Analytical Modeling of Metal Transfer for GMAW in the Globular Mode

A lumped parameter dynamical model is developed to describe the metal transfer for gas metal arc welding (GMAW) in the globular mode. The oscillations of molten drop are modeled using a mass-spring-damper system with variable mass and spring coefficient. An analytical solution is developed for the variable coefficient system to better understand the effect of various model parameters on the drop oscillations. The effect of welding drop motion on the observed current and voltage signals is investigated and the model agrees well with the experimental results. Furthermore, the effect of wire feeding rate (or welding current) on the metal transfer cycle time is studied and the model successfully estimates the cycle times for different wire feeding rates.

A Comparative Study on Hydraulic Bulge Testing and Analysis Methods

Hydraulic bulge testing is a material characterization method used as an alternative to tensile testing with the premise of accurately representing the material behavior to higher strain levels (∼70% as appeared to ∼30% in tensile test) in a biaxial stress mode. However, there are some major assumptions (such as continuous hemispherical bulge shape, thinnest point at apex) in hydraulic bulge analyses that lead to uncertainties in the resulting flow stress curves. In this paper, the effect of these assumptions on the accuracy and reliability of flow stress curves is investigated. The goal of this study is to determine the most accurate method for analyzing the data obtained from the bulge testing when continuous and in-line thickness measurement techniques are not available. Specifically, in this study the stress-strain relationships of two different materials (SS201 and Al5754) are obtained based on hydraulic bulge test data using various analysis methods for bulge radius and thickness predictions (e.g., Hill’s, Chakrabarty’s, Panknin’s theories, etc.). The flow stress curves are calculated using pressure and dome height measurements and compared to the actual 3-D strain measurement from a stereo optical and non-contact measurement system ARAMIS. In addition, the flow stress curves obtained from stepwise experiments are compared with the ones from above methods. Our findings indicate that Enikeev’s approach for thickness prediction and Panknin’s approach for bulge radius calculation result in the best agreement with both stepwise experiment results and 3D optical measurement results.

Effect of Electrical Pulsing on Various Heat Treatments of 5XXX Series Aluminum Alloys

Previous studies have shown that the presence of a pulsed electrical current, applied during the deformation process of an aluminum specimen, can significantly improve the formability of the aluminum without heating the metal above its maximum operating temperature range. The research herein extends these findings by examining the effect of electrical pulsing on 5052 and 5083 Aluminum Alloys. Two different parameter sets were used while pulsing three different heat treatments (As Is, 398°C, and 510°C) for each of the two aluminum alloys. For this research, the electrical pulsing is applied to the aluminum while the specimens are deformed, without halting the deformation process. The analysis focuses on establishing the effect the electrical pulsing has on the aluminum alloy’s various heat treatments by examining the displacement of the material throughout the testing region of dogbone shaped specimens. The results from this research show that pulsing significantly increases the maximum achievable elongation of the aluminum (when compared to baseline tests conducted without electrical pulsing). Significantly reducing the engineering flow stress within the material is another beneficial effect produced by electric pulsing. The electrical pulses also cause the aluminum to deform non-uniformly, such that the material exhibits a diffuse neck where the minimum deformation occurs near the ends of the specimen (near the clamps) and the maximum deformation occurs near the center of the specimen (where fracture ultimately occurs). This diffuse necking effect is similar to what can be experienced during superplastic deformation. However, when comparing the presence of a diffuse neck in this research, electrical pulsing does not create as significant of a diffuse neck as superplastic deformation. Electrical pulsing has the potential to be more efficient than traditional methods of incremental forming since the deformation process is never interrupted. Overall, with the greater elongation and lower stress, the aluminum can be deformed quicker, easier, and to a greater extent than is currently possible.

Modeling Machining at High Speeds as a Fluid Mechanics Problem

Even though many models for machining exist, most of them are for low-speed machining, where momentum is negligible and material behavior is well approximated by quasi-static plastic constitutive laws. In machining at high speeds, momentum can be important and the strain rate can be exceedingly high. For these reasons, a fluid mechanics approach to understanding high-speed, very high-speed, and ultra-high-speed machining is attempted here. Namely, a potential flow solution is used to model the behavior of the material around a sharp tool tip during machining at high speeds. It is carefully argued that the potential flow solution is relevant and can be used as a first approximation to model the behavior of a metal during high-speed, very high-speed, or ultra-high-speed machining events; and at a minimum, the potential flow solution is qualitatively useful in understanding mechanics of machining at high speeds and above. Interestingly, the flow solution predicts that there is a stagnation point on the rake face, not at the tool tip as is usually assumed. Because the stagnation point is not at the tool tip, the flow solution predicts a significant amount of deformation in the workpiece resulting in large residual strains that may lead to a temperature rise on the finished surface.

Mathematical Modelling and Finite Element Simulation of Pre-Bending Stage of Three-Roller Plate Bending Process

Continuous three roller bending process is widely used in practice to bend the plates into cylinders. Bending load for plate material under bending is affected by plate thickness, width and shell diameter combinations. Maximum top roller load is encountered during the edge pre-bending stage as top roller is set at an offset distance from its mid position. Shell diameter, thickness and material for cylindrical structural element to be produced are fixed by design. Width of the plate for roller bending decides number of cylindrical segments required to achieve the designed shell length. Maximum pre-bending width depends on maximum top roller load imparting capacity. Looking to the above considerations, maximum width which can be pre-bend at limiting top roller load (for designed shell diameter, thickness and material combinations) specifies the capacity. Presented work aims at developing the mathematical model of top roller load for pre-bending. Top roller offset for pre-bending were calculated based on practical top roller pre-bending load data, for different grades of C-Mn steel plates (as per ASME sec II part-A). Based on these top roller offsets, finite element analysis (FEA) of pre-bending stage were performed using Hyperform LS-DYNA. Effect of co-efficient of friction at roller plate interfaces was analyzed. FE simulation of pre-bending of cladded plate (54 mm thick C-Mn steel plate of material grade SA-387Gr11Cl2 having 3 mm thick layer of stain less steel material grade SS-308) was performed. FEA load results were found in good agreement with the practical load results and can be used for capacity assessment and analysis of roller bending machines.

Graphical MPC for Fast Dynamic Systems

Software configuration and engineering costs have limited the application of model predictive control (MPC) for small but fast dynamic systems. This work illustrates the benefits of using a graphical programming framework for the configuration and implementation of MPC controllers. Graphical programming facilitates the understanding and configuration of advanced applications so that engineers in industry can be responsible for the installation and maintenance of advanced controllers. Costs reduction and minimal specialized labor opens the possibilities of applying MPC to small systems with fast dynamics. Fast MPC execution is achieved by including the optimization constraints as penalty terms in the cost function. An air-heater pilot system is successfully used to demonstrate the advantages of a graphical framework for process modeling, design, and real-time implementation of MPC controllers in systems with fast dynamics.

Implementation of Multirate Estimation for the Cylindrical Grinding Process

This paper presents implementation results of the multirate estimation scheme, proposed by Lee (Lee, C.W., 2007, “Multirate Estimation for the Machining Process under Multirate Noise,” Proceedings of the 2007 ASME IMECE, November 11–15, 2007, Seattle, WA), on the cylindrical plunge grinding process. The multirate scheme is an efficient tool for integrating real-time sensor signals with postprocess inspection data for estimating the immeasurable variables. In order to accomplish this goal, process models for grinding power, surface roughness and wheel wear are developed using experimental data. Case studies are performed on simultaneous state-parameter estimation for actual grinding batches after the multirate observers are built based on the process models. Results from case studies validate the applicability of the proposed scheme to challenging estimation tasks in the manufacturing industry that cannot be undertaken by traditional approaches.

A New Position Feedback Method for Manufacturing Equipment

This paper presents an innovative real time 2-dimensional position feedback method, which processes visual input data from a target image on an actively-controlled planar pixel matrix. The objective is to demonstrate the ability to position an X-Y stage with high resolution, using direct position sensing of a dynamically controlled image. In order to achieve high spatial resolution using a pixel array as a target, an algorithm that processes both the geometric shape and the grayscale intensities of the image is implemented. The test platform consists of an X-Y stage carrying a Liquid Crystal Display (LCD) screen that is imaged by a stationary digital camera. The pixel intensities on the LCD screen are modified dynamically to provide 2-dimensional position command inputs that translate to the desired stage motion. The digital images acquired by the camera are used to provide position error feedback to the controller. Experimental results show that direct position sensing is possible to a certain degree of accuracy. However, in order to match today’s CNC machines’ accuracy levels further processing of the digital images is required. A noise reduction algorithm to filter the fluctuations of the measurements in the digital images is proposed as future work, as well as other considerations.

Some Discussions of Virtual Testing of Cutting Tools

The drive for ever increasing productivity puts continuously increasing demands on cutting tool performance. With the cost of a single prototype tool design near $10,000, the benefits of virtual development are clear. Computer simulation can provide accurate information on chip form, cutting force, temperature, workpiece surface integrity and other vital performance information. Recent advances in simulation technology, combined with ever increasing available of computational power at low cost, have vastly expanded the range of machining applications which can be studied in practical times. This paper examines finite element solver technology, recent research and test results enabling virtual development and prototyping of cutting tools.

A Smart Actuator Design for Multiple Bio-Reagent Mixing in a High Pressure Optical Cell for Bio-Physical Research Applications

During the past two decades, bio-physicists have had an increasing interest in finding out what happens when two bio-material solutions are mixed under high pressure. Compared to temperature, pressure makes more contributions to our fundamental understanding of the structure-function relationship of biological systems, because pressure produces only volume changes under isothermal conditions, and pressure results can then be interpreted in a more straightforward manner. Window-type High Pressure Optical Cell (HPOC) such as the one designed by Paladini and Weber have provided biophysicists with a powerful tool to understanding the structure-function relationships of biological molecules. However, the conventional HPOC is only good for single solution testing and does not allow for quick mixing and stirring of additional components while the specimen is under pressure. This research is to thoroughly study the feasibility of Shape Memory Alloy (SMA) as an actuator to perform mixing and agitation functions; and five types of SMA actuators were designed, simulated and tested for unplugging and mixing purposes. To conduct this research, SMA helical springs were fabricated in house according to the design requirements. With different combinations of SMA tensile springs, SMA compressive spring and biasing spring, significant ranges of vibration were developed. To further improving mixing process, a unique hybrid design of SMA as an actuator to unplug the stopper and micromotor as a stir device to agitate the solutions was developed. Rapid mixing of 95% of total solution in 10 seconds was achieved under 300 bars. A new HPOC was designed according to the new cuvette with its new unplug and mixing mechanism. Our industrial partner, ISS, further modified our design for easy manufacturing reason and fabricated the HPOC which made SMA actuator mixing test under pressure possible. A complete testing of the new HPOC system to observe bio-reagent mixing and reaction under high pressure was conducted and the results were satisfactory.