Manufacture of Defined Residual Stress Distributions in the Friction-Spinning Process: Investigations and Run-to-Run Predictive Control

Friction-spinning as an innovative incremental forming process enables high degrees of deformation in the field of tube and sheet metal forming due to self-induced heat generation in the forming area. The complex thermomechanical conditions generate non-uniform residual stress distributions. In order to specifically adjust these residual stress distributions, the influence of different process parameters on residual stress distributions in flanges formed by the friction-spinning of tubes is investigated using the design of experiments (DoE) method. The feed rate with an effect of −156 MPa/mm is the dominating control parameter for residual stress depth distribution in steel flange forming, whereas the rotation speed of the workpiece with an effect of 18 MPa/mm dominates the gradient of residual stress generation in the aluminium flange-forming process. A run-to-run predictive control system for the specific adjustment of residual stress distributions is proposed and validated. The predictive model provides an initial solution in the form of a parameter set, and the controlled feedback iteratively approaches the target value with new parameter sets recalculated on the basis of the deviation of the previous run. Residual stress measurements are carried out using the hole-drilling method and X-ray diffraction by the cosα-method.

Study on Size-Related Product Quality of Multiscale Central-Punched Cups Fabricated by Compound Forming Directly Using Brass Sheet

Meso/microforming has gained much more attention in the last decades and is widely used as a reliable method to fabricate meso/micro-scaled metallic components. In this research, a compound meso/microforming system which combines deep drawing, punching and blanking operations was developed to fabricate multiscale central-punched cups by using brass sheets. The parts with three scales were produced by using the brass sheets with various thicknesses and grain sizes to investigate geometrical and grain size effects on the deformation behaviors, dimensional accuracy, and material flow behaviors in the forming process. Through physical experiments and finite element simulations, it is revealed that the ultimate deformation load in the drawing-punching stage is smaller than that in the single deep drawing stage under microscale, but the results in the meso-scaled scenarios are opposite. In addition, the thickness variation is increased with grain size, but the variation of the normalized thickness variation does not show an obvious tendency with different size scales. In the bending area, the material flow is tangential to the thickness direction, leading to the formation of thinning area. In addition, the material flow is almost opposite to the punching direction in the punching area, avoiding the expanding deformation of the hole. Thus, the punching operation barely affects the dimensional accuracy including the thickness and hole diameter of the formed parts. Furthermore, the micro-scaled cups with finer grains have a better surface quality. These findings enhance the understanding of size effect in compound meso/microforming with the combined deep drawing and punching operations.

Preparation and Properties of Autocatalytic Biobased Waterborne Polyol from Rosin Based Epoxy Resin

Due to the complex heterogeneous film forming process of two-component waterborne polyurethane (2K-WPU), the crosslinking reaction rate of 2K-WPU cannot meet the demand of efficient application in coatings. In order to improve the crosslinking reaction rate of 2K-WPU, a waterborne polyol containing tertiary amine groups was synthesized from rosin based epoxy resin and secondary amine compound, and then autocatalytic 2K-WPU was prepared by crosslinking the rosin based waterborne amino polyol with polyisocyanate. The structure of the polyol from rosin based epoxy resin was characterized with Fourier infrared (FT-IR) and nuclear magnetic resonance (NMR). The crosslinking kinetics and the crosslinked product of the rosin based waterborne amino polyol were also compared with a commercial acrylic polyol. It was shown from the results that the crosslinking reaction rate of the rosin based waterborne amino polyol was faster than that of the commercial acrylic polyol, which indicated the tertiary amine groups chemically bonded in the rosin based polyols could autocatalyze the crosslinking reaction of 2K-WPUs with catalysts free. The film of the rosin based waterborne amino polyol had excellent impact strength, adhesion, flexibility, hardness, gloss, fullness and solvent resistance, showing a good application prospect in the field of waterborne coatings.

Friction Characteristics Analysis of Symmetric Aluminum Alloy Parts in Warm Forming Process

There are many typical symmetric large plastic deformation problems in aluminum alloy stamping. Warm stamping technology can improve the formability of materials and obtain parts with high-dimensional accuracy. Friction behavior in the stamping process is significant for the forming quality. An accurate friction coefficient is helpful in improving the prediction accuracy of forming defects. It is hard to obtain a unified and precise friction model through simple experiments due to the complicated contact conditions. To explore the effect of friction behavior on the forming quality, warm friction experiments of the AA6061 aluminum alloy and P20 steel with different process parameters were carried out using a high-temperature friction tester CFT-I (Equipment Type), including temperatures, the interface load, and sliding speeds. The variation curves of the friction coefficient with various parameters were obtained and analyzed. The results show that the friction coefficient increases with temperature and decreases with the sliding speed and load. Then, the influences of process parameters on the surface morphology of the samples after friction were observed by an optical microscope; adhesive wear occurred when the temperature increased, and the surface scratch increased and deepened with the increase in the load. Finally, the friction coefficient models of the speed and load were established by analyzing the data with Original software. Compared with the experimental and the finite element analysis results of the symmetrical part, the errors of the velocity friction model in thickness and springback angle are less than 4% and 5%, respectively. The mistakes of the load friction model are less than 6% and 7%, respectively. The accuracy of the two friction models is higher than that of the constant friction coefficient. Therefore, those coefficient models can effectively improve the simulation accuracy of finite element software.

Theoretical and Experimental Investigation on the 3D Surface Roughness of Material Extrusion Additive Manufacturing Products

Material extrusion (ME), one of the most widely used additive manufacturing technique, has the advantages of freedom of design, wide range of raw materials, strong ability to manufacture complex products, etc. However, ME products have obvious surface defects due to the layer-by-layer manufacturing characteristics. To reveal the generation mechanism, the three-dimensional surface roughness (3DSR) of ME products was investigated theoretically and experimentally. Based on the forming process of bonding neck, the 3DSR theoretical model in two different directions (vertical and parallel to the fiber direction) was established respectively. The preparation of ME samples was then completed and a series of experimental tests were performed to determine their surface roughness with the laser microscope. Through the comparison between theoretical and experimental results, the proposed model was validated. In addition, sensitivity analysis is implemented onto the proposed model, investigating how layer thickness, extrusion temperature, and extrusion width influence the samples’ surface roughness. This study provides theoretical basis and technical insight into improving the surface quality of ME products.

Solidification performances of contaminants by red mud-based cementitious paste filling material and leaching behavior of contaminants in different pH and redox potential environments

Considering the urgent need for disposal of red mud and the comprehensive treatment of coal mined-out areas, this paper presented red mud-based cementitious paste filling material (RMFM) to achieve the purpose of green filling treatment. However, the solidification performance of alkaline RMFM for contaminants can be affected when in contact with acid goaf water in practice, which may in turn causes secondary pollution to the surroundings. The leaching tests of RMFM under different pH and redox potential (Eh) conditions were designed to investigate the effects of environmental elements on the solidification performance of RMFM, and primarily investigated the treatment effectiveness of RMFM on goaf water. The test results manifest that the acidic and oxidizing environments could damage the hydration products generated by alkali and sulfate activation, thus affecting the solidification performance, while the alkaline and reducing environments could effectively prevent the release of the contaminants by enhancing the degree of alkali activation and inhibiting oxidation acid forming process. In the possible exposure environment, RMFM could effectively stabilize its own pollutants without secondary pollution. In addition, the powder RMFM samples had significant removal effects on heavy metals, the values of Cu, Pb, and As removal efficiency all reached more than 96.15%.