Advanced Materials Research Vol. 423

Abstract: In the aeronautic industries, composite materials are increasingly being used for structural parts. Carbon Fibre Reinforced Plastics (CFRP) are often used in combination with metallic materials, mostly aluminium alloys. This raises new problems in aircraft assembly when it comes to machining the holes for thousands of fasteners. The preferred method for this is a one-shot drilling-reaming-countersinking operation usually using a power tool and with the need to respect tight dimensional and geometric specifications. The solutions proposed so far with existing cutting tools, involving reduced feed rate, are unsatisfactory from an economic point of view. This study first focuses on identifying machining defects and difficulties encountered during drilling of aluminium/CFRP stacks. Then, based on the results of different works on drilling [1,3], an experimental study is proposed to define the critical macro-and micro-geometric parameters of a carbide drill. The criteria relate to the fragmentation of the metallic chips, burr avoidance and zero damage to the CFRP. The first results obtained with the new generation cutters developed show the importance of a constant axial rake angle and of the tool point angle in the chip fragmentation phenomenon but also in preserving the health of the CFRP material. The influence of the constant rake angle on the axial forces generated is also shown. Finally, an optimal combination of the tool geometrical parameters is achieved in order to obtain the expected results.

Abstract: The equal channel angular extrusion (ECAE) is an ingenious severe plastic deformation process used to modify texture and microstructure without reducing sample cross-section. The ECAE of polypropylene (PP) was conducted under various extrusion velocities and back-pressure levels using a 90° die. The application of single ECAE pass to PP was meticulously investigated at room temperature. The ECAE-induced deformation behaviour was examined in relation to the load versus ram displacement curves. Depending on extrusion conditions, PP displayed various types of plastic flow. For ram velocities beyond 4.5 mm/min, severe shear bands consisting of successive translucent and opaque bands were observed, accompanied on the top surface by more or less pronounced periodic waves. Although the application of a back-pressure significantly reduced the wave and shear-banding phenomena, slightly inhomogeneous shear deformation was still observed. Shear bands were only suppressed by decreasing extrusion velocity. The strain-induced crystalline microstructure was investigated by X-ray scattering. Shear-banded samples exhibited a strong texturing of the (hk0) planes along the shear direction in the translucent bands whereas perfect crystalline isotropy appeared in the opaque bands. Application of backpressure and/or reducing ram velocity resulted in uniform texturing along the extruded sample. Yet, texturing changed from single shear to twin-like shear orientation about the shear direction. Mechanical properties changes of the extruded specimens due to back-pressure and extrusion velocity effects were analyzed via uniaxial tensile tests. The tensile samples displayed multiple strain localizations in shear-banded materials whereas quite homogeneous deformation appeared for non-banded ones. These effects were connected with the crystalline texturing. The results also revealed significant increase in the strain hardening after ECAE. Full-field strain was measured under tensile loading using an optical strain measuring technique based upon Digital image correlation technique, suitable for large deformation, which confirms these effects.

Abstract: Increasing demand for smaller consumer electronic devices with multi-function capabilities has driven the packaging architectures trends for the finer-pitch interconnects, thus increasing chances of their failures. A simulation of the Board Level Drop-Test according to JEDEC (Joint Electron Device Council) is performed to evaluate the solder joint reliability under drop impact test. After good insights to the physics of the problem, the results of the numerical analysis on a simple Euler-Bernoulli beam were validated against analytical analysis. Since the simulation has to be performed on ANSYS Mechanical which is an implicit software, two methods were proposed, the acceleration-input and the displacement-input. The results are the same for both methods. Therefore, the simulation is carried on the real standard model construction of the board package level2. Then a new improved model is proposed to satisfy shape regular element and accuracy. All the models are validated to show excellent first level correlation on the dynamic responses of Printed Circuit Board, and second level correlation on solder joint stress. Then a static model useful for quick design analysis and optimization’s works is proposed and validated. Finally, plasticity behavior is introduced on the solder ball and a non-linear analysis is performed.

Abstract: This paper presents an experimental/numerical methodology which aims to improve 3D welded tube considering their anisotropic effect, geometrical singularities found in the welded joint, and heat affected zone behaviour by hydroforming process. This process contributes to reduce the number of welding and assembly operations needed to generate complex structures, while improving the weight saving and quality of finished parts. In spite of the advances in the performance of this manufacturing technology, some problems are linked to particularities of certain raw materials and additional studies must be developed, like in the case of welded tubes. The experimental study is dedicated to the identification of stress-strain flow of the base metal and the heat-affected zone from the global measure of tube displacement, thickness evolution and internal pressure expansion. Nanoindentation test is adapted to investigate the heat affected zone mechanical behaviour. Workpiece behaviour's models used to simulate the expansion tests, made it possible to highlight the combined effects of the inhomogeneous behaviour of basic material and heat affected zone, as well as the geometrical singularities found in the welded tubes. From the simulations carried out, it is clear the influence of the plastic flow behaviour of the welded tube in the final results (thickness distribution, stress instability, tube circularity, critical thinning and rupture).

Abstract: Most optimization problems, particularly those in engineering design, require the simultaneous optimization of more than one objective function. In this context, the solutions of these problems are based on the Pareto frontier construction. Substantial efforts have been made in recent years to develop methods for the construction of Pareto frontiers that guarantee uniform distribution and exclude the non-Pareto and local Pareto points. The Normal Boundary Intersection (NBI) is a recent contribution that generates a well-distributed Pareto frontier efficiently. Nevertheless, this method should be combined with a global optimization method to ensure the convergence to the global Pareto frontier. This paper proposes the NBI method using Adaptive Simulated Annealing (ASA) algorithm, namely NBI-ASA as a global nonlinear multi-objective optimization method. A well known benchmark multi-objective problem has been chosen from the literature to demonstrate the validity of the proposed method, applicability of the method for structural problems has been tested through a truss problem and promising results were obtained. The results indicate that the proposed method is a powerful search and multi-objective optimization technique that may yield better solutions to engineering problems than those obtained using current algorithms.

Abstract: The six axis robots are widely used in automotive industry for their good repeatability (as defined in the ISO92983) (painting, welding, mastic deposition, handling etc.). In the aerospace industry, robot starts to be used for complex applications such as drilling, riveting, fiber placement, NDT, etc. Given the positioning performance of serial robots, precision applications require usually external measurement device with complexes calibration procedure in order to reach the precision needed. New applications in the machining field of composite material (aerospace, naval, or wind turbine for example) intend to use off line programming of serial robot without the use of calibration or external measurement device. For those applications, the position, orientation and path trajectory precision of the tool center point of the robot are needed to generate the machining operation. This article presents the different conditions that currently limit the development of robots in robotic machining applications. We analyze the dynamical behavior of a robot KUKA KR240-2 (located at the University of Bordeaux 1) equipped with a HSM Spindle (42000 rpm, 18kW). This analysis is done in three stages. The first step is determining the self-excited frequencies of the robot structure for three different configurations of work. The second phase aims to analyze the dynamical vibration of the structure as the spindle is activated without cutting. The third stage consists of vibration analysis during a milling operation.

Abstract: This paper proposes a method to vibration analysis in order to on-line monitoring of milling process quality. Adapting envelope analysis to characterize the milling tool materials is an important contribution to the qualitative and quantitative characterization of milling capacity and a step by modeling the three-dimensional cutting process. An experimental protocol was designed and developed for the acquisition, processing and analyzing three-dimensional signal. The vibration envelope analysis is proposed to detect the cutting capacity of the tool with the optimization application of cutting parameters. The research is focused on Hilbert transform optimization to evaluate the dynamic behavior of the machine/ tool/workpiece.

Abstract: The better understanding of the material cutting process has been shown with the benefit of the forces and moments measurement since some years ago. In paper, simultaneous six mechanical components and chip orientation measurements were realized during turning tests. During these tests, the influence of the depth of cut or feed rate has been observed and a link between the chip orientation and the moment vector orientation or the central axis characteristics has been shown. Nomenclature * corresponding author

Abstract: To better understand the complex phenomena involved in the cutting process is to better qualify the behaviour law used in the simulatiotrn of machining processes (analytical and finite element modeling). The aim of this paper is to present the choices made regarding the behaviour law in this context, indeed, commonly used behaviour laws such as Jonhson-Cook can bring unsatisfactory results especially for high strain and large deformation processes. This study develops a large deformation strain-gradient theoretical framework with hypothesis linked with to metal cutting processes. The emphasis of the theory is placed on the existence of high shear phenomena creating a texture in the primary shear band. To account for the texture, the plastic spin is supposed to be relevant in this theory. It is shown that the theory as the capability of interpreting the complex phenomena found in machining and more particularly in high speed machining.