scholarly journals Improvement of Manufacturing Technology for Thin-Walled Pipes Made of Copper Alloys

2018 ◽  
Vol 918 ◽  
pp. 140-144 ◽  
Author(s):  
Aleksandr Aleksandrovich Bogatov ◽  
Denis Rinatovich Salikhyanov ◽  
Aleksandr Sergeevich Ovchinnikov
Keyword(s):  
Surface Defects ◽  
Scientific Evidence ◽  
Copper Alloys ◽  
Ferrous Metal ◽  
Dimensional Accuracy ◽  
Quality Characteristics ◽  
Labor Input ◽  
Instrument Making ◽  
Thin Walled ◽  
Gost State Standard

Thin-walled pipes made of copper alloys – the brass grades L96, L68, L63, LANKMc; the bronze grade BrOF (the GOST state standard) are of great demand in aircraft, shipbuilding, automotive, defense, diesel and instrument-making industries. Pipe diameter ranges between 4.0 and 20 mm, and wall thickness is in the range from 0.1 to 0.6 mm. The manufacture of these pipes using traditional technological schemes is characterized by high labor input and low stability in providing quality characteristics, such as dimensional accuracy, the presence of surface defects and the level of mechanical properties. This study presents scientific evidence, new technological schemes developed for manufacturing pipes made of copper alloys with the use of the equipment and technology of multiple drawing on a long movable mandrel and results of their adoption at Revda Non-Ferrous Metal Processing Works JSC.

scholarly journals Selective laser melting for improving quality characteristics of a prism shaped topology injection mould tool insert for the automotive industry

2021 ◽  
pp. 095440622198938
Author(s):  
Mennatallah F El Kashouty ◽  
Allan EW Rennie ◽  
Mootaz Ghazy ◽  
Ahmed Abd El Aziz
Keyword(s):  
Surface Roughness ◽  
Selective Laser Melting ◽  
Automotive Industry ◽  
Injection Moulding ◽  
Dimensional Accuracy ◽  
Quality Characteristics ◽  
Surface Topology ◽  
Laser Melting ◽  
Injection Mould ◽  
Tool Insert

Manufacturing process constraints and design complexities are the main challenges that face the aftermarket automotive industry. For that reason, recently, selective laser melting (SLM) is being recognised as a viable approach in the fabrication of injection moulding tool inserts. Due to its versatility, SLM technology is capable of producing freeform designs. For the first reported time, in this study SLM is recognized for its novel application in overcoming fabrication complexities for prism shaped topology of a vehicle headlamp’s reflector injection moulding tool insert. Henceforth, performance measures of the SLM-fabricated injection mould tool insert is assessed in comparison to a CNC-milled counterpart to improve quality characteristics. Tests executed and detailed in this paper are divided into two stages; the first stage assesses both fabricated tool inserts in terms of manufacturability; the second stage assesses the functionality of the end-products by measuring the surface roughness, dimensional accuracy and light reflectivity from the vehicle reflectors. The results obtained show that employing SLM technology can offer an effective and efficient alternative to subtractive manufacturing, successfully producing tool inserts with complex surface topology. Significant benefits in terms of surface roughness, dimensional accuracy and product functionality were achieved through the use of SLM technology. it was concluded that the SLM-fabricated inserts products proved to have relatively lower values of surface roughness in comparison to their CNC counterparts.

scholarly journals Characteristics, Industrial Application, and Prospects of Continuous Extrusion Technology

2019 ◽  
Vol 1 (1) ◽  
Author(s):  
Hongjiang Pan ◽  
Yi Zhong ◽  
Zhihao Zhang ◽  
Chengmin Pan
Keyword(s):  
Industrial Application ◽  
Industrial Production ◽  
Energy Savings ◽  
Ferrous Metal ◽  
Automatic Production ◽  
Continuous Extrusion ◽  
Thin Walled ◽  
Material Utilization ◽  
Extrusion Technology ◽  
Development Prospects

At present, continuous extrusion technology is applied in the industrial production of traditional non-ferrous metal profiles, composite profiles, and thin-walled hollow profiles, such as pipes, belts, wires and rows. This technology yields energy savings, high material utilization rates, automatic production, large manufacturing-product lengths, labor savings, and requires small floor space. The present paper introduces the characteristics of continuous extrusion technology and some industrial application examples, and focuses on the development prospects of multi-blank multi-round continuous extrusion technology.

On the manufacturability of Inconel 718 thin-walled honeycomb structures by laser powder bed fusion

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
José M. Zea Pérez ◽  
Jorge Corona-Castuera ◽  
Carlos Poblano-Salas ◽  
John Henao ◽  
Arturo Hernández Hernández
Keyword(s):  
Mechanical Properties ◽  
Inconel 718 ◽  
Dimensional Accuracy ◽  
Honeycomb Lattice ◽  
Lattice Structures ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Content Type ◽  
Powder Bed ◽  
Thin Walled

Purpose The purpose of this paper is to study the effects of printing strategies and processing parameters on wall thickness, microhardness and compression strength of Inconel 718 superalloy thin-walled honeycomb lattice structures manufactured by laser powder bed fusion (L-PBF). Design/methodology/approach Two printing contour strategies were applied for producing thin-walled honeycomb lattice structures in which the laser power, contour path, scanning speed and beam offset were systematically modified. The specimens were analyzed by optical microscopy for dimensional accuracy. Vickers hardness and quasi-static uniaxial compression tests were performed on the specimens with the least difference between the design wall thickness and the as built one to evaluate their mechanical properties and compare them with the counterparts obtained by using standard print strategies. Findings The contour printing strategies and process parameters have a significant influence on reducing the fabrication time of thin-walled honeycomb lattice structures (up to 50%) and can lead to improve the manufacturability and dimensional accuracy. Also, an increase in the young modulus up to 0.8 times and improvement in the energy absorption up to 48% with respect to those produced by following a standard strategy was observed. Originality/value This study showed that printing contour strategies can be used for faster fabrication of thin-walled lattice honeycomb structures with similar mechanical properties than those obtained by using a default printing strategy.

scholarly journals Characterization of machining quality attributes based on spindle probe, coordinate measuring machine, and surface roughness data

2014 ◽  
Vol 1 (2) ◽  
pp. 128-139 ◽  
Author(s):  
Tzu-Liang Bill Tseng ◽  
Yongjin James Kwon
Keyword(s):  
Surface Roughness ◽  
Coordinate Measuring Machine ◽  
Dimensional Accuracy ◽  
Quality Characteristics ◽  
Machining Parameters ◽  
Production Environment ◽  
Significant Interaction Effect ◽  
Machining Quality ◽  
Measuring Machine ◽  
Touch Probe

Abstract This study investigates the effects of machining parameters as they relate to the quality characteristics of machined features. Two most important quality characteristics are set as the dimensional accuracy and the surface roughness. Before any newly acquired machine tool is put to use for production, it is important to test the machine in a systematic way to find out how different parameter settings affect machining quality. The empirical verification was made by conducting a Design of Experiment (DOE) with 3 levels and 3 factors on a state-of-the-art Cincinnati Hawk Arrow 750 Vertical Machining Center (VMC). Data analysis revealed that the significant factor was the Hardness of the material and the significant interaction effect was the Hardness + Feed for dimensional accuracy, while the significant factor was Speed for surface roughness. Since the equally important thing is the capability of the instruments from which the quality characteristics are being measured, a comparison was made between the VMC touch probe readings and the measurements from a Mitutoyo coordinate measuring machine (CMM) on bore diameters. A machine mounted touch probe has gained a wide acceptance in recent years, as it is more suitable for the modern manufacturing environment. The data vindicated that the VMC touch probe has the capability that is suitable for the production environment. The test results can be incorporated in the process plan to help maintain the machining quality in the subsequent runs.

scholarly journals The Dimensional Accuracy of Thin-Walled Parts Manufactured by Laser-Powder Bed Fusion Process

2020 ◽  
Vol 4 (3) ◽  
pp. 91
Author(s):  
Josef Tomas ◽  
Leonhard Hitzler ◽  
Marco Köller ◽  
Jonas von Kobylinski ◽  
Michael Sedlmajer ◽  
...  
Keyword(s):  
Residual Stresses ◽  
Dimensional Accuracy ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Cooling Channels ◽  
Thin Walled ◽  
Scanning Strategies ◽  
Different Diameters ◽  
Functional Components

Laser-Powder Bed Fusion brings new possibilities for the design of parts, e.g., cutter shafts with integrated cooling channels close to the contour. However, there are new challenges to dimensional accuracy in the production of thin-walled components, e.g., heat exchangers. High degrees of dimensional accuracy are necessary for the production of functional components. The aim is to already achieve these during the process, to reduce post-processing costs and time. In this work, thin-walled ring specimens of H13 tool steel are produced and used for the analysis of dimensional accuracy and residual stresses. Two different scanning strategies were evaluated. One is a stripe scan strategy, which was automatically generated and provided by the machine manufacturer, and a (manually designed) sectional scan strategy. The ring segment strategy is designed by manually segmenting the geometry, which results in a longer preparation time. The samples were printed in different diameters and analyzed with respect to the degree of accuracy and residual stresses. The dimensional accuracy of ring specimens could be improved by up to 81% with the introduced sectional strategy compared to the standard approach.

scholarly journals Application of Modified Cores for Grain Refinement in Castings of Aircraft Turbine Blades

2017 ◽  
Vol 17 (3) ◽  
pp. 19-22 ◽  
Author(s):  
F. Binczyk ◽  
J. Cwajna ◽  
P. Gradoń
Keyword(s):  
Grain Refinement ◽  
Surface Defects ◽  
External Surface ◽  
Turbine Blades ◽  
Internal Surface ◽  
Aircraft Engine ◽  
Grain Refiner ◽  
Cast Part ◽  
Wax Pattern ◽  
Thin Walled

Abstract Paper presents the results of research on modified surface grain refinement method used in investment casting of hollow, thin-walled parts made of nickel based superalloys. In the current technology, the refining inoculant is applied to the surface of the wax pattern and then, it is transferred to the ceramic mould surface during dewaxing. Because of its chemical activity the inoculant may react with the liquid metal which can cause defects on the external surface of the cast part. The method proposed in the paper aims to reduce the risk of external surface defects by applying the grain refiner only to the ceramic core which shapes the internal surface of the hollow casting. In case of thin-walled parts the grain refinement effect is visible throughout the thickness of the walls. The method is meant to be used when internal surface finish is less important, like for example, aircraft engine turbine blades, where the hollowing of the cast is mainly used to lower the weight and aid in cooling during operation.

Enhancement of Porosity of the Ceramic Shell in Investment Casting Process Using Needle Coke and Camphor

2014 ◽  
Vol 592-594 ◽  
pp. 269-275 ◽  
Author(s):  
Khyati Tamta ◽  
D. Benny Karunakar
Keyword(s):  
Investment Casting ◽  
Complex Geometry ◽  
Gas Permeability ◽  
Ferrous Metal ◽  
Dimensional Accuracy ◽  
Casting Process ◽  
Ceramic Shell ◽  
Needle Coke ◽  
Thin Sections ◽  
Investment Casting Process

Investment casting process has been a widely used process for centuries. It is known for its ability to produce components of complex shapes with dimensional accuracy and excellent surface finish. Investment casting has been used to make manufacture weapons, jewellery and art castings during the ancient civilization and today it is used to manufacture engineering components. In Investment casting wax patterns are made by wax injection and then coating of the wax patterns are done by ceramic slurry, made with silica flour and binder. After dewaxing and firing molten metal is poured in the shell and solidified casting can be achieved. Investment casting can be cast any ferrous and non ferrous metal which is difficult in die casting. Finishing operations are negligible and very thin sections as.75mm can also be cast which is not possible in sand casting but there are many challenges in Investment casting. It is relatively slow process because preparation of ceramic shell consumes a lot of time, permeability of shell is very low which causes gas permeability. Incorporation of chills is very difficult. Among all these challenges gas porosity is main problem because of poor permeability, entrapment of gases due to complex geometry of the shell, reuse of scrap metal. In the present work porosity of the shell can be increase by addition of mixture of Camphor and needle coke. After firing of the shell camphor and needle coke will be burnt leaving pores for the escape of entrapped gases. Mechanical properties of the both shell will be compared with each other.

scholarly journals A Comparative Study of the Mechanical Properties of FDM 3D Prints Made of PLA and Carbon Fiber-Reinforced PLA for Thin-Walled Applications

Materials ◽  
2021 ◽  
Vol 14 (22) ◽  
pp. 7062
Author(s):  
Jerzy Bochnia ◽  
Malgorzata Blasiak ◽  
Tomasz Kozior
Keyword(s):  
Mechanical Properties ◽  
Carbon Fiber ◽  
Lean Manufacturing ◽  
Industrial Revolution ◽  
Base Material ◽  
Dimensional Accuracy ◽  
Strength Analysis ◽  
Fused Deposition Modelling ◽  
Fused Deposition ◽  
Thin Walled

This study focused on the analysis of the mechanical properties of thin-walled specimens fabricated by fused deposition modelling (FDM). Two materials were considered, i.e., polylactide (PLA) and polylactide with carbon fiber (PLA-CF). The article describes how the specimens with different thicknesses and printing orientations were designed, printed, measured to assess their geometric and dimensional accuracy, subjected to tensile testing, and examined using scanning electron microscopy. The data provided here can be used for further research aimed at improving filament deposition and modifying the base material by combining it with different components, for example carbon fiber. The investigations revealed that the properties of thin-walled elements produced by FDM varied significantly depending on the thickness. So far, this problem has not been investigated extensively. Research by analyzing the key parameter, which is the direction of printing that is important for thin-walled models, provides a lot of new information for designers and technologists and opens the way to further extended scientific research in the field of the strength analysis of thin-walled models produced by 3D printing, which is very applicable to structure optimization in the era of the industrial revolution 4.0 and progress in the LEAN manufacturing process.

scholarly journals Surface Topography Prediction Model in Milling of Thin-Walled Parts Considering Machining Deformation

Materials ◽  
2021 ◽  
Vol 14 (24) ◽  
pp. 7679
Author(s):  
Zhitao Chen ◽  
Caixu Yue ◽  
Xianli Liu ◽  
Steven Y. Liang ◽  
Xudong Wei ◽  
...  
Keyword(s):  
Prediction Model ◽  
Cutting Force ◽  
Surface Topography ◽  
Surface Quality ◽  
Three Dimensional ◽  
Dimensional Accuracy ◽  
Significant Feature ◽  
Force Model ◽  
Deformation Model ◽  
Thin Walled

With the continuous improvement of the performance of modern aerospace aircraft, the overall strength and lightweight control of aircraft has become a significant feature of modern aerospace parts. With the wide application of thin-walled parts, the requirements for dimensional accuracy and surface quality of workpieces are increasing. In this paper, a numerical model for predicting surface topography of thin-walled parts after elastic deformation is proposed. In view of the geometric characteristics in the cutting process, the cutting force model of thin-walled parts is established, and the meshing relationship between the tool and the workpiece is studied. In addition, the influence of workpiece deformation is considered based on the beam deformation model. Cutting force is calculated based on deformed cutting thickness, and the next cutting–meshing relationship is predicted. The model combines the radial deflection of the workpiece in the feed direction and the changing meshing relationship of the tool–workpiece to determine the three-dimensional topography of the workpiece. The error range between the experimental and the simulation results of surface roughness is 7.45–13.09%, so the simulation three-dimensional morphology has good similarity. The surface topography prediction model provides a fast solution for surface quality control in the thin-walled parts’ milling process.

scholarly journals PECULIAR FEATURES OF NON-FERROUS METAL INDUSTRY AND METALWORKING IN PROTOTOWN CENTRES IN CENTRAL PREDURALYE

2021 ◽  
Vol 15 (3) ◽  
pp. 494-506
Author(s):  
Nataliya Borisovna Krylasova ◽  
Andrei Mihailovich Belavin
Keyword(s):  
Large Scale ◽  
Middle Age ◽  
Copper Alloys ◽  
Ferrous Metal ◽  
Raw Material ◽  
Metal Industry ◽  
Metal Workers ◽  
Historical Processes ◽  
History Of ◽  
Ferrous Metal Industry

In her research M. G. Ivanova raised various questions concerning the Middle Age history of Udmurtia. One of them is the question of origins of prototown settlements which were craft, trade and political centres on the territory. The Idnakar settlement used to play the key role among the prototowns of the day. In her work a lot of attention is paid to craft activities characterization, among others non-ferrous metalworking. Very similar cultural and historical processes may be observed on the territory of Central Preduralye - its Udmurt and Perm areas. Today’s research shows that metal workers in Central Preduralye produced copper alloys, cast ingots and exported these as trade goods. Alongside furskins, metal as a strategic raw material was one of the most sought-after trade items. Local artisans made some impressive achievements in non-ferrous metalworking - metal casting, gold-work, and copper smithy. Non-ferrous metal industry and metalworking, traditional among the Finno-Ugrian population, was much less dependent on craft centres of large feudal states than thought previously. However, it was clearly under the influence of these centres. Local production of various everyday items and decorations using non-ferrous materials is confirmed by many traces of mass craft production in prototown centres, and in Idnakar in particular. It is brightly manifested by the large number of specialized workshops that have been found across the Perm Region in recent years. Today it is beyond any doubt that there were in Central Preduralye regional centres of copperware production - particularly of cauldrons - as well as a peculiar Bulgar-Kama gold-work school whose items have peculiar unique features. Thanks to large-scale research at key Middle-Age sites, our views changed dramatically on specific features of metalworking in Central Preduralye and the import ratio on these territories among the unearthed Middle-Age artefacts.

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