Process Design and Thermal Performance in Deep Drawing of SiCp/2024Al Composite Sheet Using Pulse Current Heating

2013 ◽  
Vol 712-715 ◽  
pp. 678-682
Author(s):  
Xiao Ming Lai ◽  
Zhe Wang ◽  
Yu Liang Zhang ◽  
Bo Wang ◽  
Kai Feng Zhang ◽  
...  
Keyword(s):  
Deep Drawing ◽  
Pulse Current ◽  
Dimensional Accuracy ◽  
Heating System ◽  
Temperature Control System ◽  
Free Products ◽  
Whole Process ◽  
Good Surface ◽  
Process System ◽  
System Temperature

The deep drawing of SiC/2024Al composites using pulse current heating were designed and established in this works. The whole process system mainly include pulse current heating system, electrode lifting system, temperature control system and deep drawing forming system. In addition, the feasibility of thermal deep drawing using pulse current heating was experimentally investigated and the optimal process parameters were explored to ensure defect-free products. The temperature of specimen is up to around 673K at a rate of 13.5K/s under the current density of 21.7A/mm2. The stainless steel inserts make temperature difference reducing by 73.3%. Moreover, the workpiece was successfully deep drawn and exhibited good surface quality. The dimensional accuracy achieved within ±0.2mm.

The Influence of Temperature on Zinc Abrasion in Deep Drawing Processes

2014 ◽  
Vol 611-612 ◽  
pp. 1039-1046 ◽  
Author(s):  
Peter Sachnik ◽  
Wolfram Volk ◽  
Roland Golle ◽  
Hartmut Hoffmann
Keyword(s):  
Deep Drawing ◽  
High Strength Steels ◽  
High Strength ◽  
Heating System ◽  
Sheet Metals ◽  
Process Stability ◽  
Forming Process ◽  
Whole Process ◽  
Different Temperatures ◽  
The Impact

Due to the development of corrosion-resistant lightweight, todays automotive manufacturers typically use zinc coated sheet metals in the forming process. However, zinc abrasion in industrial presses decreases the process stability and often causes interruption of the whole process. The application of high strength steels leads to a significant increase of the temperature due to the plastic work. So far a detailed, quantitative analysis of the relation between temperature and zinc abrasion is not available. Therefore, this paper examines the impact of the temperature on abrasion behaviour in sheet metal processes. To achieve this, a progressive die was built. The deep drawing stage of this tool is connected to a cooling / heating system in order to obtain a constant temperature during the forming process. A variety of different galvanized sheet metals compared to commonly used tool materials has been tested. For each combination of materials five experiments at different temperatures were performed to determine the effect of the temperature on the zinc abrasion. Applying the method of total reflection x-ray fluorescence (TXRF) the quantity of zinc abrasion was measured. A relation between low temperatures and reduced zinc abrasion can be clearly observed. Industrial experiments revealed that temperature exerts a high influence on the zinc abrasion. The new insights into the impact of the temperature show a significant way to lower the zinc abrasion and therefore increase the process stability in deep drawing processes.

Deep Drawing and Bulging Processes of Hard-Deformed Light Alloy Sheet with Resistance Heating

2014 ◽  
Vol 541-542 ◽  
pp. 268-272
Author(s):  
Zhan Jiao Gao ◽  
Kai Feng Zhang ◽  
Bo Wang ◽  
Chao Li
Keyword(s):  
Magnesium Alloy ◽  
Deep Drawing ◽  
Heat Dissipation ◽  
Pulse Current ◽  
Dimensional Accuracy ◽  
Alloy Sheet ◽  
Resistance Heating ◽  
Aluminium Matrix Composite ◽  
Heating Efficiency ◽  
Deformation Properties

For enhance the heating efficiency and the formability of the magnesium alloy and aluminium matrix composite sheets, pulse current is adopted to the gas bulging and stamping processes. During the bulging process of magnesium alloy sheet, the effects of dynamic pulse current on the formed sheet combine both thermoelectricity and electro-plasticity. The effect and the applicability of the pulse current heating have been evaluated. The deformation properties, microstructure characteristics, and dislocation movement of the AZ31 alloy sheet during bulging process by the resistance heating are investigated. And the resistance heating has been adopted to improve the formability of SiCp/2024Al composites in stamping process. The pulse current density achieved 21.7A/mm2and temperature of SiCp/2024Al composite correspondingly reached to around 400°C in the 50s. The results showed that stainless steel inserts between sheet and copper electrodes successfully prevented the heat dissipation and promote temperature uniformity over the sheet during electrifying. In addition, workpiece formed by the pulse current deep drawing shows better shape retention, surface quality and high geometry dimensional accuracy.

Study on the Propagation of Dimensional Deviation in the Hull Block Building Process

2020 ◽  
Vol 36 (02) ◽  
pp. 143-151
Author(s):  
Changhui Liu ◽  
Jianfeng Liu ◽  
Yansong Zhang ◽  
Sun Jin ◽  
Can Wang ◽  
...  
Keyword(s):  
Critical Role ◽  
Dimensional Accuracy ◽  
Butt Joint ◽  
Measured Data ◽  
Accuracy Control ◽  
Bottom Block ◽  
Whole Process ◽  
Building Process ◽  
Dimensional Deviation ◽  
Industry Practice

Dimensional accuracy of hull block plays a critical role in guaranteeing the whole ship accuracy and reducing the hull butt-joint cost. The current industry practice of dimensional control in shipbuilding mainly focuses on the prediction of cutting and welding deformation based on engineering experience. Its main limitation is that the propagation and accumulation of deviations in the whole building process are neglected. In this article, cutting errors, assembly deviations, welding shrinkages, turnover distortions, and thermal expansions generated at different stages are analyzed. The propagation and accumulation of deviations and variations in the double-bottom block building process are studied based on the measured data in the whole process. Finally, the correlations of deviations between the adjacent stage are concluded. The conclusions can be used to guide the accuracy control in the hull block building process and reduce dimension trimming.

Miniaturized Embossed Low Resistance Fine Line Coils in LTCC

2009 ◽  
Vol 6 (1) ◽  
pp. 42-48 ◽  
Author(s):  
R. Perrone ◽  
H. Bartsch de Torres ◽  
M. Hoffmann ◽  
M. Mach ◽  
J. Müller
Keyword(s):  
Thick Film ◽  
Cross Section ◽  
Screen Printing ◽  
Dimensional Accuracy ◽  
High Dimensional ◽  
Stencil Printing ◽  
Fine Line ◽  
Low Resistance ◽  
Whole Process ◽  
Line Widths

Embedded ceramic coils stand out because of their excellent dielectric, thermal, and RF properties. However the relatively high sheet resistance (low thickness) of printed thick-film conductors restricts their functionality for applications where current values of several amps are needed. Using embossed structures it is possible to manufacture conductors with increased thickness and low resistance on LTCC tapes. The manufacturing process for wide conductors with high dimensional accuracy was shown in previous publications. In this work fine line embossed structures with line widths and spaces of 50 and 75 μm respectively were realized. The cross section of the embossed channels was about 50 μm. The fine line screen printing, stencil printing, and the photo definable Fodel® processes were used to fill the small structures with thick-film ink. The whole process was used to manufacture several types of low resistance coils in LTCC that can be used for current values up to approximately 3 A. They were realized as embedded as well as SMD components. Thus, the functionality of LTCC modules and LTCC SMD coils was increased. In this paper, the filling and patterning characteristics of all structuring methods are compared and the results discussed. Furthermore, the advantages of this process are shown by electrical, thermal, and RF measurements.

Residual Stress Characterization of Electroformed Ni-Base Alloy for μ-Gear Mold

2013 ◽  
Vol 773-774 ◽  
pp. 640-645
Author(s):  
Seong Ho Son ◽  
Sung Cheol Park ◽  
Hyeong Mi Kim ◽  
Won Sik Lee ◽  
Hong Kee Lee
Keyword(s):  
Residual Stress ◽  
Pulse Current ◽  
Base Alloy ◽  
Dimensional Accuracy ◽  
Powder Injection ◽  
Outer Diameter ◽  
Fe Content ◽  
Injection Molded ◽  
Fe Alloys

The micro gear molds for powder injection molding were fabricated by electroforming process of Ni-Fe alloys. The residual stress at interface between electrodeposit and substrate was important for micro electroforming. Addition of 6 g/L saccharin lowered residual stress from 466.3 MPa up to 32.8 MPa and increase of Fe content resulted in increase of residual stress. Electrodeposition by pulse current decreased residual stress in deposit although Fe content was increased. These results reveal clearly that decrease of residual stress due to pulse current is larger than increase of residual stress due to higher Fe content. The micro electroformed gear molds with 550 μm and 2,525 μm in outer diameter and 400 μm in height were fabricated by micro electroforming and 316L feedstock was injection-molded into micro molds. As a result, it is suggested strongly that micro electroforming is very useful process to manufacture micro mold with high dimensional accuracy for micro PIM.

Siemens PLC Software Redundancy in the Design and Implementation of Biomass Pellet Fuel Gasification Test of Strength

2014 ◽  
Vol 945-949 ◽  
pp. 2578-2584
Author(s):  
Xing Lan Li ◽  
Jin Liu ◽  
Yue Xie ◽  
Tan You Yun
Keyword(s):  
Raw Material ◽  
Strong Basis ◽  
Control Equipment ◽  
Whole Process ◽  
Gasification Process ◽  
Process System ◽  
Automation And Control ◽  
Living Material ◽  
Monitoring Data Processing ◽  
And Control

Scientific and technological research for improving raw material gas quality test conducted using redundant control technology, build a platform-based control system hardware and software redundancy Siemens S7-300PLC soft environment, including system design, working principle, hardware and software design. Realization of loading and unloading, gasification combustion, feeding, excessive combustible gas containing oxygen treatment, processing and gas shutdown emptying, composition and temperature computing gasification process control, equipment control, remote centralized monitoring, data processing and management data communications and surveillance and other important parts of pellet fuel from biomass gasification to purify the whole process automation and control, equipment design and process design for a living material gas industrialization process system provides a strong basis.

Vibration in Traverse Cut Cylindrical Grinding - Experiments and Analysis

2011 ◽  
Vol 264-265 ◽  
pp. 1124-1129 ◽  
Author(s):  
Ramesh Rudrapati ◽  
Pradip Kumar Pal ◽  
Asish Bandyopadhyay
Keyword(s):  
Process Parameters ◽  
Surface Finish ◽  
Dynamic Performance ◽  
Dimensional Accuracy ◽  
Vibration Signals ◽  
Cylindrical Grinding ◽  
Good Surface ◽  
Good Surface Finish ◽  
Grinding Machines ◽  
Grinding Machine

Good surface finish is one of the important demands from the outputs of a cylindrical grinding machine. Also it is expected that dimensional accuracy, including accuracy in roundness, is fine in traverse cut cylindrical grinding. Now, like any other machine tool, cylindrical grinding machines also do vibrate, and vibration will affect accuracy and surface finish of the parts produced in grinding. The analysis of vibration in cylindrical grinding is then very much important. In the present study some aspects of vibration – behavior of cylindrical grinding machine have been experimented and analyzed. The process parameters have been varied and vibration signals have been measured in different directions by positioning an accelerometer at tail stock of the machine. The data have been analyzed through various statistical techniques to identify and predict vibration at given combinations of process parameters. The results and analysis of data give useful idea about dynamic performance of cylindrical grinding machine in traverse cut cylindrical grinding operation.

scholarly journals Optimization and application of temperature field in rapid heat cycling molding

2021 ◽  
pp. 291-291
Author(s):  
Mingliang Hao ◽  
Haimei Li
Keyword(s):  
Injection Molding ◽  
Electric Heating ◽  
Heating System ◽  
Mold Temperature ◽  
Temperature Control System ◽  
Cavity Surface ◽  
Injection Mold ◽  
Molding Process ◽  
Molded Parts ◽  
Automotive Part

The rapid thermal cycle molding (RHCM) belongs to the injection mold temperature control system which is helpful to improve mold ability and enhance part quality. Despite many available literatures, RHCM does not represent a well-developed area of practice. The challenge is the uneven distribution of temperature in the cavity after heating, which mostly leads to defects on the surface of the products. In order to obtain uniform cavity surface temperature distribution of RHCM, the power of heating rods of the electric-heating system in an injection mold was optimized by the response surface method(RSM) in this work. The proposed optimization result was applied to design a complex RHCM injection mold with side core-pulling, holes and different thickness of an automotive part to verify its effectiveness by injection molding. Compared with initial design, the mold temperature uniformity was remarkably improvedby79%. Based on the optimization and injection molding numerical simulation results, the workable molding process to weaken the weld-lines effects on the quality was suggested and the practical injection molded parts were well produced.

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