Search results for "metalwork"
showing 10 items of 53 documents
Springback evaluation in fully 3-D sheet metal forming processes
1997
Abstract In the modern manufacturing industries the knowledge and proper control of the sheet metal springback after forming is a fundamental aspect in the achievement of near net shape stamped parts. In this paper an effective springback prediction in some fully three-dimensional stamping processes is carried out. Such a prediction is based on a combined approach in which an explicit finite element code has been employed to simulate the forming phase while a traditional implicit procedure has been used to analyse the springback phase. The results obtained have been compared with a set of experimental tests and an excellent correlation between the predicted and experimental data has been fo…
Investigation of thick sheet AHSS springback in combined bending under tension
2012
In this paper, we investigate the springback behavior of several advanced high-strength sheet steels (TRIP, Dual-Phase, ferrite-bainite) with thicknesses up to 4 mm. Samples were tested by means of the bending-under-tension (BUT) test. The BUT has been extensively applied, in the literature, to relatively thin (1 mm and thinner) sheet metals for automotive applications; the applicability of several guidelines from the literature was investigated in this work in the context of thick advanced high strength steel (AHSS) sheets and using a sample width of 12 mm. The monotonic decrease of springback as back force increased was confirmed for this category of sheet steels, and a general trend for …
Design and control of a novel 3D casting manipulator
2010
This paper focuses on casting manipulation and presents an innovative mechanism that allows objects placed in a three-dimensional space to be reached with a relatively small robot. Casting manipulation is a technique by which a robotic end-effector is thrown and its ballistic flight is controlled through a tether cable so as to reach a target object. Previous work presented a solution that is viable only when the position of the target object is perfectly known or aligned with the throwing plane. Our work extends the technique by use of a novel mechanical design of the arm, and a suitable control scheme for the flight of the end-effector, which makes it applicable for objects placed at gene…
Visual-based Feedback Control of Casting Manipulation
2006
In this paper, we present a method to control casting manipulation by means of real-time visual feedback. Casting manipulation is a technique to deploy a robotic end-effector at large distances from the robot’s base, by throwing the end-effector and controlling its ballistic flight using forces transmitted through a light tether connected to the end-effector itself. The tether cable can also be used to retrieve the end-effector and exert forces on the robot’s environment. Previous work has shown that casting manipulation is able to catch objects at a large distance, proving it viable for applications such as sample acquisition and return, rescue, etc. In previous experiments, the position o…
Influence of the channel design on the heat and mass exchange of induction channel furnace
2011
PurposeThe purpose of this paper is to present in‐depth numerical modelling of heat and mass exchange in industrial induction channel furnace (ICF).Design/methodology/approachThe turbulent heat and mass exchange in the melt is calculated using a three‐dimensional (3D) electromagnetic model and a 3D transient large eddy simulation method. The simulation model has been verified by flow velocity and temperature measurements, which were carried out using an industrial sized channel inductor operating with Wood's metal as a low temperature model melt.FindingsThe ICF is well‐established for melting, holding and casting in the metallurgical industry. But there are still open questions regarding th…
Aspects of Improving the Cost-Performance Ratio for the Manufacturing of Small-Size Cast Parts
2010
Abstract The paper analyses some of the commercially available solutions for casting small-size metallic parts and outlines possible solutions that would reduce the cost of such systems while maintaining a high performance level. high performance level. One typical application area for small-size parts is human prosthetics, so the commercial casting machines analysed here are used mainly in this application domain. The paper shows how high-cost systems added to the machines for providing protective atmospheres can be replaced by low-cost solutions with the same results in terms of part quality. Moreover, a solution is described that avoids the typical drawbacks of the currently used casting…
Friction Stir Welding of AA6082-T6 T-joints: Process Engineering and Performance Measurement
2006
In the paper the authors present the results of a wide range of experiments on T-parts. First, friction stir welding process engineering has been developed with the aim of determining the specific process parameters that make up the soundness of the obtained T-parts. Then the performance of the obtained T-joints has been compared with T-joints obtained by metal inert gas welding and extruded T-parts. The parts have been tested utilizing a customized bending test with the aim of highlighting their behaviour both in elastic and plastic fields.
The evaluation of springback in 3D stamping and coining processes
1998
Abstract An effective predictive technique of the elastic springback in a fully 3D 90° V-punch V-die bending process is presented. This is based on a combined approach in which an explicit finite element code was used to simulate the loading phase of the process whilst an implicit procedure was used to analyse the springback phase. Two different punches with a nose radius of 4 and 8 mm were used. An increase in the springback ratio with the coining load was observed with the lower nose radius. Conversely, an increase in the springback ratio with the coining load up to a peak value (>1), corresponding to a force of about 20 kN, followed by a decrease in the springback ratio with increasing t…
Interactive simulation of one-dimensional flexible parts
2006
Computer simulations play an ever growing role for the development of automotive products. Assembly simulation, as well as many other processes, are used systematically even before the first physical prototype of a vehicle is built in order to check whether particular components can be assembled easily or whether another part is in the way. Usually, this kind of simulation is limited to rigid bodies. However, a vehicle contains a multitude of flexible parts of various types: cables, hoses, carpets, seat surfaces, insulations, weatherstrips... Since most of the problems using these simulations concern one-dimensional components and since an intuitive tool for cable routing is still needed, w…
Real-time Control of Metallurgic Processes
1996
The careful control of the liquid metal solidification and the solid shell growth is of central importance in all metallurgic processes. These have a considerable influence on the formation of cracks and other defects which can be formed in the cast material. To ensure defect free products, the liquid metal is to be cooled down according to a pattern which depends i.e. on metal grade, product dimension, cooling speed and machine design. On the other hand, the control of the liquid/solid interface is a key element in optimising the liquid solidification with respect to good productivity. So, the heat transfer plays a very important role in metallurgic casting processes, especially when casti…