Vol. 15 No. 1 January 2016 Editorial Board Contents ... · E-mail: [email protected] Web: 06 - 09 Apr 2016 Die & Mould India International Exhibition BIEC, Bengaluru Contact: Bhaskar

Vol. 15 No. 1 January 2016

ContentsTechnical Papers

• Development of a fast, reliable fringe projection profilometry system

Madhusudhan Rao R, Deepa R, Kavitha V and Usha S3

• Excimer laser applications in micromachining Sunil Magadum, Chellamalai M and Balashanmugam N 12

• Teaching learning based optimization: An optimization technique for job shop scheduling

Nageswara Reddy K and Dr. Padmanabhan G19

• Design and fabrication of asymmetric multi-electrodes for fabrication of corrugated steel panels

Rakesh Kumar N, Nirmala O, Diwakar Reddy V and Bhanodaya Reddy G

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Photo Gallery: Vintage Machine: Dalton Lathes and Combination Machine By Dalton Mfg. Corporation, New York USA, 1920

31

Calendar of Events 32

Manufacturing Technology Abstracts 35

Select Bibliography of Standards: Machine Vision 43

Select Bibliography: Machine Vision and Vision System 44

Technology Trends 46

Patent Abstracts: Machine Vision System 48

Product Information: Machine Vision System 53

IPR News: A - Z Definitions of Intellectual Property Terminology 55

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Editorial Board

*All payments are to be made by demand draft drawn in favour of ‘Central Manufacturing Technology Institute, Bengaluru'

Disclaimer: Technical Data presented and views expressed by the authors are their own. CMTI does not assume any responsibility for the same.

ChairmanS Satish Kumar

Technical Paper Review PanelS UshaN BalashanmugamDr. C K SrinivasaK K RajagopalB R Mohanraj

EditorMallikarjun G

Editorial Assistants

Shashi Rekha NMala RC

Events

Manufacturing Technology Today, January 201632

20 Jan 2016International Seminar on Forming TechnologyBangalore International Exhibition Centre (BIEC), BengaluruContact: Mr. Abhishek on, e-mail : [email protected] ;Tel : 080 - 6624 6829 | 6665Indian Machine Tool Manufacturers’ Association10th Mile, Tumkur Road, Madavara Post,Bengaluru - 562 123Tel: +91 80 6624 6600 Fax: +91 80 6624 6661E-mail: [email protected] Web: http://www.imtex.in/isft2016

20 - 22 Jan 201624th Edition of Convergence India 2016- "Digital India" International Exhibition & ConferencePragati Maidan, New DelhiContact: SJ Singh, PresidentExhibitions India Group, 217 B, 2nd Floor, Okhla Industrial Estate Phase III, New Delhi - 110 020Tel: +91 11 4279 5000 Fax: +91 11 4279 5098E-mail: [email protected] Web: http://www.convergenceindia.org/

21 - 26 Jan 2016IMTEX Forming 2016 & Tooltech 2016Bangalore International Exhibition Centre (BIEC), BengaluruContact: Indian Machine Tool Manufacturers’ Association (IMTMA), Bangalore International Exhibition Centre (BIEC), 10th Mile, Tumkur Road, Madavara post, Bengaluru - 562 123Tel: +91 80 6624 6600 Fax: 91 80 6624 6661E-mail: [email protected] Web: http://www.imtma.in

27 - 29 Jan 2016ARRMA-2016 — Conference on Advances in Refractory and Reactive Metals and AlloysMultipurpose Hall, TSH, Anushaktinagar, MumbaiContact: J. K. Chakravartty, Chairman, Director, Materials Group, BARC, Sanjib Majumdar, Convener, Materials Group, BARCDr. Sanjib Majumdar, Convener, ARRMA 2016Scientific Officer, Materials Processing DivisionBhabha Atomic Research Centre, Mumbai 400085Tel: +91-22-2559 5313 Fax: +91-22-2559 5151E-mail: [email protected]: http://www.arrma2016.com

29 Jan - 01 Feb 2016Industrial Engineering Expo- IEE 2016Labhganga Exhibition Center, Near Radisson Hotel, Indore, Madhya PradeshContact: Future Communications, Lokmanya Nagar, Kesharbaug Road, Indore 452009 (M.P.), IndoreWeb:http://10times.com

04 - 06 Feb 2016International Conference on Trends in Industrial and Mechanical Engineering (ICTIME 2016)MANIT, BhopalContact: Dr. Ajay Verma/Dr. V.K. Soni/Dr. P.K. SoniCoordinators (ICTIME-2016)Department of Mechanical Engineering, Maulana Azad National Institute of Technology (MANIT)Bhopal-462051, Madhya PradeshTel: +91 9406623070/+91 8989441173

13 - 17 Feb 2016ElECRAMA 2016BIEC, BengaluruContact: Tel: +91 (022) 24936528 E-mail: [email protected] Web: www.elecrama.com

06 - 09 Apr 2016Die & Mould India International ExhibitionBIEC, BengaluruContact: Bhaskar Kanchan, Tools & Gauge Manufacturers Association - India A- 33, Nand Jyot Industrial Estate, Safed Pool, Andheri - Kurla Road, Mumbai Tel: +91(22) 28526876, +91-22-28526876 Fax: +91-22-28503273E-mail: [email protected] Web: www.diemouldindia.org

19 - 20 May 2016Fastener Fair IndiaPragati Maidan Exhibition Centre, New DelhiContact: Web: www.fastenerfair.com

16 - 20 Jun 2016ACMEE 2016Chennai Trade Centre,ChennaiContact: S Raghavan, Tel: +91 (0) 9790974048 E-mail: [email protected] Web: www.acmee.in

NATIoNAl

Events

Manufacturing Technology Today, January 2016 33

INTERNATIoNAl 25 - 28 Jun 2016ICAAMM-2016 International Conference on Aeromechanical Materials for ManufacturingMLR Institute of Technology, Hyderabad-500043Contact: Dr. M Satyanarayana Gupta, Convener ICAAMM-2016, Dept of Aeronautical Engg & Dept of Mech Engg, MLR Institute of Technology, Dundigal Police Station Road, Qutbullapur(M), Hyderabad-500043, TelanganaTel:+91 9515121961, 9515131961, 9160404640 E-mail: [email protected]: http://www.icaamm.com

08 - 11 Jul 2016AMTEX 2016 - Asian Machine Tool ExhibitionPragati Maidan, New DelhiContact: Reed Triune Exhibitions Pvt. Ltd. , #25, 3rd Floor, 8th Main Road, Vasanthnagar, Bengaluru - 560 052Tel: +91-80 43307474 M: +91 098450 89641 Fax: +91 80 22352772E-mail: [email protected] Web: http://www.amtex-expo.com

22 - 25 Aug 2016AuToMATIoN 2016Bombay Convention and Exhibition Centre Goregaon (E) MumbaiContact: Mr Arokiaswamy / Ms. Jyoti, Mob: +91-9920489667IED Communications Ltd., 64, Empire Building D N Road, Fort, Mumbai 400001Tel: 91-22-22079567 / 22073370 E-mail: [email protected]: http://www.iedcommunications.com

27 - 29 Aug 2016GARTEX 2016Pragati Maidan, New DelhiContact: Mex Exhibitions Pvt. Ltd., 9-LGF Sant Nagar, East of Kailash, New Delhi- 110 065Web: http://www.indiatradefair.com/

23 - 25 Sep 2016Automation & Robotics Expo -2016Autocluster Exhibition Centre, Chinchwad, H-Block, Plot No. C-181, Chinchwad, Pune, MaharashtraContact: Ajay Kumar Ph: 9702961888, +91-97022-93599, Autocluster Exhibition Centre, Chinchwad, H-Block, Plot No. C-181, Chinchwad, Pune, MaharashtraTel: +91-22-28574011 E-mail: [email protected] Web: http://www.automationexpo.net

24 - 28 Jan 201629th IEEE International Conference on Micro Electro Mechanical Systems (MEMS)Shanghai International Convention Center (SHICC)2727 Riverside Ave, Pudong, Shanghai, ChinaContact: IEEE MEMS 2016 ConferenceChina International Conference Center for Science and Technology, No. 86 Xueyuan Nan Road, Haidian District, Beijing 100081, ChinaTel: +86-10-62103105 Fax: +86-10-62174126E-mail: [email protected], [email protected] Web: www.shicc.net/shicc/

26 - 29 Jan 2016Trade fair for manufacturing technology and engineeringMesse Hamburg, Messeplatz 1, 20357 Hamburg, Hamburg, GermanyContact: Hamburg Messe und Congress GmbHMesseplatz 1, Hamburg, GermanyTel: +49 (0)40 35690 Fax: +49 (0)40 35692180E-mail: [email protected] Web:http://www.tradefairdates.com

08 - 10 Feb 2016AeroDef 2016 - Manufacturing Conference and ExhibitionLong Beach Convention Center, CaliforniaContact: Aerodef manufacturing event 300 E Ocean BlvdLong Beach, CA 90802 United StatesE-mail: [email protected] Web: aerodefevent.com

16 - 17 Feb 2016AmCon Design & Contract Manufacturing ExpoMeydenbauer Center, Bellevue, WAContact: AmCon, 27 Congress St. Suite, Salem, MA 01970Tel: 800-829-7467, 978-744-7680 Fax: 978-744-8903E-mail: [email protected] Web: http://www.amconshows.com/

02 - 05 Mar 2016The MFG Meeting 2016AMT--The Association For Manufacturing Technology and National Tooling and Machining Association (NTMA)

Events


Contact: JW Marriott Desert Springs Resort & Spa, 74-855 Country Club Dr., Palm Desert, CATel: 760-341-2211 Web:themfgmeeting.com

09 - 12 Mar 2016CIRE 2016 - The 5th China (Tianjin) International Industrial Robot ExhibitionMeijiang Convention & Exhibition Center, Tianjin, ChinaContact: Zhenwei Exhibition Group, Tianjin Zhenwei Exhibition Co., Ltd., Add: Zhenwei Exhibition Mansion, the 6th Ave. Service Outsourcing Industrial Park, TEDA, Tianjin, ChinaTel: +86-22-66224066/4088 Fax: +86-22-66224099E-mail: [email protected] Web: http://www.chinacire.com.cn/

09 - 12 Mar 2016IEME 2016 - The 12th China (Tianjin) International Equipment & Manufacturing Industry ExpoMeijiang Convention & Exhibition Centre, Tianjin, ChinaContact: Cathy Liu, Mob: +86-185 2263 4025Tel: +86-22-6583 6627 Fax: +86-22-6622 4099E-mail: [email protected] Web: http://en.ieme.com.cn/2015/en

23 - 25 Mar 20162nd Edition Smart Materials & Surfaces Conference, SMS KoREA 2016Seoul, South KoreaContact: Setcor Media FZ-LLC, Dubai Studio City, Executive Desk N. 13, Boutique Studio N. 10, Dubai, UAETel: + 33 (0) 6 4557 4009 Fax: + 33 (0)1 48 72 88 98E-mail: [email protected] Web: www.setcor.org

13 - 14 Apr 2016DESIGN & Manufacturing New England Trade ExhibitionBoston Convention & Exhibition Center, Boston,Contact: UBM Canon, 2901 28th Street, Suite 100, Santa Monica, CA 90405, USATel: +1 310/445-4200 Fax: +1 310/445-4299Web: http://www.expodatabase.com/tradeshow

13 - 17 Apr 2016SIMToS 2016Korea International Exhibition Center (KINTEX), South KoreaContact: Tel: +91 (22) 34532721 E-mail: [email protected] Web: www.simtos.org

19 Apr 20165th Ed. [MC]2 ConferenceAMT—The Association For Manufacturing Technology and the MTConnect InstituteContact: Dallas, TXWeb: mc2conference.com

25 - 29 Apr 2016ICMCTF'16 - Intl Conf on Metallurgical Coatings & Thin FilmsSan Diego, CA, United StatesContact: Exhibits Manager, Jeannette DeGennaroAVS, 125 Maiden Lane, 15th Floor, New York, NY 10038, USAContact: Conference Secretary, Mabel Zabinski, 328 Whitney Court, Havre de Grace, MD 21078, USATel: 201-961-5268 Fax: 212-248-0245E-mail: [email protected] Web: http://www2.avs.org/conferences/icmctf/

05 - 08 May 2016Mtduo: Taipei Manufacturing Technology ShowTWTC Nangang Exhibition Hall, 1 Jingmao 2nd Rd., Nangang District, Taipei, TaiwanContact: Taiwan External Trade Development Council (TAITRA) 5-7 Fl., 333 Keelung Rd., Section 1, Taipei 11012, Taiwan ROCTel: +886 (2) 2725-5200 Fax: +886 (2) 2757-6245E-mail: [email protected] Web: http://www.mtduo.com.tw

16 - 19 May 20162nd International Conference on Progress on Additive ManufacturingNanyang Technological University, Nanyang Executive Centre, SingaporeContact: Ping Conference, Pro-AM 2016 Conference Manager, C/o. PING Healthcare Pte Ltd, 20 Sin Ming Lane, #06-55 Midveiw City, Singapore Tel: (65) 6778 5620 Fax: (65) 6778 1372E-mail: [email protected]: http://www.pro-am2016.com ◘

Abstracts


Manufacturing technology abstracts

CASTING & FouNDRy PRACTICE 36

CoATING & FINIShING 37

FoRMING 38

ShEET METAl WoRKING 40

PoWDER METAlluRGy 40

hyDRAulICS & PNEuMATICS 41

INDuSTRIAl ENGINEERING 41

JoINING AND ASSEMBly 42

The topics on various aspects of manufacturing technology can be discussed in term of concepts, state of the art, research, standards, implementations, running experiments, applications, and industrial case studies.

Authors from both research and industry contributions are invited to submit complete unpublished papers, which are not under review in any other conference or journal.

Contact: Central Manufacturing Technology Institute (CMTI) Tumkur Road, Bengaluru – 560 022, Karnataka, IndiaEmail: [email protected]

Abstracts


Manufacturing technology abstracts

CASTING & FouNDRy PRACTICE

110556 Study of metal injection molding of highly porous titanium by physical modeling and direct experiments

Tuncer, Nihan; Bram, Martin; Laptev, Alexander; Beck, Tilmann; Moser, Alexander; Buchkremer, Hans Peter [J of Materials P r o c e s s i n g Technology, v 214,

n 7, July 2014, Starting Page 1352, Pages 9] The prospects of metal injection molding (MIM) technique for manufacturing of highly porous titanium parts was studied by physical modeling, based on feedstock warm compaction experiments. The space holder method and typical MIM binder were used in all cases of the study. The influence of the starting powder (dehydrided and atomized) in feedstock on resulting properties of porous titanium was investigated. The size of space holder particles and space holder amount were adjusted to obtain porosity and pore size desired for medical implants application. NaCl and KCl were studied and compared as prospective space holder materials. The porous samples were characterized regarding their microstructure, uptake of interstitial contents and mechanical properties. For comparison, same investigations have been conducted on samples, which were prepared by established space holder technology based on cold isostatic pressing (CIP) and sintering. Finally, first direct MIM experiments and attempts of feedstock optimization were carried out. The peculiarities and problems of metal injection molding of highly porous titanium have been discussed. (15 refs, 8 figs, 3 tables) (AA)

110557 Fabrication of cemented tungsten carbide components by micro-powder injection moulding

Fayyaz, Abdolali; Muhamad, Norhamidi; Sulong, Abu Bakar; Rajabi, Javad; Wong, Yee Ning [J of Materials Processing Technology, v 214, n 7, July 2014, Starting Page 1436, Pages 9] Micro-powder injection moulding (micro-PIM) is an advanced net-shaping process

for the fabrication of metal and ceramic complex micro-components. Cemented tungsten carbide (WC–Co) hardmetal is known for its high hardness and wear resistance in various applications. Micro-PIM is a new alternative manufacturing technique for hardmetal micro-parts. In this work, the fabrication of WC–Co components via a micro-PIM process was studied. A fine WC–10Co–0.8VC (wt.%) powder was mixed with a binder system consisting of paraffin wax, low density polyethylene and stearic acid. A micro-component was injected at low pressure using a semi-automatic injection moulding machine. The injection temperature was determined from the rheological investigation of the feedstock. The binder extraction was carried out in solvent and thermal debinding methods under an argon atmosphere. Thermal gravimetric analysis was used to confirm the removal of the soluble binder from the green part. The sintering process has been performed within a temperature range of 1330–1450 °C under vacuum. After sintering, a density of 94.5% theoretical density was obtained, which is a reasonable value. The micro-components showed length shrinkage between 16 and 22% and good surface quality and hardness values when compared with conventional powder metallurgy. This research shows that micro-PIM is able to produce small WC–Co components with properties comparable to conventional powder metallurgy. (32 refs, 17 figs, 5 tables) (AA)

110558 hot Extrusion of Thin-Wall Multichannel Copper Profiles

Kraft, Frank F; K o c h i s , Jonathan [J of Manufacturing Sci & Engg: ASME Trans,

v 135, n 6, Dec 2013, Starting Page 061008, Pages 8] This paper presents the development of a unique, net shape, hot-extrusion process to produce precision, thin-wall, multichannel copper profiles for high efficiency heat-exchangers. This process is a departure from conventional copper extrusion, which is a nonisothermal process used primarily to produce simple semifinished products and hollow profiles requiring cold drawing after hot extrusion. A lab-scale apparatus was developed to simultaneously extrude multiple heated billets through a porthole type hollow die to form the

Abstracts


multi-channel profiles. The process is performed at 700–750 °C, essentially at isothermal extrusion conditions. Temperature and tooling strength considerations necessitated the use of superalloys for the apparatus (which included dies, container, ram stems, and support tooling). A 250 kN computer controlled servo-hydraulic MTS® machine was used to provide the extrusion ram force. Two part designs were extruded to demonstrate process feasibility and versatility. A two-channel design with 0.2 mm wall thicknesses and an 11-channel design with wall-thicknesses of 0.3 mm were extruded. The extrusion ratios for these profiles are 67 and 25, respectively. Experimental data and an approach to analytically model the process are presented. Because solid-state welds in the tube walls are necessitated by the use of hollow extrusion dies, the microstructure in these regions is also presented. (12 refs, 14 figs, 1 table) (AA)

110559 Influence of a wiper on residual stresses in AA7050 rolling plate ingots

Drezet, JM; Th. Pirling [J of M a t e r i a l s P r o c e s s i n g Technology, v 214, n 7, July 2014, Starting Page 1372,

Pages 7] As-cast stresses in the foot of the ingot corresponding to the transient start-up phase of the direct chill casting have been determined in aluminum alloy AA7050 rectangular ingots. This high strength alloy is usually cast with a wiper that is placed below the mold and ejects the falling water from its surface thus reducing the cooling intensity. The ingot being hotter, internal stresses are relaxed. The efficiency of a wiper has been evaluated using both neutron diffraction measurements on ingots cast with and without a wiper and a 3D numerical model simulating the stress generation during casting. The stress level is reduced by 33% when a wiper is used during casting and the stored elastic energy by 50%. (27 refs, 10 figs) (AA)

CoATING & FINIShING

110560 Numerical modeling of passive layer formation and stabilization in electrochemical polishing processTailor, Piyushkumar B; Agrawal, Amit; Joshi, Suhas S [J of Manufacturing Processes, v 18, Apr 2015, Starting Page 107, Pages 10] The electrochemical polishing generates surface finish in micro-/

nano-scale. The process, primarily works on the principle of preferential anodic dissolution owing to the passive layer formation. The current–voltage characteristics curve of

the process shows that stable passive layer by anodic dissolution is obtained in plateau region that is a favorable condition for the electrochemical polishing process. This work presents numerical simulations of effect of main process parameters: inlet velocity, diffusion coefficient of electrolyte, inter-electrode gap and roughness of anode surface on uniformity and time to obtain steady passive layer. It is observed that all the above parameters govern uniformity of the passive layer. The inlet velocity and diffusion coefficient of electrolyte mainly govern the time required for stabilization of the passive layer followed by the inter-electrode gap; however, surface roughness at anode has a negligible effect. Further, the process gives better performance when the inlet velocity is 0.007–0.008 m/s, diffusion coefficient is 10−8 to 10−9 m2/s and inter-electrode gap is greater than 6 mm. (43 refs, 13 figs, 4 tables) (AA)

110561 Experimental investigation of process parameters for roll-type linear chemical mechanical polishing (Roll-CMP) system

Lee, Hyunseop; Wang, Han; Park, Jaehong; Jeong, Haedo [Precision Engg, v 38, n 4, Oct 2014, Starting Page 928, Pages 7] The fabrication processes

for electronic components are now demanding a higher degree of planarity for integration and multistacking, with chemical mechanical polishing (CMP) processes replacing conventional etching or mechanical polishing owing to their ability to attain global planarization. As CMP has been applied to more and more fields, new types of CMP machines have been developed. This study introduces a novel roll-type linear CMP (Roll-CMP) process that uses a line-contact material removal mechanism to for the polish flexible substrates, and examines the effect of the process parameters on the material removal rate (MRR) and its nonuniformity (NU). The parameters affecting the Roll-CMP process include down force, roll speed, table feed rate, slurry flow rate, slurry temperature, and the table oscillation length. Increasing the down force, roll speed, slurry flow rate, and slurry temperature resulted in a high

Abstracts


average MRR (MRRavg). Further, the MRRavg was found to decrease with an increase in the oscillation length because of the effect of the polishing area. A large down force, high roll speed, high table feed rate, and high slurry flow rate were effective for reducing the NU. These results will be helpful for understanding the newly developed Roll-CMP process. (22 refs, 17 figs, 1 table) (AA)

FoRMING

110562 Plastic flow behavior, microstructure, and corrosion behavior of AZ61 Mg alloy during hot compression deformationTsao, LC; Chen, CH; Wu, RW; Chang, SY; Chen, RS [J of Manufacturing Processes, v 18, Apr 2015, Starting Page 167, Pages 8] AZ61 alloy was hot-compressed on a Gleeble-2000 thermal simulation testing machine, and the compression flow stress, microstructure, microhardness, and corrosion properties of samples with three different geometries were analyzed after deformation at temperatures ranging from 573 K to 773 K and a strain rate of 0.5 s−1. The true stress–true strain curves of the as-extruded AZ61 Mg alloy indicated that the deformation behavior significantly depended on the testing temperature. The flow curves exhibited typical flow behavior with dynamic recrystallization softening. The geometry affected the formability of AZ61 alloys; increasing the aspect ratio (H/D) reduced the strain-hardening coefficient (nh) and increased the strain-softening coefficient (ns). But in the CU sample with a raised collar shape, the strain-softening phenomenon was retarded. Increasing the deformation temperature increased the grain size and decreased the microhardness. The corrosion behavior of AZ61 compressed alloys deteriorated with increased temperature, especially at 773 K. (28 refs, 11 figs, 3 tables) (AA)

110563 The effect of grain refinement by multi-pass continuous hybrid process on mechanical properties of low-carbon steel wires

Hwang, Sun Kwang; Baek, Hyun Moo; Im, Yong-Taek; Son, Il-Heon; Bae, Chul Min; Lee, Ho Won [J of Materials P r o c e s s i n g

Technology, v 214, n 7, July 2014, Starting Page 1398, Pages 10] In this work, a multi-pass continuous hybrid (CH) process simulated by finite element analyses is investigated for producing grain-refined low-carbon steel wires in a

continuous manner. The effect of grain-refined microstructure on mechanical properties such as tensile strength, ductility, micro-hardness, and fatigue limit is studied. For this purpose, the multi-pass CH process was experimentally set up and applied up to five passes with route A at room temperature. The experimental findings were compared with those for the multi-pass conventional wire drawing (WD) process. According to the present observation, the five-pass CH process refined the grains in the wires with many well-defined high angle grain boundaries, resulting in enhanced ultimate tensile strength and comparable ductility compared to the WD process. In addition, the fatigue limit of the specimen produced by the CH process was enhanced due to the grain-refined microstructure of the specimen compared to the one of the WD process. Based on the present investigation, it was found that the multi-pass CH process will be more efficient in manufacturing the fine-grained wires with enhanced mechanical properties compared to the WD process. (30 refs, 14 figs, 3 tables) (AA)

110564 The effect of tool heating arrangement on fibre material forming

Tanninen, Panu; Kasurinen, Marko; Eskelinen, Harri; Varis, Juha; Lindell, Henry; Leminen, Ville; Matthews, Sami; Kainusalmi, Mika [J of Materials P r o c e s s i n g

Technology, v 214, n 8, Aug 2014, Starting Page 1576, Pages 7] In this paper, a new heating arrangement has been developed for improving the performance of paperboard forming process. Problem areas of current heating methods were identified by analyzing several forming moulds used for tray production in packaging industry. This analysis was used as basis for design process of the new and more advanced mould. The new process utilizes oil to distribute heat evenly in the mould resulting in reduced process parameter adjustment during production. The versatility of the improved design manifests in less variance in outer dimension of trays and reduced volume of rejects. (10 refs, 18 figs, 2 tables) (AA)

110565 Numerical and experimental investigations of hydro-mechanical deep drawing process of laminated aluminum/steel sheetsBagherzadeh, S; Mirnia, MJ; Dariani, B Mollaei [J of Manufacturing Processes, v 18, Apr 2015, Starting Page 131, Pages 10] The

Abstracts


application of hydro-mechanical deep drawing (HMDD) process on laminated sheets combines advantages of both process and material to improve the forming condition of poor formable light-weight metals such as

aluminum alloys. In this research, the HMDD process of anisotropic laminated bimetallic sheets has been analyzed using a 3D finite element simulation with implementing Fortran based code for accurate modeling of non-uniform oil pressure distribution. To verify FE results, experimental works were conducted on the widely used laminated aluminum/steel sheets. Based on the developed FE model, parametric studies were performed to investigate the effect of material parameters such as layers thickness and lay-up arrangement on the forming condition, process window and formability of aluminum sheet as key process parameters. Results demonstrated that suitable process condition to attain a successful forming of bimetallic aluminum/steel sheets can be predicted by developed FE model reasonably. Also, It shown that wider working zone was achievable with decrease in drawing ratio, reduction in thickness of sheet with lower strength layer and also when aluminum sheet is in contact with punch (A/S lay-up). In addition, the higher limiting drawing ratio (LDR) and lower thinning in low formable aluminum sheet would be achievable in A/S lay-up than S/A lay-up. (23 refs, 15 figs, 2 tables) (AA)

110566 Modelling of high speed selective jet electrodeposition process

Mridul Singh Rajput, Pulak Mohan Pandey, Sunil Jha [J of Manufacturing Processes, v 17, Jan 2015, Starting Page 98,

Pages 10] High speed selective jet electrodeposition (HSSJE) employs a jet of electrolyte with potential difference between anode and cathode for deposition at cathode. The HSSJE process is a new process and is at its developmental stage. The HSSJE process can be utilized for maskless fabrication of metallic micro features for micro electro mechanical systems (MEMS) and

other applications. The HSSJE process uses an electrolyte jet which makes the process difficult to control. A theoretical model as well as analysis is necessary for design and development of control system of HSSJE process. In this work, mathematical models for predicting deposition rate and deposition height with respect to input process parameters (applied voltage, concentration of metal ions, and inter electrode gap) have been developed. This model also predicts the distribution of potential gradient on the substrate surface and potential distribution within the jet. Experimental study has also been conducted to validate the proposed model. (13 refs, 12 figs, 3 tables) (AA)

110567 Enhancing formability in hydromechanical deep drawing process adding a shallow drawbead to the blank holder

Halkaci, Huseyin Selcuk; Turkoz, Mevlut; Dilmec, Murat [J of M a t e r i a l s P r o c e s s i n g Technology, v 214, n 8, Aug 2014,

Starting Page 1638, Pages 9] In this paper, a new method proposed in order to enhance the limiting drawing ratio (LDR) of AA5754-O in the hydromechanical deep drawing process (HDD). In the proposed method, a shallow drawbead was added to the blank holder to increase LDR so as to provide strain hardening of a large region on the flange of the sheet material in addition to pre-bulging process which affects particularly only the initial stage but not the later ongoing process. So the LDR of the AA5754-O was increased from 2.65 to 2.787 by enlarging the region of strain hardening in the flange and partially reducing wrinkling tendency due to occurred tensile stresses using the convenient pressure and blank holder force profiles. The importance levels and their convenient values for height of drawbead, pre-bulge height and pressure, surface roughness of the punch were determined with analysis of variance (ANOVA) is a statistical method. ANOVA analysis illustrated that adding a shallow drawbead to the blank holder is the most effective factor between the investigated factors for the HDD process. While the effects of the pre-bulging pressure and pre-bulging height were determined as quite small, the surface roughness of the punch was found unimportant compared to the effect of the shallow drawbead. (22 refs, 13 figs, 6 tables) (AA)

Abstracts


ShEET METAl WoRKING

110568 Explorative study of tandem skew rolling process for producing seamless steel tubes

Wang, Fu-jie; Shuang, Yuan-hua; Hu, Jian-hua; Wang, Qing-hua; Sun, Jing-chao [J of Materials P r o c e s s i n g Technology, v 214, n 8, Aug 2014, Starting Page 1597,

Pages 8] The tandem skew rolling (TSR) process is a new metal forming technique for producing seamless steel tubes of various dimensions. In this paper, the overall details of the TSR process are described and the important process parameters that control the TSR process are systematically discussed. A new experimental method, developed under laboratory conditions, showed that the TSR process can produce seamless steel tubes with high manufacturing quality. Numerical simulations of the TSR process were carried out using commercially available FEM software (Deform) to show the stress, strain, and temperature distributions in the rolled tubes. In addition, the variation of forces and rolling torques during the process are analyzed. Based on the experimental and numerical investigations, the TSR technique has been found to be a viable process for enhancing the quality and productivity of formed tubular products. (11 refs, 16 figs, 1 table) (AA)

110569 Formability limits by fracture in sheet metal forming

Isik, K; Silva, MB; Tekkaya, AE; Martins, PAF [J of Materials P r o c e s s i n g Technology, v 214, n 8, Aug 2014, Starting Page 1557, Pages 9] The aim of this paper is twofold: first, to revisit the forming

limit diagram (FLD) in the light of fundamental concepts of plasticity, damage and ductile fracture mechanics and, second, to propose a new experimental methodology to determine the formability limits by fracture in sheet metal forming. The first objective makes use of the theory of plasticity applied to proportional strain loading paths, under plane stress conditions, to analyze the fracture forming limit line (FFL) and to

introduce the shear fracture forming limit line (SFFL). The second objective makes use of single point incremental forming (SPIF), torsion and plane shear tests to determine the experimental values of the in-plane strains at the onset of fracture. Results show that the proposed methodology provides an easy and efficient procedure to characterize the formability limits by fracture in sheet metal forming. In particular, the paper shows that the FFL determined by means of tensile and conventional sheet formability tests is identical to that determined from SPIF tests on conical and pyramidal truncated specimens. The new proposed approach is expected to have impact in the established methodologies to outline the formability limits on the basis of the forming limit curves (FLC’s) at the onset of necking. (22 refs, 7 figs, 1 table) (AA)

PoWDER METAlluRGy

110570 Reliability comparison between SAC305 joint and sintered nanosilver joint at high temperatures for power electronic packaging

Chen, Gang; Yu, Lin; Mei, Yun-Hui; Li, Xin; Chen, Xu; Lu, Guo-Quan [J of M a t e r i a l s P r o c e s s i n g T e c h n o l o g y , v 214, n 9, Sep

2014, Starting Page 1900, Pages 9] Ratcheting behavior of sintered nanosilver joints was examined by cyclic shearing tests at different temperatures. Fatigue lives of sintered nanosilver joints were compared with those of soldered SAC305 joints. An improved non-contact displacement detecting system combining infrared heating was developed to measure the deformation of the joints. Effects of temperature, mean stress, and stress amplitude on the ratcheting behavior of both kinds of the joints were analyzed. Shear strength of the sintered nanosilver joints is larger than that of the soldered SAC305 ones. The ratcheting displacement and its rate in both kinds of the joints increase with increase in temperature, mean stress, and stress amplitude. The fatigue life of sintered nanosilver joint is much longer than that of soldered SAC305 one under the same loading conditions. It is concluded that sintered nonosilver joint has demonstrated a longer fatigue life and better response to shearing and cyclic loading than SAC305 joint, especially at high temperatures. An improved temperature-dependent modified Goodman

Abstracts


model is proposed and is proved to be able to accurately predict the fatigue life of the sintered nanosilver joints and the soldered SAC305 joints by introducing the temperature-dependent fatigue strength exponent and the fatigue strength coefficient. (28 refs, 11 figs, 4 tables) (AA)

110571 NiTi with 3D-interconnected microchannels produced by liquid phase sintering and electrochemical dissolution of steel tubes

Bewerse, C; Brinson, LC; Dunand, DC [J of Materials Processing Technology, v 214, n 9, Sep 2014, Starting Page 1895, Pages 5] A process was developed for fabricating 3D fully i n t e r c o n n e c t e d microchannels in

superelastic NiTi-Nb for bone implant applications by combining spaceholder powder metallurgy and liquid-phase sintering. Prealloyed NiTi powders were blended with 3.1 at.% Nb and cold-pressed around a 3D scaffold of carburized steel tubes acting as space-holders. The tubes were then electrochemically dissolved to form orthogonally interconnected microchannels with 400 μm diameter and ∼34% volume fraction. Finally, the powder preform was heated to 1185 °C to form a quasi-binary NiTi-Nb eutectic liquid, which liquid-phase-sintered the NiTi powders without filling the microchannels. The resulting continuously bonded matrix contains an additional 16% porosity, for a total structure porosity of ∼50%. NiTi-Nb micro-architectured structures have excellent potential as bone implant scaffolds due to the high versatility in channel size, fraction, and spatial arrangement. Fully interconnected 3D microchannels also increase fluid transport within the scaffold, assisting in nutrient delivery and waste transport to and from cells deep within the scaffold. (22 refs, 5 figs) (AA)

hyDRAulICS & PNEuMATICS

110572 Practical and intuitive controller design method for precision positioning of a pneumatic cylinder actuator stage

Sato, Kaiji; Sano, Y u s u k e [Precision Engg, v 38, n 4, Oct 2014, Starting Page 703, Pages 8] The present

paper describes a practical and intuitive controller design method for precision positioning of pneumatic cylinder actuator stages. Pneumatic actuators are easy to use and have numerous advantages, which has led to these actuators having a wide variety of applications. However, pneumatic actuators have notable nonlinear characteristics, which make precision positioning difficult to achieve. The purpose of the present study is to clarify a practical and intuitive controller design procedure for precision positioning of a pneumatic cylinder actuator. In addition to positioning performance, the present study focuses on the realization of easy controller design without the need for the exact model parameters or knowledge in control theory for general-industrial-use pneumatic cylinder actuators with friction characteristics. These considerations are important in order to fully exploit the advantages of pneumatic cylinder actuators in a wide variety of applications. As such, three elements are added to the conventional continuous-motion nominal characteristic trajectory following (CM NCTF) controller. A new design procedure of the improved CM NCTF controller for pneumatic cylinder actuator stages is introduced, and the positioning performance of the designed control system is examined experimentally under several conditions. The positioning results generally indicate a positioning error of 50 nm, which is equal to the sensor resolution. (25 refs, 18 figs, 1 table) (AA)

INDuSTRIAl ENGINEERING

110573 Efficient meta-heuristics based on various dominance criteria for a single-machine bi-criteria scheduling problem with rejectionMoghaddam, Atefeh; Yalaoui, Farouk; Amodeo, Lionel [J of Manufacturing Systems, v 34, Jan 2015, Starting Page 12, Pages 11] In this paper, we try to fill in the gap between theory and practice in production scheduling by defining a new term as “rejection” and treating the corresponding scheduling problem with multi-objective optimization approach. We study a bi-objective single machine scheduling problem with rejection. At the beginning of scheduling time horizon, scheduler needs to decide which job shall be rejected due to the resource constraints regarding two objective functions: minimization of total weighted completion time of accepted jobs and total rejection penalty of rejected jobs. We develop different algorithms to find the best estimation of Pareto-optimal front for this problem. In order to improve the quality of the solutions,

Abstracts


on the one hand, and facilitate the process of selecting best solution for the final decision maker, on the other hand, we integrate various dominance criteria into our proposed algorithms. Finally we compare the performance of those methods by testing on a large set of instances and highlight the advantages and weak points of each one. (39 refs, 10 figs, 5 tables) (AA)

110574 lean production system design for fishing net manufacturing using lean principles and simulation optimization

Yang, Taho; Kuo, Yiyo; Su, Chao-Ton; Hou, Chia-Lin [J of Manufacturing Systems, v 34, Jan 2015, Starting Page 66, Pages 8]

Value stream mapping (VSM) is a useful tool for describing the manufacturing state, especially for distinguishing between those activities that add value and those that do not. It can help in eliminating non-value activities and reducing the work in process (WIP) and thereby increase the service level. This research follows the guidelines for designing future state VSM. These guidelines consist of five factors which can be changed simply, without any investment. These five factors are (1) production unit; (2) pacemaker process; (3) number of batches; (4) production sequence; and (5) supermarket size. The five factors are applied to a fishing net manufacturing system. Using experimental design and a simulation optimizing tool, the five factors are optimized. The results show that the future state maps can increase service level and reduce WIP by at least 29.41% and 33.92% respectively. For the present study, the lean principles are innovatively adopted in solving a fishing net manufacturing system which is not a well-addressed problem in literature. In light of the promising empirical results, the proposed methodologies are also readily applicable to similar industries. (29 refs, 7 figs, 4 tables) (AA)

110575 Single machine scheduling problems with exponentially time-dependent learning effectsCheng, Mingbao; Tadikamalla, Pandu R; Shang, Jennifer; Zhang, Bixi [J of Manufacturing Systems, v 34, Jan 2015, Starting Page 60, Pages 6] In this paper, we introduce a single-machine scheduling problem with an exponentially time-dependent learning effect. The processing time of a job is assumed to be an exponential function of the total normal processing time of jobs already processed before it. For such a scheduling

problem, we first provide the upper bound for the maximum lateness and for the total weighted completion time. Next, we show that problems with the following criteria: makespan, the total completion time, the total weighted completion time, the total earliness/tardiness penalties and the maximum lateness under some agreeable conditions, are polynomially solvable. (28 refs, 1 table) (AA)

JoINING AND ASSEMBly

110576 Studies on A-TIG welding of 2.25Cr-1Mo (P22) steel

Arivazhagan, B; Vasudevan, M [J of M a n u f a c t u r i n g Processes, v 18, Apr 2015, Starting Page 55, Pages 5] In the present study, 12 mm thick double side square butt joint was fabricated on 2.25Cr-1Mo (P22) steel plates using A-TIG welding process with in-house developed activated fluxes. Microstructure and

mechanical properties of the weld joint were characterized. Effect of post weld heat treatment (PWHT) on the impact toughness was studied. In the as-welded condition toughness was found to be 133 J. There was no proeutectoid ferrite in the weld. After PWHT, the toughness of weld was increased to 177 J due to dissolution and coarsening of existing precipitates. A-TIG weld joint of 2.25Cr-1Mo steel exhibited high hardness and good impact toughness in the as welded condition. (14 refs, 8 figs, 2 tables) (AA) ◘

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Vol. 15 No. 1 January 2016 Editorial Board Contents ... · E-mail: [email protected] Web: 06 - 09 Apr 2016 Die & Mould India International Exhibition BIEC, Bengaluru Contact: Bhaskar

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