scholarly journals Developing a novel manufacturing method to produce stiffened plate structures

2021 ◽  
Author(s):  
Andrew J. H. Garrick ◽  
Athanasios I. Toumpis ◽  
Alexander M. Galloway
Keyword(s):  
Flat Plate ◽  
Rolling Mill ◽  
Cold Work ◽  
3D Structure ◽  
Stiffened Plate ◽  
Machining Time ◽  
Efficient Manner ◽  
Current Form ◽  
Manufacturing Method ◽  
Billet Material

AbstractIsogrid is a highly efficient stiffened plate structure which was developed in the aerospace industry for use in rocketry and space structures. Its current form is unviable outwith these applications, as the available production methods are expensive due to excessive machining time in addition to considerable material wastage. The method detailed in this body of work was developed to manufacture Isogrid in a more efficient manner, so that its weight-saving properties may become more widely accessible. This novel Isogrid manufacturing process uses a rolling mill with patterned rollers to imprint a 3D structure of ribs into the surface of a billet material. To validate this method, a patterned roller was designed, manufactured and fitted to a rolling mill to produce sheets of aluminium AA1050 Isogrid. This process successfully created Isogrid in a sustainable, rapid manner. The samples produced were tested in 3-point bending and compared against flat plate of the same material. They were found to be 100% stronger in bending compared to a neutral flat plate with a strength shape factor of 1.6 after discounting the effect of cold work.

Alternative Lubricants: Study on Plant-Based Lubricants in Metal Forming Process

2016 ◽  
Vol 819 ◽  
pp. 469-473
Author(s):  
M.A. Nurul ◽  
Samion Syahrullail
Keyword(s):  
Pure Aluminum ◽  
Cold Work ◽  
Viscosity Index ◽  
Experimental Result ◽  
Forming Process ◽  
Lower Viscosity ◽  
Experimental Apparatus ◽  
Billet Material ◽  
Metal Forming Process ◽  
Taper Die

In this paper, the effect of metal-to-metal contact from the application of plant-based lubricants, RBD palm olein and jatropa were investigated by cold work forward plane strain extrusion experiments. A pair of taper die and a symmetrical workpiece (billet) was placed inside extrusion rig which acted as main experimental apparatus. The billet material was annealed pure aluminum A1100 with radius 5 mm in deformation area. The experimental result shows that the lower viscosity index, will lead to lower friction effect to the deformed area, as well as product area.

Titanium Hot Stretch Forming: Experimental and Modeling Residual Stress Analysis

2014 ◽  
Vol 611-612 ◽  
pp. 149-161 ◽  
Author(s):  
Antonello Astarita ◽  
Luca Giorleo ◽  
Fabio Scherillo ◽  
Antonino Squillace ◽  
Elisabetta Ceretti ◽  
...  
Keyword(s):  
Residual Stresses ◽  
New Technologies ◽  
Raw Material ◽  
Hole Drilling ◽  
Stretch Forming ◽  
Machining Time ◽  
Efficient Manner ◽  
Forming Technology ◽  
Minimum Stress ◽  
Inside Radius

Titanium alloys, due to their high mechanical properties coupled with light weight and high corrosion resistance, are finding a widespread use in the aeronautic industry. The use of titanium in replacing the conventional alloys, such as aluminum alloys and steel, is reduced by both the high cost of the raw material (it costs anywhere from 3 to 10 times as much as steel or aluminium) and the machining costs (at least 10 times that to machine aluminium). For such a reason new technologies have been studied and developed. In particular many researchers are searching for technologies, such as the precision hot forming, that allows to obtain components with a low buy to fly ratio. Many of the airframe component structures are designed to fit against the inside radius of the fuselage curvature. By combining traditional stretch forming technology with hot titanium forming techniques, the HSF guarantees a saving in material and machining time, which are two serious cost issues for todays aircraft manufacturers. In addition, the process allows for consistent quality in a productively efficient manner, assuring the sustainable attainment of delivery and build schedules. In order to develop and improve the HSF process a modeling of the process itself was executed in order to study the stresses and strains undergone by the material among the deformation. The FEM model was validated through the residual stresses, and in particular the residual stresses provided by the model were compared with the ones experimentally measured using the hole drilling technique. Good agreement, in terms of stress range, was recorded both for the maximum and the minimum stress.

Hot Stretch Forming of a Titanium Alloy Component for Aeronautic: Mechanical and Modeling

2013 ◽  
Vol 554-557 ◽  
pp. 647-656 ◽  
Author(s):  
Antonello Astarita ◽  
Enrico Armentani ◽  
Elisabetta Ceretti ◽  
Luca Giorleo ◽  
Pasquale Mastrilli ◽  
...  
Keyword(s):  
Alloy Component ◽  
Stretch Forming ◽  
Commercial Aircraft ◽  
Machining Time ◽  
Efficient Manner ◽  
Forming Technology ◽  
Experimental Campaign ◽  
Innovative Process ◽  
Inside Radius ◽  
New Applications

The development of Hot Stretch Forming (HSF) by the Cyril Bath Company was in response to airframe designers needing to use Titanium airframe components in new commercial aircraft. Many of the airframe component structures are designed to fit against the inside radius of the fuselage curvature. By combining traditional stretch forming technology with hot titanium forming techniques, the HSF guarantees a saving in material and machining time, which are two serious cost issues for today’s aircraft manufacturers. In addition, the process allows for consistent quality in a productively efficient manner, assuring the sustainable attainment of delivery and build schedules. The HSF is an innovative process on the cutting edge of the technologies, so focused research is needed in order to better understand this technology and develop new applications for this process. in this paper the HSF process is investigated: the machine and the different steps that characterized the process were described and the results of a preliminary experimental campaign was discussed focusing the attention on the metallurgical aspect. Moreover a modeling of the process was executed in order to study the stresses and strains undergone by the material among the deformation.

Influence of Corrugated Sheet on 3D Structure in Turbulent Wake of Flat Plate

2016 ◽  
Vol 2016 (0) ◽  
pp. 0227
Author(s):  
Yoshifumi JODAI ◽  
Masashi ICHIMIYA ◽  
Yasuyuki MORIKAMI
Keyword(s):  
Flat Plate ◽  
3D Structure ◽  
Turbulent Wake

Miniature Hemispherical Bowl-Shaped Forming Using SLA Punch and Die: Modeling and Experimental Analysis

2019 ◽  
Author(s):  
Debabrata Mondal ◽  
Jeffrey David Morris ◽  
Bin Zhang ◽  
Wen Meng ◽  
Uttam Chakravarty ◽  
...  
Keyword(s):  
Element Model ◽  
Circular Plates ◽  
Manufacturing Method ◽  
Wide Range ◽  
Punch Load ◽  
Before And After ◽  
Billet Material ◽  
Microstructural Morphology ◽  
Numerical Finite Element ◽  
Bulk Production

Abstract Forming processes are a convenient means for bulk production of parts. These parts are used in a wide range of applications from automotive industries to micro-devices in bioengineering. Manufactured parts are required to be precise in their final dimension, and since the billet material undergoes significant plastic deformation during forming, billet material characterization and prediction of final form is essential. In this study, miniaturized bowl-shaped samples of 3003-H14 aluminum alloy were formed using a die and punch manufactured using the stereolithography (SLA) additive manufacturing method. Tensile testing was performed in order to characterize the material properties of the SLA resin. Using the SLA-created die and punch, hemispherical bowl-shaped forms were generated. In order to investigate possible small size effects, experimental load versus displacement results were obtained for billet plate thicknesses of 0.4–0.8 mm. A numerical finite element model was developed to predict the required punch load to manufacture various thickness bowl-shaped forms. A comparison was made between the load verses displacement curves for the different thicknesses, and the numerical model was validated by the experimental results. The validated computational model can then be used to predict the process parameters prior to starting bulk production. Finally, a model with grains was developed and simulated to show the virtual microstructural morphology of the circular plates before and after the forming operation.

Evaluation of Paraffinic Mineral Oil as Lubricant in Cold Work Extrusion Process

2014 ◽  
Vol 554 ◽  
pp. 327-331 ◽  
Author(s):  
Samion Syahrullail ◽  
Mohd Ahyan Nurul Aini
Keyword(s):  
Plane Strain ◽  
Pure Aluminum ◽  
Cold Work ◽  
Extrusion Process ◽  
Mineral Oil ◽  
Experimental Result ◽  
Friction Effect ◽  
Billet Material ◽  
Deformation Area ◽  
Taper Die

In this paper, the effect of frictional constraint from the application of three different viscosity of additive free paraffinic mineral oil as lubricant were investigated by cold work forward plane strain extrusion experiments. The experiment used a cold work plane strain extrusion apparatus consist of a pair of taper die and a symmetrical workpiece (billet). The billet material was annealed pure aluminum A1100 with radius 5 mm in deformation area. The experimental result shows that the higher viscosity, will lead to lower friction effect to the deformed area, as well as product area.

scholarly journals An Experimental Investigation on Micro Drilling of Cold Work Steel X153CrMoV12 By EDM

2021 ◽  
Author(s):  
FERHAT CERİTBİNMEZ ◽  
Erdoğan Kanca
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Metal Removal ◽  
Removal Rate ◽  
Cold Work ◽  
Process Quality ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Metal Removal Rate ◽  
Machining Time

Abstract In this study, it was aimed to analyze the effects of machining parameters on the process quality by drilling holes in heat treated cold work tool steel with a hardness of 60-62 HRC using the electrical discharge machining (EDM) method and Ø2 mm diameter brass electrodes. In this context, drilling was performed using three different current values ​​(5, 6, 7 A), three different voltage values ​​(1, 2, 3 V), three different discharge pulse frequency Ton (23, 26, 29 µs) as well as Toff (3, 5 µs) respectively, and the effects of these machining parameters on the machining time, material removal rate (MRR), electrode wear rate (EWR), surface roughness (SR) and hardness of around the white layer were analyzed using micro, macro and analytical measurements, especially with Scanning Electron Microscopy (SEM) and Energy Dispersive X-Ray Analysis (EDX). As a result of the analysis, ıt was observed that current, voltage, Ton and Toff had an effect on machining time, MRR, EWR, SR and hardness, but current was the most effective parameter, and also worn electrode as well as workpiece residues affected the process quality. Increasing the machining current increased sparking between the workpiece and the electrode, resulting in increased point melting and evaporation, resulting in increased average surface roughness, metal removal rate, and electrode wear rate. As a result of the high metal removal rate, the machining time was greatly reduced and the thermal effect time was reduced, which led to a decrease in the hardness variation on the machined surfaces.

Influence of Thermo-Mechanical Processing on the Microstructure of Beryllia Dispersed Nickel Alloys

1973 ◽  
Vol 31 ◽  
pp. 184-185
Author(s):  
M.S. Grewal ◽  
S.A. Sastri ◽  
N.J. Grant
Keyword(s):  
High Temperature ◽  
Nickel Alloys ◽  
Thermomechanical Processing ◽  
Cold Work ◽  
High Temperature Strength ◽  
Strengthening Effect ◽  
Mechanical Processing ◽  
Uniform Dispersion ◽  
Oxide Particles ◽  
Nickel Base

Currently there is a great interest in developing nickel base alloys with fine and uniform dispersion of stable oxide particles, for high temperature applications. It is well known that the high temperature strength and stability of an oxide dispersed alloy can be greatly improved by appropriate thermomechanical processing, but the mechanism of this strengthening effect is not well understood. This investigation was undertaken to study the dislocation substructures formed in beryllia dispersed nickel alloys as a function of cold work both with and without intermediate anneals. Two alloys, one Ni-lv/oBeo and other Ni-4.5Mo-30Co-2v/oBeo were investigated. The influence of the substructures produced by Thermo-Mechanical Processing (TMP) on the high temperature creep properties of these alloys was also evaluated.

The low-resolution 3D-structure of porin, a channel-forming protein in E. coliouter membranes

1983 ◽  
Vol 41 ◽  
pp. 440-441
Author(s):  
A. Engel ◽  
D.L. Dorset ◽  
A. Massalski ◽  
J.P. Rosenbusch
Keyword(s):  
Crystal Packing ◽  
3D Structure ◽  
Gram Negative Bacteria ◽  
Protein Ratio ◽  
Crystal Forms ◽  
Large Molecules ◽  
Functional Studies ◽  
Voltage Dependent ◽  
Planar Membranes ◽  
Hexagonal Arrays

Porins represent a group of channel forming proteins that facilitate diffusion of small solutes across the outer membrane of Gram-negative bacteria, while excluding large molecules (>650 Da). Planar membranes reconstituted from purified matrix porin (OmpF protein) trimers and phospholipids have allowed quantitative functional studies of the voltage-dependent channels and revealed concerted activation of triplets. Under the same reconstitution conditions but using high protein concentrations porin aggregated to 2D lattices suitable for electron microscopy and image processing. Depending on the lipid-to- protein ratio three different crystal packing arrangements were observed: a large (a = 93 Å) and a small (a = 79 Å) hexagonal and a rectangular (a = 79 Å b = 139 Å) form with p3 symmetry for the hexagonal arrays. In all crystal forms distinct stain filled triplet indentations could be seen and were found to be morphologically identical within a resolution of (22 Å). It is tempting to correlate stain triplets with triple channels, but the proof of this hypothesis requires an analysis of the structure in 3 dimensions.

Examination of Rabbit Fc Crystals

1968 ◽  
Vol 26 ◽  
pp. 140-141
Author(s):  
J. P. Robinson ◽  
P. G. Lenhert
Keyword(s):  
Molecular Weight ◽  
Flat Plate ◽  
Phosphate Buffer ◽  
Asymmetric Unit ◽  
X Ray Diffraction ◽  
X Ray ◽  
Neutral Ph ◽  
Small Crystals ◽  
Carbon Coated ◽  
Diffraction Patterns

Crystallographic studies of rabbit Fc using X-ray diffraction patterns were recently reported. The unit cell constants were reported to be a = 69. 2 A°, b = 73. 1 A°, c = 60. 6 A°, B = 104° 30', space group P21, monoclinic, volume of asymmetric unit V = 148, 000 A°3. The molecular weight of the fragment was determined to be 55, 000 ± 2000 which is in agreement with earlier determinations by other methods.Fc crystals were formed in water or dilute phosphate buffer at neutral pH. The resulting crystal was a flat plate as previously described. Preparations of small crystals were negatively stained by mixing the suspension with equal volumes of 2% silicotungstate at neutral pH. A drop of the mixture was placed on a carbon coated grid and allowed to stand for a few minutes. The excess liquid was removed and the grid was immediately put in the microscope.

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