Machining of bi-metallic aluminium-grey cast iron engine block - Process optimisation by means of FEM

Bi-metallic design concept has been introduced in automotive industries to meet the increasingly tighter standards on carbon emission. Yet, machining of bi-metallic engine blocks is accompanied by several challenges like short tool life and long cycle times. This study presents a novel methodology that combines the concept of experimental design with Finite Element (FE) to optimise the tool performance and enhance the productivity when finish face milling of aluminium-grey cast iron engine blocks. This simulation-assisted approach led to an approximately 32% decrease in machining cycle time as compared to that of a reference cutting condition

Modeling of Workpiece Shape Deviations in face Milling of Parallel Workpiece Compounds

The mass reduction of components is one of the most effective ways to reduce fuel consumption and emissions in the automotive and aircraft industry. A lightweight strategy used for highly loaded components is the combination of different materials to workpiece compounds. In that way components can be designed depending on the local load using the most qualified material. For the production of high-performance workpiece compounds high quality requirements concerning the accuracy of dimension and shape as well as surface roughness must be fulfilled. However, machining of workpiece compounds leads to unfavorable changes of the workpiece quality in comparison to machining of the single materials. Significant shape deviations occur when different materials are machined alternately in one cutting operation. This is due to unequal material properties, cutting characteristics, chip formation mechanisms as well as characteristic interactions between the single components. This paper describes the causes of the three main criteria material height deviation, transition deviation and surface roughness deviation that significantly influence the surface quality in parallel machining. The focus is on the process understanding as well as modeling of the surface defects. The approaches and results show that the characteristic shape deviations can be predicted. With the knowledge of the causes that lead to the surface defects in parallel machining it is possible to optimize the process setup for a surface quality oriented machining process of a workpiece compound. Copyright © 2013 Elsevier B.V

Influence of the cutting tool compliance on the workpiece surface shape in face milling of workpiece compounds

A currently common method to design high-performance workpieces is to combine two or more materials to one compound. In this way, workpieces can be composed of the most qualified materials according to local loads. When machining high-performance workpiece compounds high quality requirements concerning the accuracy of dimension and shape as well as surface roughness must be fulfilled. However, in case of parallel machining, where the cutting edge moves from one material into the other within one cutting tool revolution, unequal cutting properties have a significant negative influence on tool wear and surface quality. Shape deviations of the surface occur, which are not detected when machining the single materials. The four most significant shape deviations that affect the workpiece quality are the material height deviation, transition deviation at the material joint as well as surface roughness deviation. This paper contains new approaches on the prediction of the surface shape that is generated by a face milling process. The focus is on the transition deviation at the material joint. It arises from a force impulse that is applied on the cutting tool and creates a wavy surface on the workpiece. This shape is predicted via cutting force prediction as well as frequency response analysis of the cutting tool and workpiece in relation to different tool holders. Furthermore, deviations between calculated surface shapes and measured surface shapes subsequent to machining tests are evaluated.DFG/DE 447/113-

Study guide on “Technology of Structural materials and Material Science” Part 3

Study guide on have been approved at the meeting of building mechanics department (minutes No 1 from 25 August 2016) The Study guide on have been approved by the Mechanical Engineering Faculty methodological committee (minutes No 1 from 29 August 2016)“Technology of Structural materials and Material Science” is one of the basic technical disciplines in the syllabus for “Engineering mechanics” field of study. During the implementation of laboratory work considerable attention is given to the educational and experimental work for the study of materials that are used in different branches of an industry; methods of treatment and external environments The study of the theory and practice of different methods of materials strengthening is to provide a high reliability and longevity of the machine’s details, devices, tools etc. After every practical class and lab activities in the laboratory, students will fill the laboratory report. The content of the laboratory class corresponds with the syllabus of the course “Technology of Structural materials and Material Science” for students of the “Engineering mechanics” field of study. The purpose of this manual is to provide guidelines for the students in preparation for independent laboratory work and to project its results in the laboratory reports

17. Simpozij „Materijali i metalurgija“ – dopuna „Zbornik sažetaka”

In Metalurgija 63 (2024) 2,303-320 published „ Book of Abstracts “ (224). Deadline for received of Abstracts was November, 30,2023 y. Many authors have request new deadline by March, 25, 2024 y. Organizing committee have accept new deadline. Now it published supplements of 103 Abstracts.U Metalurgiji 63 (2024) 2,303-320 objavljen je Zbornik sažetaka (224). Rok za primitak sažetke je bio 30. studeni 2023. god. Mnogi autori zatražili novi rok do 25.03.2024. Organizacijski odbor Simpozija je prihvatio novi termin. Objavljuje se sada dodatnih još 160 sažetaka

Advances in Laser Materials Processing

Laser processing has become more relevant today due to its fast adaptation to the most critical technological tasks, its ability to provide processing in the most rarefied and aggressive mediums (vacuum conditions), its wide field of potential applications, and the green aspects related to the absence of industrial cutting chips and dust. With the development of 3D production, laser processing has received renewed interest associated with its ability to achieve pointed to high-precision powder melting or sintering. New technologies and equipment, which improve and modify optical laser parameters, contribute to better absorption of laser energy by metals or powder surfaces and allow for multiplying laser power that can positively influence the industrial spread of the laser in mass production and advance the existing manufacturing methods. The latest achievements in laser processing have become a relevant topic in the most authoritative scientific journals and conferences in the last half-century. Advances in laser processing have received multiple awards in the most prestigious competitions and exhibitions worldwide and at international scientific events. The Special Issue is devoted to the most recent achievements in the laser processing of various materials, such as cast irons, tool steels, high entropy alloys, hard-to-remelt materials, cement mortars, and post-processing and innovative manufacturing based on a laser

Ultrafine-Grained Metals

Ultrafine-grained metallic materials produced by severe plastic deformation methods are at the cutting edge of modern materials science. UFG-metals exhibit outstanding properties which make them very interesting for structural or functional engineering applications. Fifteen articles in this special issue address a broad variety of topics: New developments in severe plastic deformation techniques, advances in modeling and simulation of the severe plastic deformation processes, mechanical properties under monotonic and cyclic loading of homogenous and graded UFG structures, dominating deformation mechanisms in UFG materials, advances and strategies for high conductivity UFG-materials, correlation between severe plastic deformation parameters and resulting materials properties and peculiarities in the corrosion behavior of UFG materials. The book covers latest results on ultrafine-grained titanium, aluminum and copper alloys and on UFG iron and steels and thus provides a deep insight to current research activities in the field of ultrafine-grained metals

Light Weight Alloys: Processing, Properties and Their Applications

There is growing interest in light metallic alloys for a wide number of applications owing to their processing efficiency, processability, long service life, and environmental sustainability. Aluminum, magnesium, and titanium alloys are addressed in this Special Issue, however, the predominant role played by aluminum. The collection of papers published here covers a wide range of topics that generally characterize the performance of the alloys after manufacturing by conventional and innovative processing routes

Study guide on “Building Material Science” Part 1“Material Science”

“Building Material Science” for students of “Civil Engineering” consists of two parts – Part 1 “Material science” and Part 2 “ Modern building materials” and studing sn 1 semesters. Part 1 “Material science” include 16 hours of lectures, 16 hours of labs and 54 hours of individual work. Part 2 “ Modern building materials” has 18 hours of lectures, 18 hours of labs and 54 hours of individual work

Book of abstracts of the 14th International Symposium of Croatian Metallurgical Society - SHMD \u272020, Materials and metallurgy

Book of abstracts of the 14th International Symposium of Croatian Metallurgical Society - SHMD \u272020, Materials and metallurgy held in Šibenik, Croatia, June 21-26, 2020. Abstracts are organized in four sections: Materials - section A; Process metallurgy - Section B; Plastic processing - Section C and Metallurgy and related topics - Section D