Analysis of the forming characteristics for Cu/Al bimetal tubes produced by the spinning process

Tube spinning technology represents a process with high forming precision and good flexibility and is increasingly being used in the manufacture of bimetal composite tubular structures. In the present study, a forming analysis of clad tube and base tube in spinning process was conducted through numerical simulations and experiments. There was an equivalent stress transition on the interface since the stress transmission was retarded from clad tube to base tube. The yield strength became a main consideration during a design bimetal composite tube. Meanwhile, the strain distributions in axial direction, tangential direction, and radial direction were also investigated to determine the deformation characteristics of each component. As the press amount increased, the strain of clad tube changed more than base tube. As the feed rate increased, the strain decreased in axial direction and tangential direction but almost unchanged in radial direction. Simultaneously, a method for controlling the wall thickness of the clad tube and the base tube is proposed. These results to guide the design of bimetal tube composite spinning process have the certain meanings

Investigation of the Scanning Microarc Oxidation Process

Scanning microarc oxidation (SMAO) is a coating process which is based on conventional microarc oxidation (MAO). The key difference is that deposition in SMAO is achieved by using a stainless steel nozzle to spray an electrolyte stream on the substrate surface as opposed to immersing the workpiece in an electrolyzer. In the present study, SMAO discharge characteristics, coating morphology, and properties are analyzed and compared to results obtained from MAO under similar conditions. Results show that MAO and SMAO have comparable spark and microarc lifetimes and sizes, though significant differences in incubation time and discharge distribution were evident. Results also showed that the voltage and current density for MAO and SMAO demonstrate similar behavior but have markedly different transient and steady-state values. Results obtained from coating A356 aluminum sheet show that oxide thickness and growth rate in SMAO are strongly dependent on interelectrode spacing and travel speed. Analysis of the SMAO coating morphology and structure showed that a denser and slightly harder layer was deposited in comparison to MAO and is attributed to reduced porosity and increased formation of α-Al2O3. Preliminary results indicate that SMAO represents a viable process for coating of aluminum surfaces

Accelerated Life Testing to Predict Service Life and Reliability for an Appliance Door Hinge

Appliance manufacturers have traditionally performed physical testing using prototypes to assess reliability and service integrity of new product designs. However, for white goods where service lives are measured in years or decades, the use of endurance testing to analyze long time reliability is uneconomical. As accelerated life testing (ALT) is more efficient and less costly than traditional reliability testing, the methodology is finding increased usage by appliance manufacturers. In the present study, a simulation-based ALT approach was used to predict the service life of a polyacetal hinge cam from a consumer refrigerator. A predictive life stress model based on cumulative surface wear under accelerated stress conditions was developed and used to predict time to failure under consumer use. Results show that the life stress model demonstrated good agreement with performance testing data and reasonably predicts hinge life

The Effects of a Six-Week HIIT Program on CVD Risk Factors in Sedentary Individuals

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Shattered Rim and Shelling of High-Speed Railway Wheels in The Very-High-Cycle Fatigue Regime Under Rolling Contact Loading

Due to the improvement of the wear property, rolling contact fatigue including shattered rim and shelling are the main failure causes of the high-speed railway wheels. In this paper, shattered rim and shelling occurred on the service wheels of the China Railway High-speed (CRH) trains were systematically investigated. The recorded data of the last ten years CRH operation indicated that all shattered rims and shelling were detected with serving \u3e106 km (corresponding to the fatigue life 107–109 cycles) which is very-high-cycle fatigue (VHCF). The crack initiationregion of shattered rim located at the depth of 10–25 mm from the tread, while that of shelling located at the depthsurfaces, i.e., similar VHCF features in uniaxial loading including the defect, fish-eye, and crack propagation region and unique VHCF features of the three dimensional crack surface feature, beach bands uniformly distributed in the crack propagation region, absence of fine granular area (FGA). The VHCF model considering the stress distribution, defect size and hardness were applied to discuss the failure mechanism of the shattered rim and shelling

Improving Student Learning Through Use of an In-class Material Processing Design Project

At Marquette University, hybrid project-based learning has been implemented in an undergraduate mechanical engineering course on materials processing and forming using a team-based approach. The goals of the project are to 1) introduce more active and student-centered activities to improve student engagement and mastery of core concepts, 2) increase students\u27 confidence in their ability to apply what they learned in the course to solving real-world problems, 3) enable students to gain experience using engineering software as part of the learning process and in applications context. While use of process modeling software in materials processing and manufacturing courses is not entirely new, the project has students actively developing a model around a realistic process, rather than passive users running canned models and reviewing the output. This paper presents details of the project and discusses preliminary results regarding its impact on student learning and confidence related to application of the course concepts. Recommendations for improving and expanding this in-class project are presented, along with a description of the assessment methods used to measure the impact on students

Investigation of Void Formation in Friction Stir Welding Of 7N01 Aluminum Alloy

Friction Stir Welding (FSW) is a solid state joining process that is widely used to produce high integrity aluminum weldments for a variety of industries. While extensive work has been conducted to understand flow behavior, much less research has been performed to identify how void defects form and how to predict them. In the present study, the relationship between rotation speed, plasticized region, and defect formation was investigated. To analyze how tunneling and cavity type void defects form during FSW, a 3-D Computational fluid dynamics(CFD) model based on the Fluent software code was used to simulate butt welding. The CFD model was validated using temperature measurements and marker materials from FSW welds made on 12 mm thick 7N01 aluminum alloy plate. Analysis of the simulation results showed that the formation of tunneling defects at lower rotation speeds correlated to a large variation in the size of the plasticized region over the plate thickness. At higher rotation speeds, analysis of material flowlines indicated an imbalance in rotational and longitudinal flow around the pin which resulted in a cavity type defect. It is considered that the results can be used to compare different weld schedules and be used to assess the likelihood of void formation in an actual weld using a CFD model

Investigation of Through Thickness Microstructure and Mechanical Properties in Friction Stir Welded 7N01 Aluminum Alloy Plate

An on-going problem in friction stir welded (FSW) joints used in the high-speed train sector is that the microstructure and mechanical properties can significantly vary in thick sections. Because inhomogeneous properties can reduce weld efficiency and degrade service performance, it is of some interest to understand how inhomogeneous properties can develop in FSW welds made from precipitation hardening alloys such as 7N01. In the current study, butt welds were made using 12 mm thick plates and then sectioned perpendicular to the weld line. Five 2.2 mm thick slices were cut from a section and used to measure tensile properties access the weld thickness. The microstructure was characterized using scanning electron microscopy (SEM) and energy dispersive spectrometry (EDS) to measure variation in grain size and second phase particle distributions over the weld zone. Results showed that, with the exception of the top slice, yield strength (σy) and ultimate tensile strength (σUTS) obtained from the slices were fairly consistent and comparable to values from the full weld. Elongation (δ) was maximum at mid-thickness decreased significantly towards the crown. Although significantly reduced elongation was found at the top of the weld, and likely limits overall weldment ductility, elongation of the full FSW weld was improved over that of the base metal and can be attributed to enhanced post-necking straining. The finest grains and second phase particles were observed at mid-thickness. In comparison, the coarsest grains were observed at the top of the nugget. This microstructural variation can be understood by considering the temperature and strain field gradients that are generated in the plasticized zone. It is expected that the findings will help to promote a better understanding of post-weld microstructure development and mechanical properties of thick plates

Crack Propagation and Microstructural Transformation on The Friction Surface of a High-Speed Railway Brake Disc

While brake disc wear represents a significant problem in high-speed rail systems, the progressive development of fatigue cracks during successive braking cycles also plays a great role in braking integrity. The modified microstructure consisting of a white etching layer (WEL) containing nanosized ferrite was observed on the friction surface of worn brake discs. In order to analyze how sequential thermal and mechanical stress affected crack propagation and microstructure evolution in brake discs, successive braking cycles were simulated on a full-scale braking bench test rig. Crack initiation and propagation mechanisms were proposed based on the experimental results, i.e., (i) occurrence of heat checking caused by heating and cooling transients during braking; (ii) heat checking increasing the roughness of the friction surface which in turn caused a local stress concentration and (iii) localized friction stress and thermal stress driving the heat checking to propagate and coalesce with the radial main crack. Analysis of the thermal-mechanical conditions that exist at the friction surface during braking indicates that WEL formation can be attributed to severe plastic deformation caused by the repeated friction between the disc and pads. Mechanical testing also indicated that WEL formation is not detrimental to brake disc integrity

Data-mining modeling for the prediction of wear on forming-taps in the threading of steel components

An experimental approach is presented for the measurement of wear that is common in the threading of cold-forged steel. In this work, the first objective is to measure wear on various types of roll taps manufactured to tapping holes in microalloyed HR45 steel. Different geometries and levels of wear are tested and measured. Taking their geometry as the critical factor, the types of forming tap with the least wear and the best performance are identified. Abrasive wear was observed on the forming lobes. A higher number of lobes in the chamber zone and around the nominal diameter meant a more uniform load distribution and a more gradual forming process. A second objective is to identify the most accurate data-mining technique for the prediction of form-tap wear. Different data-mining techniques are tested to select the most accurate one: from standard versions such as Multilayer Perceptrons, Support Vector Machines and Regression Trees to the most recent ones such as Rotation Forest ensembles and Iterated Bagging ensembles. The best results were obtained with ensembles of Rotation Forest with unpruned Regression Trees as base regressors that reduced the RMS error of the best-tested baseline technique for the lower length output by 33%, and Additive Regression with unpruned M5P as base regressors that reduced the RMS errors of the linear fit for the upper and total lengths by 25% and 39%, respectively. However, the lower length was statistically more difficult to model in Additive Regression than in Rotation Forest. Rotation Forest with unpruned Regression Trees as base regressors therefore appeared to be the most suitable regressor for the modeling of this industrial problem.ThisinvestigationwaspartiallysupportedbyProjects TIN2011-24046,IPT-2011-1265-020000andDPI2009- 06124-E/DPIoftheSpanishMinistryofEconomyand Competitiveness.WethanktheUFIinMechanicalEngineer- ing oftheUPV/EHU(UFIMECA-1.0.2016(ext))forits support