scholarly journals Analysis of Micro-Machining Process for External Thread of Micro Round Tube

Materials ◽  
2021 ◽  
Vol 14 (15) ◽  
pp. 4327
Author(s):  
Tsung-Chia Chen ◽  
Jyun-Jie Lian ◽  
Cheng-Chi Wang
Keyword(s):  
Stainless Steel ◽  
Size Effect ◽  
Parameter Analysis ◽  
Machining Process ◽  
Stress And Strain ◽  
Stress Strain ◽  
Round Tube ◽  
Maximum Torque ◽  
External Thread ◽  
Simulation And Experiment

This study aims to analyze the stainless steel micro round tube external threading process for the influence of different outer threading pitches (0.25 mm, 0.4 mm) and outer diameters (Ø1.9, Ø1.94, Ø2). This study also analyzes the effects of different friction factors (0.1, 0.3, 0.5, 0.7, and 0.9) and different tube thicknesses (0.4, 0.45, 0.5, 0.55, and 0.6 mm) on the threading process. This study considers size effect to use corrected material parameters for the microtube to conduct the finite element analysis by DEFORM-3D software. The goal is to understand stainless steel (SUS304) micro round tube threading and the difference by using macro material parameter analysis. The historic forming data from the simulation and experiment of threading processing are presented, and the corresponding stress/strain distribution and thread shape are also calculated. The experiment results are compared to the simulation results to verify the reliability of this analysis method. The result shows that the torque/stress/strain obtained by the modified model is always lower than by Swift’s model. It means that the size effect can be considered to apply on the forming process and provided proper torque to form the external thread of the micro round tube, e.g., the maximum torque of the round die for M2 × 0.25 occurs over the fourth stroke. For the influence of the outer diameter of the micro round tube, the larger diameter induces the larger maximum torque on the round die for M2 × 0.4, but for the smaller pitch of M2 × 0.25, the larger maximum torque is not influenced by the diameter of the tube. When the pitch of the round die is increased, the torque, stress and strain are also increased relatively. As the friction factor and torque between the round die and tube increase, the stress and strain become lower. Changing the tube thickness will not significantly change the torque, the stress, and the strain. These results guide the simulation and experiment of optimized micro round tube threading development and design to reduce cost and increase product quality.

Prediction of Stress–Strain Curves of Metastable Austenitic Stainless Steel Considering Deformation-Induced Martensitic Transformation

2017 ◽  
Vol 139 (3) ◽  
Author(s):  
T. Kumnorkaew ◽  
V. Uthaisangsuk
Keyword(s):  
Stainless Steel ◽  
Flow Stress ◽  
Martensitic Transformation ◽  
Austenitic Stainless Steel ◽  
Effective Stress ◽  
Local Stress ◽  
Uniaxial Tensile ◽  
Stress And Strain ◽  
Trip Effect ◽  
Stress Strain

Transformation-induced plasticity (TRIP) effect is the outstanding mechanism of austenitic stainless steel. It plays an important role in increasing formability of the steel due to higher local strain hardening during deformation. In order to better understand forming behavior of this steel grade, the strain-induced martensitic transformation of the 304 stainless steel was investigated. Uniaxial tensile tests were performed at different temperatures for the steel up to varying strain levels. Stress–strain curves and work hardening rates with typical TRIP effect characteristics were obtained. Metallographic observations in combination with X-ray diffraction method were employed for determining microstructure evolution. Higher volume fraction of martensite was found by increasing deformation level and decreasing forming temperature. Subsequently, micromechanics models based on the Mecking–Kocks approach and Gladman-type mixture law were applied to predict amount of transformed martensite and overall flow stress curves. Hereby, individual constituents of the steel and their developments were taken into account. Additionally, finite element (FE) simulations of two representative volume element (RVE) models were conducted, in which effective stress–strain responses and local stress and strain distributions in the microstructures were described under consideration of the TRIP effect. It was found that flow stress curves calculated by the mixture law and RVE simulations fairly agreed with the experimental results. The RVE models with different morphologies of martensite provided similar effective stress–strain behavior, but unlike local stress and strain distributions, which could in turn affect the strain-induced martensitic transformation.

Studying The Effect of a New Mixed Cutting Fluid on Surface Roughness

2020 ◽  
Vol 38 (11A) ◽  
pp. 1593-1601
Author(s):  
Mohammed H. Shaker ◽  
Salah K. Jawad ◽  
Maan A. Tawfiq
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Cutting Parameters ◽  
Machining Process ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Machining Processes ◽  
Dry Cutting ◽  
Cutting Speeds

This research studied the influence of cutting fluids and cutting parameters on the surface roughness for stainless steel worked by turning machine in dry and wet cutting cases. The work was done with different cutting speeds, and feed rates with a fixed depth of cutting. During the machining process, heat was generated and effects of higher surface roughness of work material. In this study, the effects of some cutting fluids, and dry cutting on surface roughness have been examined in turning of AISI316 stainless steel material. Sodium Lauryl Ether Sulfate (SLES) instead of other soluble oils has been used and compared to dry machining processes. Experiments have been performed at four cutting speeds (60, 95, 155, 240) m/min, feed rates (0.065, 0.08, 0.096, 0.114) mm/rev. and constant depth of cut (0.5) mm. The amount of decrease in Ra after the used suggested mixture arrived at (0.21µm), while Ra exceeded (1µm) in case of soluble oils This means the suggested mixture gave the best results of lubricating properties than other cases.

Modeling of Size Effects on the Flow Stress of Type 304 Stainless Steel and Application in Coining Process

2007 ◽  
Author(s):  
Gap-Yong Kim ◽  
Muammer Koc ◽  
Jun Ni
Keyword(s):  
Grain Size ◽  
Stainless Steel ◽  
Flow Stress ◽  
Size Effect ◽  
Size Effects ◽  
Specimen Size ◽  
304 Stainless Steel ◽  
Length Scales ◽  
Type 304 ◽  
Type 304 Stainless Steel

Application of microforming in various research areas has received much attention due to the increased demand for miniature metallic parts that require mass production. For the accurate analysis and design of microforming process, proper modeling of material behavior at the micro/meso-scale is necessary by considering the size effects. Two size effects are known to exist in metallic materials. One is the “grain size” effect, and the other is the “feature/specimen size” effect. This study investigated the “feature/specimen size” effect and introduced a scaling model which combined both feature/specimen and grain size effects. Predicted size effects were compared with experiments obtained from previous research and showed a very good agreement. The model was also applied to forming of micro-features by coining. A flow stress model for Type 304 stainless steel taking into consideration the effect of the grain and feature size was developed and implemented into a finite element simulation tool for an accurate numerical analysis. The scaling model offered a simple way to model the size effect down to length scales of a couple of grains and extended the use of continuum plasticity theories to micro/meso-length scales.

scholarly journals Infarcted Left Ventricles Have Stiffer Material Properties and Lower Stiffness Variation: Three-Dimensional Echo-Based Modeling to Quantify In Vivo Ventricle Material Properties

2015 ◽  
Vol 137 (8) ◽  
Author(s):  
Longling Fan ◽  
Jing Yao ◽  
Chun Yang ◽  
Dalin Tang ◽  
Di Xu
Keyword(s):  
Wall Thickness ◽  
Material Properties ◽  
Strain Curve ◽  
Stress And Strain ◽  
Stress Strain ◽  
Material Stiffness ◽  
The Mean ◽  
Lv Volume ◽  
Parameter Values

Methods to quantify ventricle material properties noninvasively using in vivo data are of great important in clinical applications. An ultrasound echo-based computational modeling approach was proposed to quantify left ventricle (LV) material properties, curvature, and stress/strain conditions and find differences between normal LV and LV with infarct. Echo image data were acquired from five patients with myocardial infarction (I-Group) and five healthy volunteers as control (H-Group). Finite element models were constructed to obtain ventricle stress and strain conditions. Material stiffening and softening were used to model ventricle active contraction and relaxation. Systolic and diastolic material parameter values were obtained by adjusting the models to match echo volume data. Young's modulus (YM) value was obtained for each material stress–strain curve for easy comparison. LV wall thickness, circumferential and longitudinal curvatures (C- and L-curvature), material parameter values, and stress/strain values were recorded for analysis. Using the mean value of H-Group as the base value, at end-diastole, I-Group mean YM value for the fiber direction stress–strain curve was 54% stiffer than that of H-Group (136.24 kPa versus 88.68 kPa). At end-systole, the mean YM values from the two groups were similar (175.84 kPa versus 200.2 kPa). More interestingly, H-Group end-systole mean YM was 126% higher that its end-diastole value, while I-Group end-systole mean YM was only 29% higher that its end-diastole value. This indicated that H-Group had much greater systole–diastole material stiffness variations. At beginning-of-ejection (BE), LV ejection fraction (LVEF) showed positive correlation with C-curvature, stress, and strain, and negative correlation with LV volume, respectively. At beginning-of-filling (BF), LVEF showed positive correlation with C-curvature and strain, but negative correlation with stress and LV volume, respectively. Using averaged values of two groups at BE, I-Group stress, strain, and wall thickness were 32%, 29%, and 18% lower (thinner), respectively, compared to those of H-Group. L-curvature from I-Group was 61% higher than that from H-Group. Difference in C-curvature between the two groups was not statistically significant. Our results indicated that our modeling approach has the potential to determine in vivo ventricle material properties, which in turn could lead to methods to infer presence of infarct from LV contractibility and material stiffness variations. Quantitative differences in LV volume, curvatures, stress, strain, and wall thickness between the two groups were provided.

End Formation of a Round Tube into a Square Section with Reduced Forming Loads

2013 ◽  
Vol 395-396 ◽  
pp. 945-948
Author(s):  
Chin Joo Tan
Keyword(s):  
Fem Simulation ◽  
Round Tube ◽  
Circular Section ◽  
Constant Diameter ◽  
Conical Die ◽  
The Press ◽  
Metal Stamping ◽  
Simulation And Experiment ◽  
The One ◽  
Conical Bottom

Low formation loads are desirable in metal stamping industries as it reduces the press capacity of the machine and the tooling cost. In the previous study, the author had successfully developed a 2-stage end formation process of a round tube into a square section having small corner radii. However, the formation load in this process increased linearly with the punch stroke in the 1st stage due to the continuous expansion of the tube end by the conical die. Hence, buckling and cracks occurred at the circular section and the bottom end of the square section respectively when the punch stroke was excessive. In this study, the author proposes a circular die having a conical bottom replacing the conical die for the expansion of the tube end. Although the formation load increases when the tube end is expanded at the conical bottom, the amount of increase becomes small when the tube end reaches the circular section of the die due to its constant diameter. At the circular section, the tube end curls and wraps over the die when the punch stroke is increased. In the 2nd stage, the squaring process is performed with a conical bottom square punch and a taper square die for the two different expanded tubes i.e. the one formed with the conical die and the one formed with the conical bottom circular die. Both Finite Element Method (FEM) simulation and experiment were performed to evaluate these two processes. The distribution of plastic strains, forming loads and product appearances are investigated. With the circular die, the maximum forming loads are successfully reduced by 20% and 33% in the 1st and the 2nd stages respectively in the experiment when compared to the ones formed with the conical die. No buckling and cracks are observed for the tube formed with the circular die.

scholarly journals Mobile Technical Calculators with a Flipped Classroom for Sustainability Machining Process

2018 ◽  
Vol 7 (3.2) ◽  
pp. 741
Author(s):  
Bayu Rahmat Setiadi ◽  
Thomas Sukardi ◽  
Sugiyono .
Keyword(s):  
Sustainable Development ◽  
Flipped Classroom ◽  
Performance Test ◽  
Sampling Technique ◽  
Primary Objective ◽  
Parameter Analysis ◽  
Machining Process ◽  
Sample Test ◽  
The Media ◽  
Machining Parameter

This study has the primary objective in planning machining practices early on through the precision of machining parameter analysis with mobile technical calculators combined with the flipped classroom. This research will compare the calculations with manual and mobile phone devices and measure the effectiveness of the media concerning the three elements of sustainable development, i.e., economic, environmental, and social. The research used posttest-control design experiment design which was divided by random sampling. The sampling technique uses saturated sampling. Data collection using performance test, observation, and questionnaire. Data analysis using independent sample test. The results show the use of mobile technical calculator with a flipped classroom is more effective in generating the accuracy of analysis than manual analysis. The t-test results state that there is a difference if this media is applied in machining practice. Also, students' perspectives on the application of these auxiliary media analyzes have an increasing impact on sustainable machinery processes concerning elements in sustainable development.  

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