Enhancing magnetic particle testing of automotive parts

The principle disadvantage in magnetic particle inspection, as generally practiced today, is the combination of variable human judgment and interpretation, and variations in the critical components' characteristics which are: magnetic particle liquid sensitivity, ultraviolet intensity variations, and magnetic field variations at the surface of the test piece. In high speed inspection systems, these variables can reduce the reliability of magnetic particle inspection flaw detection to only about 70% [I]. What is needed is an online, heavy duty, high speed parts inspection with online documentation and almost perfect flaw detect ability within calibrated equipment, if possible, by using modem electronic systems. Currently, the automated MT systems are still in their first stages and are developed on individual researchers' basis [2]. Also, the few current systetns in the market which can automatically perform magnetic particle testing are extremely expensive. Hence, the need to provide a reasonable automated MT system with a comparable performance for inspecting surface defects in ferromagnetic materials automotive component

PROCESS SIMULATION AND QUALITY EVALUATION IN INCREMENTAL SHEET FORMING

Single Point Incremental Forming (SPIF) is a promising sheet-metal-forming process that permits the manufacturing of small to medium-sized batches of complex parts at low cost. It allows metal forming to work in the critical ‘necking-to-tearing' zone which results in a strong thinning before failure if the process is well designed. Moreover, the process is complex due to the number of variables involved. Thus, it is not possible to consider that the process has been well assessed; several remaining aspects need to be clarified. The objective of the present paper is to study some of these aspects, namely, the phenomenon of the wall thickness overstretch along depth and the effect of the tool path on the distribution of the wall thickness using finite element simulations. Abstrak: Pembentukan Tokokan Mata Tunggal (Single Point Incremental Forming (SPIF)) merupakan satu proses pembentukan kepingan logam yang membolehkan pembuatan dalam jumlah yang kecil hingga sederhana, bahagian-bahagian yang kompleks pada kos yang rendah. Jika proses ini direka dengan baik, kaedah ini membolehkan pembentukan logam yang baik terhasil. Jika tidak, semasa peringkat zon kritikal ‘perleheran-ke-pengoyakan' menyebabkan penipisan keterlaluan yang boleh menyebabkan logam tersebut rosak. Tambahan pula, proses ini agak kompleks, kerana ia melibatkan beberapa pemboleh ubah. Maka, walaupun proses ini telah dinilaikan seeloknya; masih terdapat beberapa aspek lain yang perlu diperjelaskan. Objektif kertas ini dibentangkan adalah untuk mengkaji beberapa aspek tertentu, seperti, ketebalan dinding regangan berlebihan di sepanjang kedalaman dan kesan tool path (beberapa siri posisi koordinat untuk menentukan pergerakan alatan memotong ketika operasi memesin) terhadap pengagihan ketebalan dinding menggunakan simulasi unsur terhingga

Process simulation and quality evaluation of incremental sheet forming

Single Point Incremental Forming (SPIF) is a promising sheet-metal-forming process that permits the manufacturing of small to medium-sized batches of complex parts at low cost. It allows metal forming to work in the critical ‘necking-to-tearing' zone which results in a strong thinning before failure if the process is well designed. Moreover, the process is complex due to the number of variables involved. Thus, it is not possible to consider that the process has been well assessed; several remaining aspects need to be clarified. The objective of the present paper is to study some of these aspects, namely, the phenomenon of the wall thickness overstretch along depth and the effect of the tool path on the distribution of the wall thickness using finite element simulations

Significant parameters for the surface roughness in incremental forming process

The features of the incremental sheet forming (ISF) process allow it to meet a wide array of customer preferences. In this paper, the variation of surface roughness (SR) in a negative ISF process was systematically studied. The variation was investigated by means of four different process parameters, namely, the vertical step size, forming tool diameter, spindle speed, and feed rate. By using Taguchi analysis with the help of design of experiment and analysis of variance (ANOVA), the effects of the above four process parameters have been studied to optimize parameter levels to realize minimum SR. The results illuminated which parameters have the greatest effect on SR variation, namely, tool size and vertical step size. The confirmation test also showed that the response tables and graphs from Taguchi analysis and ANOVA constitute effective and efficient methods for determining each design parameter’s optimal level to produce the minimum value of the SR

Research and progress in incremental sheet forming processes

Incremental sheet forming (ISF) is an emerging metal-forming technology in which the tool motion is controlled numerically. The process is economical to form complex parts in small to medium batches and provides a short and inexpensive way of forming products having a relatively simple but interesting shape. In this article, a review of the present state-of-the-art technologies and the potential applications of incremental sheet metal forming are presented in brief. This article seeks to address the approaches and methods that are prevalently applied. Furthermore, the article also seeks to guide researchers for future work, by identifying inadequacies of the current approaches and potential for valuable contributions in the field of incremental forming

Finite element investigatigation of some aspects affecting the depth and wall thickness of a part formed by single point incremental forming process

Single Point Incremental Forming (SPIF) is an emerging sheet-metal-forming technology, capable of manufacturing complex parts at low cost for small to medium batch production. The present paper is focused on phenomenon of overstretch the wall thickness along depth and the effect of the tool path on the distribution of the wall thickness

An investigation of temperature effect on incremental forming

metal change with an increase in temperature. For these reasons it is very important to investigate the temperature effect on the manufactured part by incremental forming. In the present paper, the temperature is investigated numerically through finite element simulation and experimentally using thermography nondestructive technique. Both experimental and numerical results are in close agreement. It was found that the maximum temperature among the forming passes reached experimentally 62 °C and numerically 68 °C at which the properties does not change. Therefore, it is considered as low temperature compared to conventional forming processes like deep drawing. Thus, it can be concluded that temperature effect on material properties in incremental forming process can be neglected