Key Engineering Materials Vol. 841

Abstract: In this paper, twin roll casting of magnesium alloys with high aluminum content such as, Mg-11 mass%Al-0.2 mass%Mn, Mg-12 mass%Al-0.2 mass%Mn, Mg-13 mass%Al-0.2 mass% have been performed for the purpose of use as an original material for hot forging. Also the mechanical properties of the cast materials were examined. A 10 miri-meters thick strip was cast by the use of a horizontal twin roll caster. The microscopic observation was conducted to investigate into the precipitation of the metal compounds such as Mg₁₇Al₁₂, and the Vickers hardness of the cast strips test were performed. From the result of the roll casting experiments, a 10 mm thick strip was continuously cast at a roll speed of 3.1 m/min. The average grain size of the casting strips was about 46 micron meters. When the aluminum content was 13%, the hardness of the twin roll cast (TRC) strips became 1.7 times higher than that of extruded AZ 31. Also, a uniaxial compression test at elevated temperature was conducted to obtain a true strain-true stress curve for examining possibility of direct hot forging (DHF) of TRC magnesium alloys with high aluminum content.

Abstract: In recent years, the movement for banning the sale of gasoline cars and diesel vehicles, especially in Europe, and allowing only electric passenger cars has been accelerated. For examples, Germany’s federal council, the Bundesrat, has passed a resolution calling for a ban on combustion engine cars by 2030. If the ban were to go through, German citizens would only be permitted to purchase electric or hydrogen-fueled cars. In Norway, until 2025 there is a movement for legislation prohibiting the registration of new gasoline passenger cars and diesel cars. Beginning in 2025 in the Netherlands, a bill prohibiting the sale of new cars gasoline and diesel vehicles was submitted to Congress. Under the circumstances, the demand for light-weight products for automotive industries has increased due to global trends in environmental preservation. Although demands for magnesium has risen dramatically, production of magnesium alloy sheet still remains at a very low level. This study seeks to establish a guideline for roll design in the roll forming of wrought magnesium alloys to extend practical use of roll-formed products of wrought magnesium alloys. A three-dimensional elasto-plastic analysis by the finite-element method has been conducted to express exact roll-forming behavior of wrought magnesium alloys that have different stress-strain curves in tension and compression. Simple V-sections were formed by a tandem six-stand roll forming machine to demonstrate the effectiveness of the simulation methods with different stress-strain curves in the case of tension and compression. Also, spring-back analysis has been performed to investigate the exact cold roll-forming phenomenon for wrought magnesium alloy sheets.

Abstract: The present experimental study proposes an alternative for diagnostic methods and quality control in cylinder head defectology. The composition of the material is characterized by spectrometry, obtaining an approximation of aluminum 2117. For the detection of defectologies, non-destructive tests (NDT) are carried out, applicable to cylinder heads such as: visual inspection (VT) under conditions of standard EN 13018, penetrating inks (PT) visible according to ASTM E 165-02 and others not yet included in the vehicle fleet.; infrared thermography (IRT) with equipment specifications under ISO 18434 - 1, ultrasound (UT) based on standard EN 583 for the use of the equipment and Eddy currents (ECT) conforming standard ISO 15548, the analysis is carried out on the flat surface of the cylinder head, combustion chamber, valve seats and intake - exhaust ports, the different defects found are: cracks, fissures, discontinuities and pitting, showing longitudinal dimensions from 0,8 [mm]. To determine the reliability of results, an analogy is made of the tests mentioned in the same defect, the method with the greatest scope is Eddy currents as it has more inspection coverage with respect to the remaining tests; the simulation of computer-aided engineering CAE of the defect is performed, applying an AC magnetic analysis to identify the flux density, current density and visualize how the Eddy currents act in the cylinder head. After this research, artificial intelligence will be used as a complementary diagnosis, to predict defectologies not perceived by the human eye and to obtain a better analysis of defectologies in cylinder heads.

Abstract: Acoustic emission signal-based prediction of surface roughness has been utilized widely, yet little work has been done in this regard on RSA443. This paper seeks to study the correlation between acoustic emission (AE) signal parameters and surface roughness. Estimation of surface roughness using AE signal parameters and subsequent examination of the influence of AE signal parameters (root mean square, peak rate and prominent frequency) on the accuracy of the RSM model in surface roughness prediction are carried out. The experiment is designed using the Taguchi L9 orthogonal array to minimize the number of experiments. Emitted acoustic signals are captured using a Piezotron sensor. Three RSM models are formulated and compared in this study: a model that uses only critical machining parameters (cutting speed, depth of cut and feed rate), a model that uses only AE signal parameters (root mean square, peak rate and prominent frequency) and a model that uses both critical machining parameters and AE signal parameters. An assessment based on the models’ mean absolute percentage error (MAPE) is made to see if AE signal parameters have any contribution towards surface roughness prediction accuracy. The order of parameter significance in the most accurate model is investigated in this paper. The mean absolute percentage error results for the models indicate that the model in which AE signal parameters are utilized in conjunction with critical machining parameters has the highest prediction accuracy of 97.32%. The model that utilizes only critical machining parameters has a prediction accuracy of 96.35% while the one that utilizes only AE signal parameters has a prediction accuracy of 84.43%. It is observed that the order of parameter significance from the most to the least significant is as follows: feed rate, cutting speed, peak rate, AErms, depth of cut and prominent frequency.

Abstract: . Electrochemical etching is widely used to process refractory metals such as tungsten and molybdenum. Flow field is one of the crucial factors that influence the surface quality in electrochemical etching. In this paper, the electrochemical etching flow field was analyzed via FLUENT, the characteristics of flow field in electrochemical etching are studied, furthermore, the effects of four different outlet forms of electrolyte on flow field uniformity, electrolyte velocity and pressure distribution are investigated. Under the same electrolyte flow rate, the flow field characteristics of different outlet forms are analyzed by velocity vector diagram, pressure distribution nephogram, velocity and pressure curve diagram. The simulation results indicate that stable electrolyte velocity and uniform pressure distribution of flow field are obtained when the outlet form of electrolyte adopts the optimized flat. Finally, the fixture for this outlet form is designed and fabricated, and experimental verification is carried out, which shown that the flow field is uniform and the crystal plane of the workpiece is well-distributed which according with the process requirements.

Abstract: Coat-hanger dies are widely used in the extrusion of polymer sheets and films. However, when designing the flat film/sheet extrusion dies manufacturing companies still facing difficulties in achieving the flow uniformity of the polymer melt. This affects the product quality and tool life. This study examines the existing extrusion die design which is used in in the industry in Kazakhstan for polypropylene sheet production and proposes better geometry of a die. These die geometries will be tested for flow uniformity in terms of velocity and pressure at the outlet.

Abstract: This study aims to identify the effect of road surface to coil spring fatigue life using the strain-life approach. Strain signals were measured by attaching a strain gauge at the critical point of the component. The car was driven on a flat road, as well as uphill, and downhill paths. The results show that the downhill road provided the lowest fatigue life, of 1.5E+4 cycles to failure, which was 53 % lower than that of the uphill and 2,233 % lower than the flat road owing to the braking factor which resulted in a higher stress to the coil spring.

Abstract: Polymer extrusion is one of the largest material manufacturing processes, which is deployed substantially in productions. The variety of the output product types is greatly attributed to the die part of the extruder because it is one of the essential components that shapes the material. The main purpose of this paper is to create a feasible and efficient design of the extrusion die, which would meet the design requirements and would be more convenient to use as well as have better performance compared to the existing design. In order to obtain adequate results, CAD model of the die bodies were created and simulated in the SolidWorks Plastics and COMSOL software. It is found from the results of the simulation that, proposed design demonstrated better performance in terms of uniformity of the flow at the outlet as well as pressure and temperature distributions.