Metal to Composite Plastic Conversion of Mechanically Loaded Part Using Numerical CAE Analyses

2016 ◽  
Vol 862 ◽  
pp. 213-221
Author(s):  
Miroslav Košík ◽  
Jozef Bílik ◽  
Antonín Náplava
Keyword(s):  
Mechanical Properties ◽  
Automotive Industry ◽  
Production Costs ◽  
Unexpected Result ◽  
Anisotropic Properties ◽  
Part Geometry ◽  
Reinforced Composite ◽  
Loaded Part ◽  
Original Metal ◽  
Complicated Part

The material replacement of component is often used procedure, which helps to reduce production costs, simplify manufacturing, improve functional properties of component and bring another benefits. In the last years, more and more metal parts are converted to plastic, also in the cases of mechanically loaded parts. For these special applications, the fibre reinforced composite plastics are successfully used. However, the mechanical properties of composite plastic are strongly dependent on the fibres orientation and following anisotropic behaviour. Moreover, the orientation of fibres is influenced by the conditions of the part production. Due to the number of these dependencies, the material conversion becomes a complex task which cannot be solved with analytical approach. Especially in case of complicated part geometry. In this study, the connection of two different numerical solvers was used for material conversion of a part from automotive industry. First, the new geometry of analyzed part was designed in order to compensate lower mechanical properties of plastic in comparison to metal. Next, the new part manufacturing was simulated and this way obtained anisotropic properties of composite plastic were described. Finally, the structural analyses of original metal and new composite plastic part with real anisotropic properties were performed to verify achievement of material conversion. The aim of this study is to demonstrate, how numerical analyses can help to predict an unexpected result.

A Hierarchical, Heterogeneous CAD Modeling Approach

2011 ◽  
Author(s):  
David W. Rosen ◽  
Namin Jeong ◽  
Yan Wang
Keyword(s):  
Mechanical Properties ◽  
Hierarchical Modeling ◽  
Geometric Model ◽  
Low Resolution ◽  
Material Microstructure ◽  
Part Geometry ◽  
Reinforced Composite ◽  
Reinforced Polymer ◽  
Macro Scale ◽  
Computational Materials

Integration of material composition, microstructure, and mechanical properties with geometry information enables many product development activities, including design, analysis, and manufacturing. In this paper, we propose the modeling of part geometry and microstructure by using a new hierarchical modeling method that utilizes a common geometric model for both macro-scale part geometry and material microstructure. A new surfacelet transform is introduced to model microstructure. The application of image processing methods enables multi-resolution representations of microstructure. Combined with methods from computational materials design, low resolution microstructure representations can be used to compute effective mechanical properties at the macro-scale. Wavelet decomposition was used to generate the low resolution representations. The models and methods are demonstrated with two examples, a simple continuous-fiber-reinforced composite and a nanofiber reinforced polymer material.

Design and development of glass/basalt fiber reinforced composite material for automobile applications

2020 ◽  
pp. 152808372093957
Author(s):  
Chandrasekaran Paramasivam ◽  
Rameshbabu Venugopal
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Impact Strength ◽  
Flexural Strength ◽  
Automotive Industry ◽  
Woven Fabrics ◽  
Curing Time ◽  
Fiber Reinforced ◽  
Fiber Reinforced Composite ◽  
Reinforced Composite

The main focus of automotive industry is on developing and applying new materials and technologies for enhancing the comfort and security levels in the vehicles. To fulfill this requirement high strength and high modulus fiber reinforced composite structures play an important role in the automotive industry. The novelty in this research work is that the composite panel made by 2 D woven fabrics by using Glass and Basalt fabric material composite structure by suitable incorporation of panel design which enhanced the mechanical properties. The blend proportion of Glass and Basalt fabric reinforcement was 100% Glass, 100% Basalt and 50:50 Glass/Basalt fabrics. Hand lay-up process was adopted to fabricate the composite panels. Different sets of panel were produce by varying the curing time, pressure. The resultant panels were analyzed for the mechanical properties such as Tensile strength, Flexural strength and Impact strength tests. From the analysis of results the panel made by using 100% Basalt fabric with 20 bar pressure and 15 minutes curing time showed a better tensile strength of 95 MPa, flexural strength of 29.91 MPa and impact strength of 12.50 MPa. Similarly, the results of 50:50 Glass/Basalt fibre with 30 bar pressure and 15 minutes curing time showed a better tensile strength of 94.83 MPa, flexural strength of 29.51 MPa and impact strength of 12.30 MPa. The outcome of the findings is that the mechanical properties of panel are directly proportional to pressure and time and blend type.

Metodología para el desarrollo de trayectorias en la aplicación por el proceso de soldadura GMAW en un robot industrial

2019 ◽  
pp. 1-4
Author(s):  
Josué Rafael Sánchez-Lerma ◽  
Luis Armando Torres-Rico ◽  
Héctor Huerta-Gámez ◽  
Ismael Ruiz-López
Keyword(s):  
Mechanical Properties ◽  
Automotive Industry ◽  
Industrial Robot ◽  
Welding Process ◽  
High Strength ◽  
Test Material ◽  
Advantages And Disadvantages ◽  
Application Characteristics ◽  
Joining Process ◽  
Gmaw Welding

This paper proposes the development of the methodology to be carried out for the metal joining process through the GMAW welding process in the Fanuc LR Mate 200iD industrial robot. The parameters or properties were considered for the application to be as efficient as possible, such parameters as speed of application, characteristics of the filler material, gas to be used as welding protection. The GMAW welding process can be applied semiautomatically using a hand gun, in which the electrode is fed by a coil, or an automatic form that includes automated equipment or robots. The advantages and disadvantages of the GMAW welding process applied in a manual and automated way were commented. The mechanical properties of the materials to which said welding can be applied were investigated; The materials with which this type of welding can be worked are the high strength materials, which are used in the automotive industry, for the forming of sheet metal. To know the properties of the material, destructive tests were carried out on the test material to be used, as well as the mechanical properties of the welding.

scholarly journals Monitoring the technological processes in the wood industry in order to make them more efficient through technical overhauling

2019 ◽  
Vol 290 ◽  
pp. 02007
Author(s):  
Radu Dan Paltan ◽  
Cristina Biriş ◽  
Loredana Anne-Marie Rădulescu
Keyword(s):  
Automotive Industry ◽  
Operating Mode ◽  
Solid Wood ◽  
Production Costs ◽  
Operating Costs ◽  
Future Research ◽  
Wood Industry ◽  
Research Article ◽  
State Of Research ◽  
The Cost

Of many techniques that are used to optimize production and costs, the studies conducted within a profile company lead to our choice for testing the 6Sigma method (the most used method in the automotive industry) in view of the economic efficiency applied in the wood Industry company. This method measures how many flaws exist in a process and determines in a systematic way how to improve it by technical overhauling and eliminating or minimizing the process for efficiency. This research article aims to study the state of research on the optimization of the production process through technical overhauling for panels reconstituted from solid wood and ways to make production more efficient by cutting costs through technical overhauling. From preliminary research, we estimate that all the items founded and others that will result from further research will result in a significant decrease in production costs that are reflected in the cost of the finished product and consequently in increasing the yield of the company by maximizing its profit. At the same time it may be the basis of future research studies in the field. The easier it is to maximize profits, the lower the operating costs are and the higher recovery rate of investments are, that will result a change in the operating mode: “working smarter not harder”.

scholarly journals Analysis of Different Complex Multilayer PACVD Coatings on Nanostructured WC-Co Cemented Carbide

Coatings ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 823
Author(s):  
Danko Ćorić ◽  
Mateja Šnajdar Musa ◽  
Matija Sakoman ◽  
Željko Alar
Keyword(s):  
Mechanical Properties ◽  
Surface Layer ◽  
Base Material ◽  
Single Layer ◽  
Production Costs ◽  
Structural Defects ◽  
Cemented Carbides ◽  
Material System ◽  
Tin Coating ◽  
Ticn Coating

The development of cemented carbides nowadays is aimed at the application and sintering of ultrafine and nano-sized powders for the production of a variety of components where excellent mechanical properties and high wear resistance are required for use in high temperature and corrosive environment conditions. The most efficient way of increasing the tribological properties along with achieving high corrosion resistance is coating. Using surface processes (modification and/or coating), it is possible to form a surface layer/base material system with properties that can meet modern expectations with acceptable production costs. Three coating systems were developed on WC cemented carbides substrate with the addition of 10 wt.% Co using the plasma-assisted chemical vapor deposition (PACVD) method: single-layer TiN coating, harder multilayer gradient TiCN coating composed of TiN and TiCN layers, and the hardest multilayer TiBN coating composed of TiN and TiB2. Physical and mechanical properties of coated and uncoated samples were investigated by means of quantitative depth profile (QDP) analysis, nanoindentation, surface layer characterization (XRD analysis), and coating adhesion evaluation using the scratch test. The results confirm the possibility of obtaining nanostructured cemented carbides of homogeneous structure without structural defects such as eta phase or unbound carbon providing increase in hardness and fracture toughness. The lowest adhesion was detected for the single-layer TiN coating, while coatings with a complex architecture (TiCN, TiBN) showed improved adhesion.

scholarly journals Mechanochemical Synthesis and Rapid Consolidation of Nanocrystalline 3NiAl-Al2O3Composites

2011 ◽  
Vol 2011 ◽  
pp. 1-5 ◽  
Author(s):  
In-Jin Shon ◽  
In-Yong Ko ◽  
Seung-Hoon Jo ◽  
Jung-Mann Doh ◽  
Jin-Kook Yoon ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Fracture Toughness ◽  
Mechanochemical Synthesis ◽  
High Frequency ◽  
Nanocrystalline Materials ◽  
Physical And Mechanical Properties ◽  
High Energy ◽  
Reinforced Composite ◽  
Energy Ball ◽  
High Frequency Induction

Nanopowders of 3NiAl and Al2O3were synthesized from 3NiO and 5Al powders by high-energy ball milling. Nanocrystalline Al2O3reinforced composite was consolidated by high-frequency induction-heated sintering within 3 minutes from mechanochemically synthesized powders of Al2O3and 3NiAl. The advantage of this process is that it allows very quick densification to near theoretical density and inhibition grain growth. Nanocrystalline materials have received much attention as advanced engineering materials with improved physical and mechanical properties. The relative density of the composite was 97%. The average Vickers hardness and fracture toughness values obtained were 804 kg/mm2and 7.5 MPa⋅m1/2, respectively.

Multicriterion Optimization: A Tool in Advanced Materials Technology

1994 ◽  
Author(s):  
Jianxiang Wang ◽  
Niels B. Thomsen ◽  
Bhushan L. Karihaloo
Keyword(s):  
Mechanical Properties ◽  
Composite Laminate ◽  
Heuristic Approach ◽  
Optimization Process ◽  
Advanced Materials ◽  
Brittle Matrix ◽  
Multicriterion Optimization ◽  
Reinforced Composite ◽  
Applied Stresses ◽  
Empirical Approaches

Abstract This paper will demonstrate on two advanced materials — a fibre-reinforced composite laminate (FRC) and a transformation toughened ceramic (TTC) — the importance of multicriterion optimization in the production of useful advanced materials with enhanced mechanical properties. In a previous paper (Thomsen et al., 1994a), the authors have demonstrated the application of single-criterion optimization to these materials which are based on a brittle matrix and thus prone to cracking at very low applied stresses. The optimization process aims at altering their microstructure so that all their desirable mechanical properties are enhanced. Currently, the advanced materials technologists must take a heuristic approach to meeting the often competing requirements. The present paper will show how multicriterion optimization can come to the aid of the technologists and reduce their reliance on empirical approaches.

Gas metal arc welding of XPF800 steel for automotive industry: Microstructural evaluation and mechanical properties investigation

2021 ◽  
pp. 146442072110567
Author(s):  
Emre Korkmaz ◽  
Cemal Meran
Keyword(s):  
Mechanical Properties ◽  
Base Metal ◽  
Automotive Industry ◽  
Heat Affected Zone ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Charpy Impact ◽  
Optical Microscope ◽  
Metal Arc Welding ◽  
Heat Affected Zone Softening

In this study, the effect of gas metal arc welding on the mechanical and microstructure properties of hot-rolled XPF800 steel newly produced by TATA Steel has been investigated. This steel finds its role in the automotive industry as chassis and seating applications. The microstructure transformation during gas metal arc welding has been analyzed using scanning electron microscope, optical microscope, and energy dispersive X-ray spectrometry. Tensile, Charpy impact, and microhardness tests have been implemented to determine the mechanical properties of welded samples. Acceptable welded joints have been obtained using heat input in the range of 0.28–0.46 kJ/mm. It has been found that the base metal hardness of the welded sample is 320 HV0.1. On account of the heat-affected zone softening, the intercritical heat-affected zone hardness values have diminished ∼20% compared to base metal.

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