Simulation of distortion due to machining of thin-walled components

The distortion of components is strongly related to the residual stress state induced by manufacturing processes like heat treatment, forming or machining. Each process step affects the initial stress state of the following process step. When removing material during machining, the component establishes a new stress equilibrium. Stresses are redistributed causing the component geometry to adjust. Especially for thin-walled components distortion potential is high. Gaining knowledge about the influence of initial loads and the release of distortion during machining processes helps to increase product quality and efficiency. The influences of different initial stress states and different machining parameters on the amount of distortion are examined using both FEM simulations and experiments. A thin-walled T-profile made of aluminum alloy Al 7075-T6 serves as test specimen. A bending process applies a load to initialize a repeatable and defined residual stress state. A groove was machined afterwards into the plastically deformed work piece to trigger stress redistribution and a release of distortion. Different loads with 35 to 45 kN and two different geometries of a groove were used. The amount of initial stress has a significant effect on the distortion potential which could be quantified in the study. Simulations show the same behavior as the experiments and the results match very well especially for a high load

Complementary Machining: Effect of tool types on tool wear and surface integrity of AISI 4140

Complementary Machining is a process strategy for the time-efficient mechanical surface treatment of metallic workpieces. The characteristic of Complementary Machining is that after machining, a mechanical surface treatment is carried out using the cutting tool. The cutting tool moves over the workpiece surface in opposite direction to the machining process and induces an elastic-plastic deformation in the surface layer. Previous investigations have shown the possibility to achieve life-enhancing surface layer states in turning of AISI 4140 with Complementary Machining and to achieve fatigue strengths comparable to those after shot peening. In this paper, the influence of the tool types and process parameters, such as the feed rate, on the resulting topography and the tool wear, represented by changes of cutting edge microgeometry, during Complementary Machining of AISI 4140 are investigated based on the previous investigations. In addition to different substrates of the cutting insert, the focus of the investigations is also on the influence of tool coating. Both the tool wear and the resulting topography were analyzed tactilely and correlated with the process parameters. The results show a clear influence of the used substrate of the cutting insert and coating on the tool wear and the resulting topography

Spatial evolution of an ion beam created by a geometrically expanding low-pressure argon plasma

The spatial distribution of an ion beam—created at the interface of a small diameter plasma source and much larger diameter diffusion chamber—is studied in a low-pressure inductively coupled plasma using a retarding field energy analyzer. It is found that the ion beam density decays axially and radially in the diffusion chamber following the expansion of the plasma from the source region. The radial distribution of the ion beam indicates that the acceleration region has a convex shape and is located just outside the source exit, giving rise to a hemispherical plasma expansion into the diffusion chamber

Process Combination of VPP-LED and Vacuum Die Casting for Producing Complex Ceramic 3D-MID

Future developments lead to increasing demands on mechatronic integrated devices (MID). Therefore, ceramics have to be used as substrate material and conductor tracks have to be located in the interior of components to be sufficiently protected. A process combination of vat photopolymerization (VPP-LED) and vacuum die casting is investigated for realizing such structures. First, optimized process parameters are derived by studying the filling behavior of straight capillaries. Subsequently, the results are transferred to complex additively manufactured substrates to derive design guidelines

Ion beam formation in a low-pressure geometrically expanding argon plasma

Supersonic ion beam formation has been observed in a geometrically expanding low-pressure inductively coupled argon plasma. It is found that the ion beam is only observed below 3mTorr and only when the discharge is operated in inductive mode. The geometrical expansion of the plasma induces density and potential gradients leading to the ion beam formation. The ion beam energy increases with decreasing source tube radius. The results show that ion beam formation can be achieved by geometrical expansion alone and that the ion beam energy depends on the ratio of the cross-sectional area of the source and expansion region

Numerical modelling of cutting forces in gear skiving

Gear skiving is a high-performance machining process for gear manufacturing. Due to its complex kinematics, the local cutting conditions vary during tool engagement. Particularly, the local rake angle can reach highly negative values, which have a significant effect on the cutting force. In this paper, the Kienzle force model with additional coefficients was implemented in a numerical model to calculate local cutting forces considering the influence of local rake angle. The experimental validation based on total cutting forces shows good results and indicates an increase of model accuracy for a wide parameter range by considering the rake angle variation

Role of Protein-Protein Interactions in Metabolism: Genetics, Structure, Function

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Cliophysics: Socio-political Reliability Theory, Polity Duration and African Political (In)stabilities

Quantification of historical sociological processes have recently gained attention among theoreticians in the effort of providing a solid theoretical understanding of the behaviors and regularities present in sociopolitical dynamics. Here we present a reliability theory of polity processes with emphases on individual political dynamics of African countries. We found that the structural properties of polity failure rates successfully capture the risk of political vulnerability and instabilities in which 87.50%, 75%, 71.43%, and 0% of the countries with monotonically increasing, unimodal, U-shaped and monotonically decreasing polity failure rates, respectively, have high level of state fragility indices. The quasi-U-shape relationship between average polity duration and regime types corroborates historical precedents and explains the stability of the autocracies and democracies.Comment: 4 pages, 3 figures, 1 tabl