Papers by Keyword: Tool Geometry

Abstract: In fine blanking, a mass production process for safety-critical components, a discrepancy exists between deterministic modeling approaches and the stochastic nature of real-world measurements, often termed process noise. This work combines Finite Element Method simulations with data from industrial-scale fine blanking experiments, featuring long stroke series across multiple coils with systematically varied die clearances. The analysis shows a strong correlation between force curve characteristics and the formation of tears, a relationship that holds across all tested geometries. In contrast, only weak and inconsistent correlations were found between the force signal and the resulting die roll. This weakness is explained by the finding that multiple physical effects, such as material strength and friction, have competing influences on die roll that are not separable in the single force signal. These results demonstrate that the utility of the force signal for quality prediction is highly dependent on the tool geometry, providing a basis for more reliable tool design strategies in fine blanking.

Abstract: In Friction Stir Welding (FSW) tool geometry plays a critical role in governing heat generation, material flow, and microstructural evolution within the weld. In this study, the feasibility and performance of FSW tools manufactured by Laser Powder Bed Fusion (L-PBF) are experimentally and numerically investigated. A non-conventional FSW tool produced in AISI 316L by L-PBF was designed and compared with a conventional machined steel tool in the welding of AA6082-T6 sheets performed using already optimized process parameters. This was followed by tensile testing and macro-and micro-hardness measurements, and a punctual microstructural analysis. In addition, a 3D thermo-mechanical finite element model was employed to forecast and analyze the temperature distribution, the effective strain and the overall material flow. The results show that the tool manufactured using L-PBF enables FSW joints to achieve mechanical properties and welding efficiency similar to those of the standard tool. Finite Elements Models (FEM), in good agreement with experimental results, show that the geometry of the additive tool promotes greater plastic deformation and lower peak temperatures, confirming both the validity of the model and the suitability of L-PBF for the advanced design of FSW tools.

Abstract: This study presents a novel approach to optimizing energy consumption in rock destruction by integrating advanced design parameters of cutting elements. A hybrid experimental-computational model was developed to evaluate the specific energy of destruction () across granite, limestone, and sandstone. Key findings include energy savings of 15% in granite, 12.5% in limestone, and 13.7% in sandstone, achieved by optimizing the angle of attack – 30º, edge curvature – 0.5 mm, and applying wear-resistant DLC coatings 2500 HV. Laboratory tests, field experiments, and finite element simulations validated the model's accuracy within ±6%. The study identifies critical parameter interactions, such as angle of attack and coating hardness, reducing shear stresses and wear losses. These advancements lower operational costs by approximately $50,000 annually per excavator and extend tool life. Limitations include the limited range of rock types tested and slight simulation overestimations in abrasive sandstone. Future research should explore adaptive cutting element designs with real-time parameter adjustments using sensor-based systems and machine learning. The findings offer practical recommendations for implementing optimized tools in mining and construction, enhancing efficiency and cost-effectiveness. This work bridges theoretical insights and industrial applications, providing a scalable framework for energy-efficient rock destruction.

Abstract: Composite fiber products and components are widely used in various industries, from highly stressed structural elements in the aerospace industry to sports equipment. In order to achieve the desired final shape, these materials are often subjected to various machining methods. Due to the inhomogeneous structure of composites and the different physical and mechanical properties of the matrix and reinforcement, specific problems arise during machining, such as delamination, intensive tool wear, increased temperature in the cutting area, or poor surface finish.This work deals with the observation of delamination size, wear, and cutting forces when drilling holes in carbon composites with tools with different rake angles. The result of this work is a recommendation for the geometry of tools for drilling this type of carbon composite.

Abstract: The joining of metallic materials by using the friction stir welding process is carried out with rotating welding tools having different geometries. The paper presents aspects that show the influence of the conical profile of the welding tool pin on the dimensions of friction stir welded joints FSW in air and SFSW in liquid environment for EN AW 1200 aluminum alloy. The tools analyzed in the experimental research have had smooth conical pin and conical pin with four flat chamfers respectively, macrostructural investigations being carried out to a comparatively analyze of the welded joint dimensions. The results are useful for experimental research on FSP processing in air and SFSP in liquid environment of aluminum alloys that will be carried out within the Nucleu PN 23 37 01 02 project underway at ISIM Timisoara.

Abstract: Friction stir welding is a solid-state joining process of metallic materials using a rotating welding tool that can have different geometric configurations. The paper presents aspects regarding the influence of the welding tool pin geometry on the dimensions of friction stir welded joints in air and in liquid working environment for EN AW 1200 aluminium alloy. Welding tools with smooth and threaded cylindrical pin were used for experimental research, the joints dimensions being comparative analysed by macrostructural investigations. The results are useful in the case of experimental research on FSP processing in air and SFSP in liquid environment of aluminium alloys within the Nucleu PN 23 27 01 02 project underway at ISIM Timisoara.

Abstract: In this paper, the optimization of the FSW tool pin profile and shoulder-to-pin ratio is carried out to achieve high tensile strength and hardness for dissimilar Al and Mg alloys. The FSW experiment with Al and Mg alloys is designed according to Taguchi's L9 orthogonal array by varying the tool pin profile and shoulder-to-pin diameter ratio. Grey relation analysis is a multiple response optimization method used to optimize the result of the experiment. The results show that the optimum tool pin profile is a cylindrical threaded pin profile tool, and the optimum shoulder-to-pin diameter ratio is 3. The maximum tensile strength, yield strength and hardness achieved in this experiment is 147 MPa, 139 MPa, and 96 HV respectively.

Abstract: The aim of the present paper is to study the aspects regarding the influence of the welding tool geometry on the joint dimensions during the SFSW (Submerged Friction-Stir Welding) of the EN AW 1200 aluminium alloy. Different tool geometries for SFSW welding of EN AW 1200 aluminium alloy parts were used, and joint size was analysed by macrostructural investigations. The key characteristics of the tool-weld interaction can be extracted, analysed and summarized to provide guidance on the optimal tool selection for a given set of welding conditions.

Abstract: The thermal analysis will be realised in a Computer Aided Parametric Design program for three tools with different pin geometries to determine the transfer and distribution of the thermal energy produced during the process and to observe the influence of the pin geometry has on the distribution. Due to the fact that the joining process can be done at a lower temperature than the melting point of the material certain steps must be followed prior and correct selection of the machine’s parameters. Information on the parameters for specific materials and the preparation of the base material are readily available but considering the method of producing the thermal energy necessary for the process the quality of the weld is highly influenced by preheat time (of the material and tool), room temperature, cooling of the tool or work piece if the machine is equipped with such a configuration. We will observe in this study the effect of tool pin geometry over dwell time for reaching a uniform temperature of the tool in the shortest amount of time. The parameters used for the acquiring the data needed for the thermal analysis regarding tool material are tungsten carbide and the material of the plates will be aluminium 1200. The paper’s subject will be the realisation of a thermal analysis of the FSW (Friction Stir Welding) tools.

Abstract: Cutting temperature is one of the most important parameters in the cutting process, which has an important influence on the machining accuracy of workpiece, the power consumed by the machining and the degree of tool wear. There are many factors influencing the cutting temperature, such as the properties of workpiece materials, geometric parameters of the tool, the use of cutting fluid and so on. In this paper, we used orthogonal experimental method, with titanium alloy TC18 as the carrier and AdvantEdge as the simulation platform, established the cutting simulation model. With the cutting temperature as the optimization goal, the geometric parameters of the cemented carbide reamer are optimized.