness direction, and the longitudinal elongation of the sheet metal is different along the transverse direction, which makes the sheet metal generate three-dimensional deformation. In this paper, the transition zones of spherical surface parts in 3D rolling process are investigated. Spherical surface parts with the same widths but different lengths are simulated in condition of the same roll gap, and their experimental results are presented. The forming precision of forming parts and the causes of transition zones in the head and tail regions are analyzed through simulated results. The simulated and experimental results show that the lengths of transition zones of spherical surfaces in the head and tail regions are fixed values in condition of the same sheet width and roll gap.

Abstract: Generally, many high-strength alloy materials used in aerospace, power and chemical industries have strength differential effect in tension and compression (SD effects). Usually, in mechanical calculations of sheet metal forming, Treasca yield criterion and Mises yield criterion are applied. Because the yield criterions don’t take SD effects into consideration, the calculation result may have errors for certain materials. However, generalized twin shear stress yield criterion, which takes into account the influence of the intermediate principal stress, is more suitable for most metal materials than Mohr-Coulomb strength theory. Therefore, this article has made plastic analysis on thin film stress issues of metal sheet forming with generalized twin shear stress yield criterion. We have obtained a unified plastic solution to the internal and external stretching issue of thin material with rounded holes and different tension and compression ratio. Providing a new result with wider applicability is very significant.

Abstract: Multi-roll stretch forming process is a new flexible manufacturing technique that the general idea of discretizing is put in use in the design of stretch forming machine. In the new process, the metal sheet can be more easily formed, and the flexibility can be much higher, which the traditional process cannot compare with. In this paper, in through extensive numerical simulations of the MRSF stretching process of toroidal saddle parts, A series of finite element simulations have done for the process of forming toroidal saddle parts using different lubricant and two kinds of rollers named damped rollers and ordinary rollers. The results show that the smaller the friction coefficient is, the easier the center of toroidal saddle part is stretched. Damped rollers can increase the stretching force and the ordinary rollers can increase the mobility of sheet metal. Arranging the damped rollers and ordinary rollers at a reasonable position can make the workpiece a more uniform stretching.

Abstract: Multi-Roll Stretch Forming process is a new flexible process which is used in forming hyperbolic-degree surface pieces. A series of finite element simulations and experiments have done for the process of forming saddle-shaped parts using two kinds of clamps named Tooth-type clamp and Wave-type clamp. The results show that Wave-type clamp can control the stretching force at an appropriate value. When the stretching force exceeds a critical value, the sheet metal can flow to the opposite direction of Stretch Forming as to maintain that stretching force. The formed part using Wave-type clamp has a better quality than the parts formed using Tooth-type clamp.

Abstract: The rapid market need of MEMS (Micro Electromechanical System) and metal microparts are increasing gradually. The plastic microforming has received more interests and applications in MEMS because it ensures high precision and manufacturing efficiency. However, it raises the higher demand on the microforming and plastic processing technology. Here we present one new process to micro-extrude microparts with laser-aided heating method. The new process is to selectively heat the workpiece with the laser radiation method to the suitable temperature that is between room temperature and recrystallization temperature, and to extrude the workpiece. This process is characterized by decreasing the influence of strain strengthening and lowering the resistance to deformation, and increasing the uniformity of material flow. The key elements of the approach concerning the warm micro-extrusion and temperature control, such as process parameters, laser heating system, micro-extrusion die structure, have been advanced. Furthermore, an important aspect of the research is that the developed system and theory of micro warm extrusion based on laser heating can be explored for further investigation and understanding of plastic microforming.

Abstract: M390 microclean® of Böhler Edelstahl is a powder metallurgical plastic mould steel with a high level of corrosion and wear resistance and therefore often used in the plastics processing industry. But as a consequence of rapidly advancing developments in the plastics processing industry the required level of wear resistance of tool steels in this field is constantly rising. For that reason a new PM tool steel with higher hardness values and an increased amount of primary carbides has been developed to improve the resistance against abrasive and adhesive wear. The wear resistance of both steels against adhesive situations for components of the plastification unit of injection moulding machines has been tested with a novel method. In case of processing polyolefins with an injection moulding machine it was found that there is adhesive wear between the check-ring and the flights of the screw tip of the non-return valve under certain circumstances. The temperature in that region was measured with an infrared temperature sensor. The existence of significant peaks of that signal was used as an indicator for an adhesive wear situation.

Abstract: Recent research and development status of wrought magnesium alloys in China is reviewed, and more attentions are paid to structure controlling, plastic processing, welding, surface treatment and product application. The control of alloy phases, grain refinement, deforming behavior and twin-roll strip casting process are discussed. The existing problems on the research and development of wrought magnesium alloys in China are analyzed.