Showing papers in "Materials and Manufacturing Processes in 2001"
TL;DR: In this paper, the effects of cryoprocessing on steel and some copper alloys were examined and shown that improvements occur in wear resistance, dimensional stability, electrical and thermal conductivity, and hardness.
Abstract: Cryoprocessing is the process of cooling a material to extremely low temperatures to generate enhanced mechanical and physical properties. This article examines the effects of cryoprocessing on steel and some copper alloys. Research has shown that improvements occur in wear resistance, dimensional stability, electrical and thermal conductivity, and hardness. The metallurgical aspects include reducing the amount of retained austenite, increasing carbide formation, and enhancing short-range diffusion. The processing steps are critical. This accounts for the considerable discrepancy in post-treated performance.
95 citations
TL;DR: In this paper, a rotary (EDM) electrical discharge machining cutting process for a hard-to-machine cylindrical workpiece was presented, and the effects of machining parameters such as pulsed current, pulse on-time, and workpiece rotation were analyzed.
Abstract: This work presents a novel rotary (EDM) electrical-discharge machining cutting process for a hard-to-machine cylindrical workpiece. An experimental analysis was carried out on an AISI D2 tool steel with a copper electrode. The effects of machining parameters such as pulsed current, pulse on-time, and workpiece rotation on material removal rate and surface roughness were analyzed. These effects were compared with those of conventional EDM without workpiece rotation. Experimental results indicated that the rotation enhanced the dielectric flow, thus effectively helping flush the debris from the gap between the electrodes. In addition, the material removal rate (MRR) increased with the rotation speed of the workpiece, whereas conventional EDM delivers only half the MRR. Surface roughness improves with increased rotation speed, a phenomenon that is attributed to the reduced recast layer during EDM.
80 citations
TL;DR: In this article, the main research points and activities towards industrialization of cast aluminum matrix composites (AMCCs) are described, and the main efforts made by associations and industrial firms focusing on AMCCs are also summarized.
Abstract: This paper briefly describes the main research points and activities which have been considered toward industrialization of cast aluminum matrix composites (AMCCs). First, the issues in liquid processing of metal matrix composites are reviewed. The different requirements for successful AMCCs are then described. Post-processingsuch as heat treatment, forming, and machining, which can beperformed on AMCCs, are discussed. The up-to-date, specially modified commercial foundry technologies that are needed for the practical production of AMCCs are briefly described. The main efforts made bysome associations and industrial firms focusing on AMCCs are also summarized. Finally, examples are given for the available practical AMCCs, either in the form of raw composite ingots or shape casting.
36 citations
TL;DR: In this article, the tool topography and chip formation during machining of AlSiC composites with different volume fraction of reinforcements were machined with cemented carbide tool inserts, and the effects of volume fraction, cutting speed, feed rate, depth of cut, and time of machining on chip disposability, chip thickness ratio, and shear angle were studied.
Abstract: This study focused on the tool topography and chip formation during machining of aluminium-silicon carbide particulate composites. The Al/SiC composites with different volume fraction of reinforcements were machined with cemented carbide tool inserts. The effects of volume fraction, cutting speed, feed rate, depth of cut, and time of machining on chip disposability, chip thickness ratio, and shear angle were studied. The quick-stop sections and chip cross sections at different conditions were also observed. The tool topography was also analyzed.
34 citations
TL;DR: In this article, a continuous copper film was deposited on SiCp by electroless copper plating, and a uniform distribution of SiCps in Cu matrix could be achieved after the sintering and extrusion process.
Abstract: Cu-SiCp composites made by the powder metallurgy method were investigated. To avoid the adverse effect of Cu-SiCp reaction, sintering was controlled at a reaction temperature less than 1032 K. Electroless plating was employed to deposit a copper film on SiCp powder before mixing with Cu powder in order to improve the bonding status between Cu and SiC particles during sintering. It was found that a continuous copper film could be deposited on SiCp by electroless copper plating, and a uniform distribution of SiCp in Cu matrix could be achieved after the sintering and extrusion process. The mechanical properties of Cu-SiCp composites with SiCp contents from 0.6 to 10 wt% were improved evidently, whereas electrical properties remained almost unchanged as compared with that of the pure copper counterpart. In the electrical discharge machining (EDM) test, the as-formed composite electrodes exhibited a character of lower electrode wear ratio, justifying its usage. The optimum conditions for EDM were Cu–2 wt% SiC...
33 citations
TL;DR: In this paper, a newly developed ultra-high-speed grinding machine and a conventional grinding machine were used for the experiments, and the surface roughness and residual stress values of the ground super-alloys and advanced ceramics were measured using a profilometer and a residual stress analyzer, respectively.
Abstract: This paper studies grinding of Inconel 718, Hastelloy, and some advanced ceramics. A newly developed ultra-high-speed grinding machine and a conventional grinding machine were used for the experiments. The ultra-high-speed grinding machine is equipped with a specially designed and built spindle unit that can run up to 200 m sec−1 and deliver a maximum output of 12 kW. The surface roughness and residual stress values of the ground super-alloys and advanced ceramics were measured using a profilometer and a residual stress analyzer, respectively. The ground surfaces were also assessed using a scanning electron microscope. The effect of h m (undeformed chip thickness) on surface topography of the difficult-to-machine materials was also investigated. A higher grinding wheel speed produces a smaller cutting depth and undeformed chip thickness, and thus smaller grinding force, decreased residual surface stress, and better surface finish. High productivity and good surfaces with ductile streaks could be obtained ...
33 citations
TL;DR: In this article, the effect of machining parameters on hole quality produced by the deep hole machining process and to develop a better understanding of these process parameters on the hole quality was investigated.
Abstract: Deep hole drilling represents the most economical method of hole producing with length-to-diameter ratios ≥5. The objective of this study was to ascertain the effect of machining parameters on hole quality produced by the deep hole machining process and to develop a better understanding of the effect of these process parameters on the hole quality. Such an understanding can provide insight into the quality control problems of the holes when the process parameters are adjusted to obtain certain characteristics. This study deals with the experimental results obtained during boring trepanning association (BTA) drilling on medium carbon steel (AISI 1060). The surface roughness, out-of-roundness, and hole size are influenced by cutting speed and feed rate of the deep hole drilling.
33 citations
TL;DR: In this paper, a filling process with aluminum alloys in the liquid or semisolid state has been proposed to obtain mold filling at low speed, which can be achieved by using innovative filling processes with aluminum alloy in liquid or semi-solid state.
Abstract: There have been many challenges in aluminum die casting to establish casting processes to produce high-integrity components from aluminum alloys. Advances in new casting technology mainly have been in pressure die casting; in particular, to obtain mold filling at low speed. This can be achieved by using innovative filling processes with aluminum alloys in the liquid or semisolid state. Different techniques such as high-pressure die casting (HPDC), Cosworth process, low-pressure systems, squeeze casting, indirect squeeze casting, metal compression forming (MCF), and semisolid metal (SSM) processing have been developed. Semisolid forming includes thixoforming and rheoforming. During the semisolid casting process, preheating by induction is needed to obtain the same temperature and the same liquid fraction through the billet in a short time. Thixocasting in the semisolid state helps to avoid turbulence during mold filling.
32 citations
TL;DR: In this article, the authors investigated the effects of the fiber's moving speed, the fiber tension force, and the viscosity of the resin on the content of resin in the resulting composite and the impregnation between the fiber and the resin.
Abstract: The process that makes the continuous fiber reinforced composite by rapid prototyping/part manufacturing process (RP&M) was investigated. The effects of the fiber's moving speed, the fiber's tension force, and the viscosity of the resin on the content of resin in the resulting composite, and the impregnation between the fiber and the resin were studied. Furthermore, a corresponding process was designed, and a set of devices was made to simulate the RP&M process. The results lay a foundation for designing and manufacturing the nozzle device, which is the key part in the RP&M equipment for continuous fiber composites.
29 citations
TL;DR: In this article, the extruded samples were studied for their integrity, microstructure, and mechanical properties, and the integrity was very good at minimum extrusion speed of 1 mm sec−1.
Abstract: Discontinuously reinforced aluminum matrix composites (DRA) have been attracting attention because of their amenability to undergo deformation processing by conventional metalworking techniques. Extrusion is used in processing of DRA composites for consolidation, redistribution of reinforcements, and shape forming. The important parameters that control the extrusion process are temperature and strain rate, which is a function of several equipment/extrusion parameters. Vacuum hot-pressed (VHP) 2124 Al/30 SiCp composite billets were extruded at different ram speeds (1, 10, 100 mm sec−1) and using different extrusion ratios (4:1, 10:1, and 20:1). The extruded samples were studied for their integrity, microstructure, and mechanical properties. The integrity of the extruded composite rod was very good at minimum extrusion speed of 1 mm sec−1, whereas 100 mm sec−1 extrusion speed resulted in extensive fir tree cracking. Extrusion of VHP billets, with necklace structure, resulted in elongated alternate stringers...
28 citations
TL;DR: In this paper, the influence of microstructure on the plane strain fracture toughness of an unalloyed, austempered ductile cast iron (ADI) with low manganese content (<0.15 wt %) and with predominantly as-cast (solidified) ferritic structure was studied.
Abstract: The influence of microstructure on the plane strain fracture toughness of an unalloyed, austempered ductile cast iron (ADI) with low manganese content (<0.15 wt %) and with predominantly as-cast (solidified) ferritic structure was studied. Test specimens were austenitized at 927°C (1700°F) for 2 hr and then austempered over a range of temperatures to produce different microstructures. The microstructures were characterized through optical microscopy and X-ray diffraction. Plane strain fracture toughness of all these materials was determined and correlated with the microstructure. The results of the present investigation indicate that the alloy (with an initially ferritic as-cast microstructure) has higher fracture toughness with an upper ausferritic structure, i.e., when austempered in the upper bainitic temperature range (above 316°C [600°F]). This behavior was markedly different from conventional ADI with a pearlitic as-cast microstructure because the pearlitic structure shows higher fracture toughness ...
TL;DR: In this paper, the influence of microstructure and fracture toughness of an alloyed cast steel containing high silicon (3.00%) and high manganese (2.00%).
Abstract: The influence of austempering on the microstructure and mechanical properties of an alloyed cast steel containing high silicon (3.00%) and high manganese (2.00%) was studied. The influence of microstructure on the plain strain fracture toughness of this new steel was also examined. The test results show that by using a suitable austempering process, i.e., by austenitizing at 1010°C (1850°F) for 2 hr and then subsequently austempering at 316°C (600°F) for 6 hr, it is possible to produce more than 80% austenite in the matrix of the material. Such a large percentage of austenite in the matrix made the steel almost nonmagnetic. Austempering resulted in a significant improvement in mechanical properties as well as fracture toughness of the material. The potential applications of this steel are in naval structural components, aircraft, and automotive components.
TL;DR: In this article, the effects of ram speed and die profile on extrusion pressure were investigated using Al-6063, the most popular commercial variety of structural aluminum, for all experiments.
Abstract: Prediction of extrusion pressure, especially in the case of complex die geometries, is an area of continued research interest. Die complexity, usually defined by “shape factor” (the ratio of the perimeter to the cross-sectional area of the profile), critically affects the flow of metal and the pressure required to extrude a given product. Applied strain rate (related directly to the ram speed of the extrusion press) also alters the product quality significantly. The current paper presents results of an ongoing study about effects of ram speed and die profile on extrusion pressure. Experiments were conducted using dies of different complexity to track the effects of ram speed variation and changing die profiles on extrusion pressure. Al-6063, the most popular commercial variety of structural aluminum, was used as the billet material for all experiments.
TL;DR: In this article, the authors investigated the brittle-ductile transition in diamond cutting of silicon from the viewpoint of material response and tool geometry, and the effect of tool rake angle on the machined surface quality.
Abstract: Silicon single crystals are not amenable to conventional machining operations because of their inherent low fracture toughness. This paper deals with an investigation of brittle-ductile transition in diamond cutting of silicon from the viewpoint of material response and tool geometry. Micro indentation and scribing tests were conducted in order to investigate the influence of applied loads on the deformation characteristics. The transition of material removal from brittle to ductile was observed by continuously changing the cutting depth. The effect of tool rake angle on the machined surface quality was studied by actual diamond turning. A mirror surface, with a roughness of 5 nm R a, was produced using a tool with a −25° rake angle. The reason for the difference in the machined surface quality is discussed based on the analysis of stress distribution in the microcutting process.
TL;DR: In this paper, a low-cost dressing device for dressing a resin-bonded diamond wheel and an improved cooling system for ductile machining of brittle materials such as ceramics is proposed.
Abstract: Ductile mode machining of brittle materials such as ceramics is recognized as an emerging technology with important applications. Ductile machining is possible if the depth of cut is less than the critical depth of cut of the machined material. By using a new device for dressing a resin-bonded diamond wheel and an improved coolant system proposed here, ductile mode grinding of silicon and glass was achieved using an inexpensive, conventional surface-grinding machine. The low-cost dressing device also ensured minimum disruption to the grinding operation and a higher level of safety. A flooding supply of coolant at the grinding zone provided better cooling performance and lubrication. A relationship appeared to exist between the surface finish and the lightness values of ground silicon surfaces.
TL;DR: In this article, the effect of TIG process parameters on weld bead dimensions was investigated, and it was shown that the rate of increase of bead width with current increase is greater than that produced by decreasing travel speed.
Abstract: The Gas Tungsten Arc Welding (GTAW) process is frequently used in welding of aluminum alloys, because of its possible heat input control. This control can be utilized through a good selection of the process variables, which in turn results in optimizing the bead dimensions. The object of this investigation was to study the effect of TIG process parameters on weld bead dimensions. Suitable combinations of tungsten electrode parameters and process variables can lead to optimum GTAW bead dimensions. With alternative current (AC) polarity, a weld bead may be formed between two 3-mm thick pieces of 5005 aluminum–magnesium alloy sheets. The effect of electrode diameter, vertex angle, and the welding current and speed on the bead dimensions were investigated. Results revealed that the rate of increase of bead width with current increase is greater than that produced by decreasing travel speed, and means that the bead width can be controlled more efficiently by welding current rather than by welding speed. For ex...
TL;DR: In this article, the structure and phase identification were evaluated by means of X-ray diffraction, electron probe microanalysis (EPMA), metallographic examination (optical and scanning electron microscopy [SEM]), energy-dispersive Xray analysis (EDS), and microhardness measurements.
Abstract: In an attempt to modify the surface properties of copper substrate, Ti–Cu intermetallic compounds were produced on oxygen-free high-conductivity (OFHC) copper by physical vapor deposition followed subsequently with diffusion annealing. The structure and phase identification were evaluated by means of X-ray diffraction, electron probe microanalysis (EPMA), metallographic examination (optical and scanning electron microscopy [SEM]), energy-dispersive X-ray analysis (EDS), and microhardness measurements. Microstructural examination revealed that the compound coating consisted of three successive layers: the outermost layer (including the transformation product of β phase formed at diffusion temperature) contains α-Ti and Ti2Cu, the intermediate layer consists of TiCu4, and the innermost layer is a solid solution of copper in titanium. Ti–Cu intermetallic coatings significantly improved the hardness of the coated surfaces. The microhardness in the intermetallic layer was about seven times and the Ti–Cu solid ...
TL;DR: In this article, external turning operations for steel 37 (AISI 1025) tubes were performed on a center lathe using high-speed steel tools, and the tool wear and the constants of the tool life equation (C, n) were studied by changing the cutting speed and the wear criterion.
Abstract: External turning operations for steel 37 (AISI 1025) tubes were performed on a center lathe using high-speed steel tools. The workpiece was machined orthogonally using a wide range of cutting speeds for both dry and wet cutting conditions. The tool wear and the constants of the tool life equation (C, n) were studied by changing the cutting speed and the wear criterion. Comparisons between dry and wet cutting for different cutting speeds were performed, and the constants of the tool life equation were studied under different wear criterion values. The economy of dry and wet cutting was also studied under different wear criterion values. As a result of using cutting fluids, percentage increase in the constant C reached 18%, whereas percentage decrease in the constant n reached 7% at 0.9 wear criterion, which leads to a percentage increase in the tool life of about 214%.
TL;DR: In this paper, the beam shape and its significant level of intensity were determined by measuring the topography of craters sputtered by focused ion beam (FIB) and then the beam function was generated for various combinations of beam parameters.
Abstract: Experimental verification of the mathematical surface roughness model for sputtered silicon was performed. The beam shape and its significant level of intensity were determined first by measuring the topography of craters sputtered by focused ion beam (FIB). Then the beam function was generated for various combinations of beam parameters. The material function was developed both by theoretical and experimental analysis. These two functions were then used in the model to calculate the theoretical surface roughness. Microsurface analysis was formed by FIB sputtering of a (100) silicon wafer. The surface roughness at the bottom of the sputtered features was then measured using an atomic force microscope. The theoretical surface roughness was found to be within ±1 and ±5 nm of the measured surface roughness with the measurement uncertainty (standard deviation) of about ±0.36 and ±0.85 nm for R a and R t, respectively.
TL;DR: Development of a computer-aided die design system for die casting that quantifies practical knowledge and experiences in die design as the formulating procedure allows engineers to make automatic and efficient designs and it will result in reduction of required expenses and time.
Abstract: Various analytical finite element method (FEM) tools have been developed for flow processes, including die casting, but they only give information about whether the predetermined die design is correct. Current shop practice uses trial-and-error methods to determine new die designs. This article describes development of a computer-aided die design system for die casting. The computer-assisted design (CAD) system was written using Auto LISP with a personal computer. This system was developed to present algorithms for automation of die design, especially a runner–gate system using three-dimensional geometry. This system quantifies practical knowledge and experiences in die design as the formulating procedure. The system allows engineers to make automatic and efficient designs and it will result in reduction of required expenses and time. The system is composed of selection of cast alloy and product design, and uses the runner–gate design. In addition, specific rules and equations for the system are presented...
TL;DR: In this paper, the results obtained from machining of thermally sprayed WC-Co coatings were obtained by using two thermal spraying processes: arc spraying and high-velocity oxy-fuel (HVOF) spraying.
Abstract: This paper reports the research results obtained from machining of thermally sprayed WC-Co coatings. WC-Co coatings are used in marine applications. The machined coatings were obtained by using two thermal spraying processes: arc spraying and high-velocity oxy-fuel (HVOF) spraying. Different techniques were tried to optimize the surface finishing of the thermally sprayed coatings based on surface finish and time required. The machining processes tried for WC-Co coatings were diamond grinding, cubic boron nitride (CBN) grinding, diamond turning, and diamond polishing. Diamond turning had the advantage of speed, however, the surface finish was not as good as that with fine grinding. Polishing should have given the best surface finish, however, this process was slow. It is suggested to reduce the machining time, first by rough grinding or diamond turning to near the final dimensions, and then by fine grinding or polishing to get the required surface finish and dimensions.
TL;DR: In this article, a series of cutting experiments were done on a copper alloy and copper single crystals with different crystallographic orientations, and it was shown that there exists a dominant frequency component and a periodicity of fluctuation of the cutting forces per workpiece revolution in a single crystal material.
Abstract: An investigation of the characteristics of microcutting forces in diamond turning of crystalline materials is presented. The characteristics of the cutting forces were extracted and analyzed using statistical and spectrum analysis methods. A series of cutting experiments were done on a copper alloy and copper single crystals with different crystallographic orientations. Experimental results indicate that there exists a dominant frequency component and a periodicity of fluctuation of the cutting forces per workpiece revolution in the diamond turning of a single crystal material. The periodicity is closely related to the crystallographic orientation of the material being cut. As the depth of cut increases, the influence of crystallographic orientation of the single-crystal materials on microcutting forces is found to be more pronounced. Moreover, the cutting force ratio between the mean thrust force and the mean cutting force is found to vary with the depth of cut, and a large ratio was observed at a small ...
TL;DR: The presence of different microstructures along the precrack fatigue front has an important effect on the critical crack tip opening displacement (CTOD), which is the relevant parameter for safe service of a welded structure.
Abstract: The presence of different microstructures along the precrack fatigue front has an important effect on the critical crack tip opening displacement (CTOD). This value is the relevant parameter for safe service of a welded structure. For a specimen with a through-thickness notch partly in the weld metal, partly in the heat-affected zone, and partly in the base material (i.e., using the composite-notched specimen), fracture behavior strongly depends on the proportion of ductile base material, size, and distribution of the mismatching factor along the vicinity of the crack front.
TL;DR: In this article, an autoclave process with conventional and optimal cure cycles for 12.5mm-thick laminates was performed and the mechanical properties of the products were determined and shown to be comparable.
Abstract: Conventional autoclave curing cycles for thermosetting composite laminates are generally derived from trial-and-error experimentation. Cure cycles are readily available for thin composite laminates. However, developing cure cycles for thick section laminates is time consuming and hence, costly. In addition, one cannot be sure that a selected cycle will be optimum if it is based on a conventional method. This paper shows that through numerical simulation and some minimal experimentation, optimized cure cycles can be developed for thick laminates. The heating cycles for thick laminates can be established by an iterative numerical method. Autoclave processing with conventional and optimal curing cycles for 12.5-mm-thick laminates was performed. The mechanical properties of the products were determined and shown to be comparable, with significant time saving realized in using the optimized cycle.
TL;DR: In this article, the properties of aluminum metal matrix composites with granulated slag and electric arc furnace dust (EAFD) were investigated. And the best results were obtained with the Al/GS composites, which reached compressive strengths up to 372 MPa.
Abstract: This work provides preliminary results of aluminum metal matrix composites (MMCs) reinforced with granulated slag (GS) and electric arc furnace dust (EAFD). The present work concerns the synthesis and properties of Al/GS and Al/EAFD composites based on powder metallurgy techniques. The hardness and compressive strength of the sintering compacts were determined to compare the mechanical properties of the composite material as a function of the GS and EAFD content. The best results were obtained with the Al/GS composites, which reached compressive strengths up to 372 MPa.
TL;DR: In this paper, a hybrid intercrosslinked network of hydroxyl-terminated polydimethylsiloxane modified epoxy and bismaleimides matrix systems were developed.
Abstract: A novel hybrid intercrosslinked network of hydroxyl-terminated polydimethylsiloxane modified epoxy and bismaleimides [N,N′-bismaleimido-4,4′-diphenylmethane and 1,6-bis(maleimido)hexane] matrix systems were developed. Epoxy resin was modified with 5, 10, and 15% (wt%) of hydroxyl-terminated polydimethylsiloxane using γ-aminopropyltriethoxysilane as crosslinking agent and dibutyltindilaurate as catalyst. The reaction between hydroxyl-terminated polydimethylsiloxane and epoxy resin was confirmed by IR spectral studies. The siliconized epoxy systems were further modified with 5, 10, and 15% (wt%) of both aromatic and aliphatic bismaleimides separately. The castings and E-glass fiber-reinforced composites prepared were characterized for their mechanical properties. Differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA) of the matrix samples were also performed to determine the glass transition temperature (T g) and thermal degradation temperature of the hybrid intercrosslinked systems. D...
TL;DR: In this article, a mathematical model for the calculation of surface roughness was developed for focused ion beam (FIB) sputtering, which is a combination of the beam function and the material function.
Abstract: A mathematical model for the calculation of surface roughness was developed for focused ion beam (FIB) sputtering. The surface roughness function is a combination of the beam function and the material function. The beam function includes ion type, ion acceleration energy, and beam parameters. Furthermore, the beam parameter incorporates ion flux, the ion beam intensity distribution profile, tailing and neighboring of the successive beams, dwell time, etc. The intensity distribution inside the ion beam is considered to be Gaussian. The cumulative intensity over the total milling area is calculated by the algebraic summation of individual beam intensity delivered to every pixel successively. The material function includes the inherent material properties related to the ion beam micromachining. If one knows the beam function and material function, surface roughness at the bottom of the sputtered features can be calculated using this model.
TL;DR: In this paper, a method is described whereby SiC preforms may be infiltrated in air by a molten aluminum alloy to yield a metal matrix composite with thermal expansion coefficients that are suitable or electronic packaging, such as in microwave integrated circuits.
Abstract: A method is described whereby SiC preforms may be infiltrated in air by a molten aluminum alloy to yield a metal matrix composite with thermal expansion coefficients that are suitable or electronic packaging, such as in microwave integrated circuits. Crucible geometries and infiltration conditions may be designed to provide inexpensive and reusable containers and useful section thicknesses in \sim 1 hr. Intricate geometries may be fabricated in the green state of the ceramic, prior to infiltration, thereby minimizing final machining of the composite.
TL;DR: In this paper, the finite element method was used for simulating orthogonal metal cutting of low-carbon steel, and the model predicts chip geometry, behavior of the metal under machining, cutting force values, stress distribution, and temperature distribution along the workpiece and the chip.
Abstract: The finite element method was used for simulating orthogonal metal cutting of low-carbon steel. The model predicts chip geometry, behavior of the metal under machining, cutting force values, stress distribution, and temperature distribution along the workpiece and the chip. Separation and the friction action between the chip and tool were simulated using a friction slideline capability. The same technique was applied to the undeformed chip–workpiece interaction zone to simulate the separation between the chip and the workpiece. The model considered the thermal effect and the friction along the tool rake face. Force values predicted from this model were compared with some experimental work for the same material at the same range of cutting speed and show good correlation.
TL;DR: In this article, the authors studied the effect of several parameters, such as thickness reduction, friction, heat treatment, and material properties, on the surface smoothness of a commercial aluminum blank.
Abstract: Ironing is a very useful metal forming process when employed in combination with deep drawing to produce a uniform wall thickness cup with greater height-to-diameter ratio. In the ironing process, a previously deep-drawn cup is drawn through an ironing ring with a moving ram to reduce the wall thickness. In cup drawing, the upper part of the cup wall usually is formed thicker than the original blank. The ironing process, therefore, must be adopted in deep drawing to produce uniform thickness in the wall. This work studied the ironing of commercial aluminum blanks. For this purpose, several ironing experiments were carried out under various conditions, and the effect of some parameters, such as thickness reduction, friction, heat treatment, and material properties, were investigated. During the experiments, the optimum condition for surface smoothness through the ironing process was obtained.