Computer aided design and optimization of bi-layered tube hydroforming process

Tube hydroforming is one of the unconventional metal forming processes in which high fluid pressure and axial feed are used to deform a tube blank in the desired shape. However, production of bi-layered tubular components using this process has not been investigated in detail in spite of the large number of research studies conducted in this area. Bi-layered tubing can be useful in complex working environments as it offers dual properties that a single layer structure doesn’t have. Consequently, for wider implementation of this technology, a detailed investigation on bi-layered tube hydroforming is required. In this research, both single and bi-layered tube hydroforming processes were numerically modelled using the finite element method (ANSYS LS-DYNA). Experiments were conducted to check the numerical models validation. In addition, Response Surface Methodology (RSM) using the Design-Expert statistical software has been employed along with the finite element modelling to attain a detailed investigation of bi-layered tube hydroforming in the X-type and T-type dies. The process outputs were modelled as functions of both the geometrical factors (tube length, tube diameter, die corner radius, and thicknesses of both layers.) and the process parameters (internal pressure coordinates, axial feed, and coefficient of friction.). Furthermore, the desirability approach was used in conjunction with the RSM models to identify the optimal combinations of each the geometrical factors and process parameters that achieve different objectives simultaneously. In addition, a different optimization approach that applies the iterative optimization algorithm in the ANSYS software was implemented in the process optimization. The finite element models of single and bi-layered tube hydroforming processes were experimentally validated. A comparison of both processes was carried out under different loading paths. Also, response surface modelling of the bi-layered tube hydroforming process outputs was successfully achieved, and the main effects and interaction effects of the input parameters on the responses were discussed. Based on the RSM models, the process was optimized by finding the inputs levels at which the desired objectives are satisfied. Finally, a comparison of the RSM based optimization approach and the iterative optimization algorithm was performed based on the optimum results of each technique

Latest Hydroforming Technology of Metallic Tubes and Sheets

This Special Issue and Book, ‘Latest Hydroforming Technology of Metallic Tubes and Sheets’, includes 16 papers, which cover the state of the art of forming technologies in the relevant topics in the field. The technologies and methodologies presented in these papers will be very helpful for scientists, engineers, and technicians in product development or forming technology innovation related to tube hydroforming processes

Impulse-Based Manufacturing Technologies

In impulse-based manufacturing technologies, the energy required to form, join or cut components acts on the workpiece in a very short time and suddenly accelerates workpiece areas to very high velocities. The correspondingly high strain rates, together with inertia effects, affect the behavior of many materials, resulting in technological benefits such as improved formability, reduced localizing and springback, extended possibilities to produce high-quality multi material joints and burr-free cutting. This Special Issue of JMMP presents the current research findings, which focus on exploiting the full potential of these processes by providing a deeper understanding of the technology and the material behavior and detailed knowledge about the sophisticated process and equipment design. The range of processes that are considered covers electromagnetic forming, electrohydraulic forming, adiabatic cutting, forming by vaporizing foil actuators and other impulse-based manufacturing technologies. Papers show significant improvements in the aforementioned processes with regard to: Processes analysis; Measurement technique; Technology development; Materials and modelling; Tools and equipment; Industrial implementation

Special Issue of the Manufacturing Engineering Society (MES)

This book derives from the Special Issue of the Manufacturing Engineering Society (MES) that was launched as a Special Issue of the journal Materials. The 48 contributions, published in this book, explore the evolution of traditional manufacturing models toward the new requirements of the Manufacturing Industry 4.0 and present cutting-edge advances in the field of Manufacturing Engineering focusing on additive manufacturing and 3D printing, advances and innovations in manufacturing processes, sustainable and green manufacturing, manufacturing systems (machines, equipment and tooling), metrology and quality in manufacturing, Industry 4.0, product lifecycle management (PLM) technologies, and production planning and risks

Optimization of Operation Sequencing in CAPP Using Hybrid Genetic Algorithm and Simulated Annealing Approach

In any CAPP system, one of the most important process planning functions is selection of the operations and corresponding machines in order to generate the optimal operation sequence. In this paper, the hybrid GA-SA algorithm is used to solve this combinatorial optimization NP (Non-deterministic Polynomial) problem. The network representation is adopted to describe operation and sequencing flexibility in process planning and the mathematical model for process planning is described with the objective of minimizing the production time. Experimental results show effectiveness of the hybrid algorithm that, in comparison with the GA and SA standalone algorithms, gives optimal operation sequence with lesser computational time and lesser number of iterations

Optimization of Operation Sequencing in CAPP Using Hybrid Genetic Algorithm and Simulated Annealing Approach

In any CAPP system, one of the most important process planning functions is selection of the operations and corresponding machines in order to generate the optimal operation sequence. In this paper, the hybrid GA-SA algorithm is used to solve this combinatorial optimization NP (Non-deterministic Polynomial) problem. The network representation is adopted to describe operation and sequencing flexibility in process planning and the mathematical model for process planning is described with the objective of minimizing the production time. Experimental results show effectiveness of the hybrid algorithm that, in comparison with the GA and SA standalone algorithms, gives optimal operation sequence with lesser computational time and lesser number of iterations

Autonomous Navigation of Automated Guided Vehicle Using Monocular Camera

This paper presents a hybrid control algorithm for Automated Guided Vehicle (AGV) consisting of two independent control loops: Position Based Control (PBC) for global navigation within manufacturing environment and Image Based Visual Servoing (IBVS) for fine motions needed for accurate steering towards loading/unloading point. The proposed hybrid control separates the initial transportation task into global navigation towards the goal point, and fine motion from the goal point to the loading/unloading point. In this manner, the need for artificial landmarks or accurate map of the environment is bypassed. Initial experimental results show the usefulness of the proposed approach.COBISS.SR-ID 27383808

Autonomous Navigation of Automated Guided Vehicle Using Monocular Camera

This paper presents a hybrid control algorithm for Automated Guided Vehicle (AGV) consisting of two independent control loops: Position Based Control (PBC) for global navigation within manufacturing environment and Image Based Visual Servoing (IBVS) for fine motions needed for accurate steering towards loading/unloading point. The proposed hybrid control separates the initial transportation task into global navigation towards the goal point, and fine motion from the goal point to the loading/unloading point. In this manner, the need for artificial landmarks or accurate map of the environment is bypassed. Initial experimental results show the usefulness of the proposed approach.COBISS.SR-ID 27383808

Fabricate 2020

Fabricate 2020 is the fourth title in the FABRICATE series on the theme of digital fabrication and published in conjunction with a triennial conference (London, April 2020). The book features cutting-edge built projects and work-in-progress from both academia and practice. It brings together pioneers in design and making from across the fields of architecture, construction, engineering, manufacturing, materials technology and computation. Fabricate 2020 includes 32 illustrated articles punctuated by four conversations between world-leading experts from design to engineering, discussing themes such as drawing-to-production, behavioural composites, robotic assembly, and digital craft

Cumulative index to NASA Tech Briefs, 1986-1990, volumes 10-14

Tech Briefs are short announcements of new technology derived from the R&D activities of the National Aeronautics and Space Administration. These briefs emphasize information considered likely to be transferrable across industrial, regional, or disciplinary lines and are issued to encourage commercial application. This cumulative index of Tech Briefs contains abstracts and four indexes (subject, personal author, originating center, and Tech Brief number) and covers the period 1986 to 1990. The abstract section is organized by the following subject categories: electronic components and circuits, electronic systems, physical sciences, materials, computer programs, life sciences, mechanics, machinery, fabrication technology, and mathematics and information sciences