Novel Direct Model for Machining Regenerative Chatter

Regenerative machining chatter or resonance in the machining process has traditionally been modeled with the stability lobe approach. This paper presents a new time based direct simulation model and compares it with traditional stability lobe modeling. The direct model has the ability to discriminate directional and time information, resulting in a number of advantages over frequency-based stability lobe analysis.

Analysis of the Fatigue Performance of Thick T-Joint Samples Considering Residual Stresses

Residual stress (RS) pattern of thick T-joint welds, which directly affects fatigue life, varies considerably depending on the thickness and number of passes. Nowadays, most approaches to predict fatigue life do not consider RS real value due to the difficulty of estimating them, hence, they tend to be conservatives. However, recent works have demonstrated that considering RS the conservative error in life prediction can be reduced down to around 15%. In the present work, the fatigue performance of multipass T-joints of S275JR plates for a thickness range from 20 to 60mm is evaluated considering RS. It is observed that maximum RS value for thick plates decreases progressively (down to 66% of yield stress). Consequently, fatigue performance of different thickness T-joint samples subjected to the same stress load cycles varies considerably in the HCF regime.

Development of 3D Finite Element Model for Predicting Process-Induced Defects in Additive Manufacturing by Selective Laser Melting (SLM)

Selective Laser Melting (SLM) is one of the important Additive Manufacturing techniques for building functional products. Nevertheless, the absence of accurate models for predicting the SLM process behavior, delays development of cost effective and defects free process. This work presents a coupled thermo-mechanical numerical model to capture the two phase (solid-liquid) solidification melting phenomena that occur in the process. The proposed model will also predict the evolvement of process-induced properties and defects particularly residual stresses caused by temperature gradient and thermal stresses. CO2 or Nd:YAG laser beam can be used as a heat source with a Gaussian distribution for the laser beam energy.

Experimental Characterization and Finite Element Modeling of Film Capacitors for Automotive Applications

As electronics keeps on its trend towards miniaturization, increased functionality and connectivity, the need for improved reliability capacitors is growing rapidly in several industrial compartments, such as automotive, medical, aerospace and military. Particularly, recent developments of the automotive compartment, mostly due to changes in standards and regulations, are challenging the capabilities of capacitors in general, and especially film capacitors. Among the required features for a modern capacitor are the following: (i) high reliability under mechanical shock, (ii) wide working temperature range, (iii) high insulation resistance, (iv) small dimensions, (v) long expected life time and (vi) high peak withstanding voltage. This work aims at analyzing the key features that characterize the mechanical response of the capacitor towards temperature changes. Firstly, all the key components of the capacitor have been characterized, in terms of strength and stiffness, as a function of temperature. These objectives have been accomplished by means of several strain analysis methods, such as strain gauges, digital image correlation (DIC) or dynamic mechanical analysis (DMA). All the materials used to manufacture the capacitor, have been characterized, at least, with respect to their Young’s modulus and Poisson’s ratio. Then, a three-dimensional finite element model of the whole capacitor has been set up using the ANSYS code. Based on all the previously collected rehological data, the numerical model allowed to simulate the response in terms of stress and strain of each of the capacitor components when a steady state thermal load is applied. Due to noticeable differences between the thermal expansion coefficients of the capacitor components, stresses and strains build up, especially at the interface between different components, when thermal loads are applied to the assembly. Therefore, the final aim of these numerical analyses is to allow the design engineer to define structural optimization strategies, aimed at reducing the mechanical stresses on the capacitor components when thermal loads are applied.

Hybrid Polymer Additive Manufacturing of a Darrieus Type Vertical Axis Wind Turbine Design to Improve Power Generation Efficiency

Utilizing the advantages of additive manufacturing methods, redesigning, building and testing of an existing integral Savonius / Darrieus “Lenz2 Wing” style vertical axis wind turbine is predicted to improve power generation efficiency. The current wind turbine blades and supports made from aluminum plate and sheet are limiting the power generation due to the overall weight. The new design is predicted to increase power generation when compared to the current design due to the lightweight spiral Darrieus shaped hollow blade made possible by 3D printing, along with an internal Savonius blade made from aluminum sheet and traditional manufacturing techniques. The design constraints include 3D printing the turbine blades in a 0.4 × 0.4 × 0.3 m work envelope while using a Stratasys Fortus 400mc and thus the wind turbine blades are split into multiple parts with dovetail joint features, when bonded together result in a 1.2 m tall working prototype. Appropriate allowance in the mating dovetail joints are considered to facilitate the fit and bonding, as well as angle, size and placement of the dovetail to maximize strength. The spiral shape and Darrieus style cross section of the blade that provides the required lift enabling it to rotate from the static condition are oriented laterally for 3D printing to maximize strength. The bonding of the dovetail joints is carried out effectively using an acetone solution dip. The auxiliary components of the wind turbine which include the center support pole, top and bottom support, and center Savonius blades are manufactured using lightweight aluminum. Design features are included in the 3D printed blade parts so that they can be assembled with the aluminum parts in bolted connections. Analysis of the 3D CAD models show that the hybrid aluminum and hollow 3D printed blade construction provides a 50% cost savings over a 3D printed fully solid blade design while minimizing weight and maximizing the strength where necessary. Analysis of the redesign includes a detailed weight comparison, structural strength and the cost of production. Results include linear static finite element analysis for the strength in dovetail joint bonding and the aluminum to 3D printed connections. Additional data reported are the time frame for the design and manufacturing of the system, budget, and an operational analysis of the wind turbine with concern for safety. Results are analyzed to determine the advantages in utilizing a hybrid additive manufacturing and aluminum construction for producing a more efficient vertical axis wind turbine. Techniques used in the production of this type of wind turbine blade are planned to be utilized in similar applications such as a lightweight hovercraft propeller blade design to be tested in future research projects.

Mechanical Response of Different Lattice Structures Fabricated Using the CLIP Technology

In the rapidly growing field of additive manufacturing (AM), the focus in recent years has shifted from prototyping to manufacturing fully functional, ultralight, ultrastiff end-use parts. This research investigates the mechanical behavior of octahedral, octet, vertex centroid, dode, diamond, rhombi octahedron, rhombic dodecahedron and solid lattice structured polyacrylate fabricated using Continuous Liquid Interface Production (CLIP) technology based on 3D printing and additive manufacturing processes. The compressive stress-strain behavior of the lattice structures observed is typical of cellular structures which include a region of nominally elastic response, yielding, plastic strain hardening to a peak in strength, followed by a drop in flow stress to a plateau region and finally rapid hardening associated with contact of the deformed struts with each other as part of densification. It was found that the elastic modulus and strength of the various lattice structured materials are proportional to each other. In addition, it was found that the octahedral, octet and diamond lattice structures are amongst the most efficient based on the measured specific stiffness and specific strength.

Study of Surface Quality and Cutting Parameter Optimization in Side Milling CFRP With Diamond Coated Carbide Tool

Composite machining is one of the hot researches currently, and optimal cutting parameters are particularly important to get ideal surface and reduce processing cost of workpiece. By comparison, the present paper selects the surface root mean square deviation Sq as the three-dimensional evaluation parameter of surface roughness to reflect the special appearance after cutting accurately. The single-factor experiment and orthogonal experiment were conducted to study the machining defects emerged and effect of parameters on surface roughness when side milling CFRP (Carbon Fiber Reinforced Plastics) with diamond coated carbide tool. The mapping relationship between cutting parameters and surface roughness was established based on the experiment results. Then, the cutting parameters were optimized by using genetic algorithm with two conflicting objectives: material removal rate and surface roughness. The experiment results show that the proposed method is feasible and effective, and can provide references for the actual processing of CFRP.

Study on the Effect of Weld Speed and Tool Rotation Speed on the Quality of Friction Stir Welded Joints by Using XRD and EBSD

Friction Stir processing, a novel welding process which weld similar and dissimilar metals and alloys in solid state for joining metallic alloys and it has replaced conventional welding processes and have become an alternative welding technique. The commonly used aluminum alloys AA6061 and AA5086 were joined together using FSW. In this study, two parameters such as weld speed and tool rotation speed are taken into account. By varying these parameters the dissimilar alloys were welded together. The welded joints were analyzed for its chemical composition and phases formed due to heat produced by friction. The composition is characterized by Electron Back Scattered Diffraction technique (EBSD) and X-ray Diffraction technique (XRD). The influence of tool rotation speed and weld speed on texture has been studied.

A Method of Fracture Toughness Measurement and Effect of Partial Annealing on Monolithic Thick Cold Sprayed Aluminum 6061 Deposits

Cold spray is a solid-state material deposition method that can create thick (>10mm) metal layers that adhere metallurgically to a base part or a substrate. Numerous potential applications exist, such as returning worn mechanical parts to their original dimension, extending their service life. For fatigue applications the fracture properties of cold spray deposited material must be known but little to no literature has been found on the fracture behavior of cold spray deposited material alone, which prompted the study presented here. Fracture toughness specimens were manufactured by depositing thick cold-sprayed layers of powdered aluminum 6061 onto an aluminum 6061 substrate using N2 as the carrier gas. The substrate was then machined away, and monolithic miniature compact tension fracture toughness specimens were machined from the cold spray deposit itself, following ASTM E-1820. The fracture behavior of the cold sprayed material was then experimentally determined using the elastic-plastic J-resistance method for compact test specimens described in ASTM E-1820. Two specimen conditions were successfully tested, “as-sprayed” and “partially annealed”. The results are that the Mode-I elastic-plastic stress intensity factor JI has been successfully measured for cold-spray deposited material alone, and that partially annealing a cold-spray deposit can dramatically increase its fracture toughness.

Automated Reengineering of Industrial Service-Based Systems

Complex systems are not of static nature. Most are governed by a particular set of laws and behave accordingly to a certain range of expected inputs and variables, but they can also evolve in response to unforeseen stimulus. The same principle can be applied to industrial information systems. Larger systems such as an entire company or a network of companies may be divided into further subsystems, including information systems, each behaving autonomously but is still under influence of the others, interacting with them in a holistic manner. This paper explores this relationship and proposes a conceptual solution to the strain of sustaining interoperability in complex service-based networks from the domain of manufacturing. To such effect, and in order to tackle the complex relationships and dependencies implicit in web-service environments, information modeling is used, allowing for the optimization of several service engineering activities and enterprise business processes while maximizing the efficiency of system’s interactions. Hence, service modeling and orchestration is here suggested as a baseline to network monitoring, and as a possible approach to automatically handle and recover from erratic behavior, providing systems with adaptive web services and self-organizing capabilities.