Journal of Manufacturing Processes (J Manuf Process )

Publisher: Elsevier

Description

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  • Website
    Journal of Manufacturing Processes website
  • Other titles
    Journal of manufacturing processes (Online), Manufacturing processes, JMP
  • ISSN
    1526-6125
  • OCLC
    44600690
  • Material type
    Document, Periodical, Internet resource
  • Document type
    Internet Resource, Computer File, Journal / Magazine / Newspaper

Publisher details

Elsevier

  • Pre-print
    • Author can archive a pre-print version
  • Post-print
    • Author can archive a post-print version
  • Conditions
    • Pre-print allowed on any website or open access repository
    • Voluntary deposit by author of authors post-print allowed on authors' personal website, arXiv.org or institutions open scholarly website including Institutional Repository, without embargo, where there is not a policy or mandate
    • Deposit due to Funding Body, Institutional and Governmental policy or mandate only allowed where separate agreement between repository and the publisher exists.
    • Permitted deposit due to Funding Body, Institutional and Governmental policy or mandate, may be required to comply with embargo periods of 12 months to 48 months .
    • Set statement to accompany deposit
    • Published source must be acknowledged
    • Must link to journal home page or articles' DOI
    • Publisher's version/PDF cannot be used
    • Articles in some journals can be made Open Access on payment of additional charge
    • NIH Authors articles will be submitted to PubMed Central after 12 months
    • Publisher last contacted on 18/10/2013
  • Classification
    ​ green

Publications in this journal

  • K. Devendranath Ramkumar, R. Jagat Sai, V. Santhosh Reddy, Sridhar Gundla, T. Harsha Mohan, Vimal Saxena, N. Arivazhagan
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    ABSTRACT: This paper investigates the weldability, microstructure and mechanical properties of 5 mm thick Inconel 718 plates obtained by pulsed current gas tungsten arc welding (PCGTAW) using ERNiCu-7, ERNiCrCoMo-1 and ERNiCr-3 fillers. Post weld heat treatment (PWHT) was also carried out at 720 °C/8 h/furnace cooling followed by 620 °C/8 h/air cooling on the weldments. A comparative evaluation based on the microstructure features and mechanical properties of both the as-welded and aged samples were studied. Further this study addressed the combined effect of filler wires and post weld heat treatment on the metallurgical and mechanical properties of the weldments. The studies showed the improvement in tensile strength and drop in impact toughness for all the weldments after direct ageing heat treatment.
    Journal of Manufacturing Processes 04/2015; 18.
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    ABSTRACT: The objective of this study is to determine a method of quantifying the energy consumption in friction stir welding (FSW). Qualitatively, it has long been known that FSW uses less energy than fusion welding processes because the average FSW weld temperature does not exceed the solidus temperature. However, tools and data to quantitatively determine the energy consumption in FSW have been missing. The power consumption as a function of time was measured during FSW of 5.2-mm-deep welds in 6061-T6 and 7075-T6 aluminum alloys on a 3-axis CNC mill. The energy consumption is divided into four parts: idle energy and standby energy related to the machine being used as well as plunge energy and FSW energy related to creating the joint. Equations for calculating each of the energy components and the total energy consumption are presented. The concept of specific weld energy is presented as an intrinsic material property that can be used to estimate the FSW power if the weld cross-section and weld speed are known. A method of estimating the weld cross-section based on the FSW tool geometry is presented. It is found that for these two aluminum alloys the specific weld energy decreases significantly with increased weld speed, however, it can be treated as independent of spindle rotation rate. The FSW process/machine is identified as low tare and it is acknowledged that the strategies to reduce total energy consumption may be different than those used for metal cutting.
    Journal of Manufacturing Processes 04/2015; 18.
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    ABSTRACT: Lap joints of 2198-T8 Al–Li alloy in 0.063 in. sheet thickness were friction stir welded to investigate the combination of this material and assembly method for the manufacturing of aerospace structures. Along with conventional friction stir welding (FSW), weaved FSW and pulsed FSW (PFSW) were evaluated to determine the potential impact of these variant technologies on weld strength. Additionally, a more traditional flat shoulder tool geometry operated with a tilt angle was compared to a tapered shoulder tool geometry operated at a 0° tilt angle, which offers the possibility of simplifying robotic welding operations. Faying surface sealant, the use of which is critical in aerospace applications, was investigated as well, to determine its impact on weld strength and to characterize its interactions with welding parameters and process variants.
    Journal of Manufacturing Processes 04/2015; 18.
  • B. Arivazhagan, M. Vasudevan
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    ABSTRACT: 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.
    Journal of Manufacturing Processes 04/2015; 18.
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    ABSTRACT: The control of weld induced residual stresses and distortions are very important in longitudinal seam (L-Seam) and circumferential (C-Seam) butt joints of cylindrical components. In this study, a three-dimensional, sequentially coupled thermo-metallurgical-mechanical analysis was performed for L-Seam and C-Seam butt weld joints of AISI 304 cylindrical components to evaluate weld characteristics during gas tungsten arc welding (GTAW) process. Initially, weld experiments were carried out to obtain the heat input and the macrographs which were further validated with the predicted weld molten pool sizes during heat source fitting (HSF) analysis. The Goldak's double ellipsoid heat source function obtained in HSF analysis was employed in the thermal and mechanical analysis. The results reveal that there are significant differences in residual stress distributions between L-Seam and C-Seam butt joints. Full scale shop floor welding experiments were performed to verify the effectiveness of the proposed numerical models and these are in good agreement with the experimental measurements.
    Journal of Manufacturing Processes 04/2015; 18.
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    ABSTRACT: Modern aeronautical and aerospace industries must face the demanding challenge of reducing operational consumption and production costs coming from materials and labor. Current trend of engineering is oriented to meet both requirements increasing the use of materials characterized by high specific resistance as titanium alloys. Hot forging can be used to reduce the production costs of titanium components: forging in closed dies of billets or semi-finished forms, at different temperatures above or below the β-transus temperature, allows the production of complex shapes with limited amount of edge trim removal and machining rework after forging. Unfortunately, as far as Ti–6Al–4V titanium alloy is regarded, several material peculiarities have to be properly taken into account in order to produce defect free Ti–6Al–4V alloy components. In the paper, an experimental and numerical campaign, focused on a typical case study for aeronautical engines, is carried out. The aim of this research is to investigate the process mechanics and the causes for the final microstructure observed through micrographic analysis. Once set-up and tested against experimental loads, the model was used to predict phases distributions after both forging and cool down.
    Journal of Manufacturing Processes 01/2015;
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    ABSTRACT: Steel case hardening is a thermo-chemical process largely employed in the machine components production mainly to solve wear and fatigue damage in materials. The process is strongly influenced by many different variables such as material properties and processing parameters. In the present study, the influence of such parameters affecting the carburizing quality and efficiency was evaluated. The aim was to streamline the process by numerical–experimental analysis allowing for the definition of optimal conditions for the success of the process. The optimization software used is modeFRONTIER® (Esteco); a set of input parameters was defined (steel composition, carbon potential, carburizing time, etc.) and evaluated on the basis of an optimization algorithm carefully chosen for the multi-objective analysis.
    Journal of Manufacturing Processes 11/2014;
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    ABSTRACT: This paper presents a geometry modelling approach to cross-section parameters of chamfered cutting edge on a ball-end mill of solid carbide (BEMSC). Both the cutting edge curve and the CR (chamfer in rake face) face models are derived. Based on the CR face model, a new method for CR face grinding path generation is proposed. By determining the relationship between the length and the angle parameters of the CR face equation, its grinding path can be derived. After solving the rake face equation using this method, its grinding path as well as the grinding paths of the LF (land on flank face) face and the second flank face can also be computed. The geometry model has been validated through a series of numerical simulations.
    Journal of Manufacturing Processes 11/2014;
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    ABSTRACT: FEM is used to investigate effects of microbumped tools on machining of mild steel.•Microbumps on the rake face of a cutting tool are effective in reducing cutting forces.•Minimum cutting force may be realized around two width values at 20 and 400 μm.•It is noted that an optimal edge distance value may exist between 320 and 420 μm.•An optimal microbump width to height ratio exists to minimize the cutting force.
    Journal of Manufacturing Processes 11/2014;
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    ABSTRACT: Prepaint sheet metals are widely used in building construction, packaging, appliance, transportation and automotive industries. Due to tooling contact, damage of polymer coating can occur during sheet metal forming processes. This paper presents an investigation of surface damage of polyvinylidene flouride (PVDF) and polypropylene (PP) coatings in various forming conditions. Strip drawing experiments were conducted to test coatings subjected to bending under tension with sliding contact. The experimental results and numerical simulations suggest that coating damage is commonly caused by low coating strength, high contact pressure, and poor lubrication. The presented experimental approach can be used to facilitate tooling design and lubricant selection in forming prepaint sheet metals.
    Journal of Manufacturing Processes 10/2014;
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    ABSTRACT: The effect of welding processes on the microstructure, residual stresses and distortion in 16 mm thick 316LN stainless steel weld joints made by TIG and A-TIG (activated flux tungsten inert gas) welding processes involving different joint configurations have been studied. The joint configurations employed were double V-groove edge preparation for double side TIG welding, square-butt preparation for double side ATIG welding and Y groove preparation for weld joint made by both TIG and ATIG welding processes. All the weld joints passed radiographic examination. Microstructural characterization was carried out using optical microscope. Residual stresses were determined using ultrasonic technique employing LCR waves, and distortion measurements were carried out using height gauge. The three weld joints exhibited different microstructures, peak tensile residual stress values and distortion. The weld joint fabricated by double side A-TIG welding exhibited the lowest peak tensile residual stress value and also minimum distortion.
    Journal of Manufacturing Processes 10/2014;
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    ABSTRACT: Electromagnetic pulse metal processing techniques (EPMPT) such as welding, forming and cutting have proven to be an effective solution to specific manufacturing problems. A high pulse magnetic field coil is a critical part of these technologies and its design is a challenging task. This paper describes a Bitter coil design using a newly developed methodology for a simplified analytical calculation of the coil and complementary finite element models (FE) of different complexity. Based on the methodology a Belgian Welding Institute (BWI) Bitter coil has been designed and tested by means of short circuit experiments, impedance and B-field measurements. A good agreement between the calculated and the experimental design parameters was found.
    Journal of Manufacturing Processes 10/2014;
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    ABSTRACT: More than 1.2 million people worldwide require regular hemodialysis therapy to treat end stage renal failure. Current hemodialysis systems are too expensive to support at-home hemodialysis where more frequent and longer duration treatment can lead to better patient outcomes. The key cost driver for hemodialysers is the cost of the hemodialysis membrane. Microchannel hemodialysers are smaller providing the potential to use significantly less membrane. Prior work has demonstrated the use of sealing bosses to form compression seals in microchannel hemodialysers. In this paper, estimates show that the percentage of the membrane utilized for mass transfer is highly dependent on the design and registration accuracy of adjacent blood and dialysate laminae. Efforts here focus on the development of a self-registration method to align polycarbonate laminae compatible with compression sealing schemes for membrane separation applications. Self-nesting registration methods were demonstrated with average registration accuracies of 11.4 ± 7.2 μm measured over a 50 mm scale. Analysis shows that the registration accuracy is constrained by tolerances in the embossing process. A dialysis test article was produced using the self-nesting registration method showing a measured average one-dimensional misregistration of 18.5 μm allowing a potential 41.4% of the membrane to be utilized for mass transfer when considering both microchannel and header regions. Mass transfer results provide evidence of a twofold to threefold increase in membrane utilization over other designs in the existing literature.
    Journal of Manufacturing Processes 10/2014;
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    ABSTRACT: The forming limit diagram (FLD) is a tool that is used by automotive engineers to assess and compare the formabilities of sheet metals. The FLD is experimentally determined by portraying the biaxial strain distribution in the plane of the sheet under proportional loading paths. However, experimental determination of the FLD is time consuming. With increasing interest in warm forming of aluminum sheets, the process for determining the forming limit diagram is further complicated and more cumbersome as the forming limits change with increasing temperatures. Accordingly, a process for predicting the FLD based on the material constitutive model is of interest. This paper presents a finite element based criterion for predicting the FLD under isothermal conditions. The paper provides experimental validation for the predicted results using select automotive 5xxx series aluminum alloys. The findings indicate that the developed criterion can adequately predict the forming limit for each strain path.
    Journal of Manufacturing Processes 09/2014;
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    ABSTRACT: A study was carried out to evaluate how the friction stir spot welding process parameters affect the temperature distribution in the welding region, the welding forces and the mechanical properties of the joints. An experimental campaign was performed by means of a CNC machine tool and FSSW lap joints on AA6060-T6 aluminum alloy plates were obtained. Five thermocouples were inserted into the samples to measure the temperatures during the tool plunging. A set of tests was carried out by varying the process parameters, namely rotational speed, axial feed rate, plunging depth and dwell time. Axial welding forces were measured during the execution of the experiments by means of a piezoelectric load cell. The mechanical properties of the joints were assessed by executing shear tests on the specimens. A correlation between process parameters and joints properties was found. The collected experimental data were also used to set up and to validate a simulative model of the process. The peculiarity of the developed FEM model is a 2D approach used for the simulation of a 3D problem, in order to guarantee a very simple and practical model able to achieve results in a very short time. The 2D FEM model, based on a specific external routine for the calculation of the developed thermal energy due to the friction between tool and workpiece, was set up using the commercial code Deform 2D. An index for the prediction of the joint shear resistance using FEM simulations was finally proposed and validated.
    Journal of Manufacturing Processes 09/2014;
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    ABSTRACT: Solar cell technology is one of the most promising sources of clean energy. However, some limitations include low efficiency, high manufacturing cost, and large consumption of material. A novel method of depositing a thin film direct bandgap semiconductor material on lightweight substrate, which would result in higher specific power (kW/kg), is explored in this work. The efficiency of such solar cells can be further increased by providing a textured surface, resulting in reduced optical losses therefore increasing light trapping. This paper reports a novel method which makes use of a mechanical instability in a soft material (polydimethylsiloxane) to make wrinkles on its surface by chemically oxidizing the surface using Piranha solution. Further, these wrinkles were arranged in order by applying external force to the soft material before chemical oxidation. Theoretical studies have been carried out and found more than 10% increase in transmittance and short circuit current if a cadmium telluride (CdTe) solar cell is to be deposited on such substrate.
    Journal of Manufacturing Processes 09/2014;
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    ABSTRACT: Effects of switching over from gas tungsten arc welding (GTAW) to pulsed current gas tungsten arc welding (PCGTAW) on the quality of joints produced in Hastelloy C-276 material were investigated. Welding was carried out both by autogenous mode and using ERNiCrMo-3 filler wire. Microstructures of weld joints produced with and without current pulsing were studied using optical and scanning electron microscopy. Microsegregation occurring in GTAW and PCGTAW joints was investigated using energy dispersive X-ray spectroscopy (EDS). Strength and ductility of weld joints produced with and without pulsing were evaluated. The results show that pulsing results in refined microstructure, reduced microsegregation and improved strength of weld joints. Secondary phase(s) noticed in GTA weldments were found to be absent in PCGTA weldments. Autogenous PCGTA weldments were found to be the best in terms of: (i) freedom from microsegregation, (ii) strength and (iii) freedom from unwanted secondary phases.
    Journal of Manufacturing Processes 09/2014;
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    ABSTRACT: Additive manufacturing is an emerging manufacturing technology that enables production of patient specific implants, today primarily out of titanium. For optimal functionality and proper integration between the titanium implant and the body tissues surface properties, such as surface oxide thickness is of particular importance, as it is primarily the surface of the material which interacts with the body. Hence, in this study the surface oxidation behavior of titanium parts manufactured by Electron Beam Melting (EBM®) is investigated using the surface sensitive techniques ToF-SIMS and AES. Oxide thicknesses comparable to those found on conventionally machined surfaces are found by both analysis techniques. However, a build height dependency is discovered for different locations of the EBM® manufactured parts due to the presence of trapped moisture in the machine and temperature gradients in the build.
    Journal of Manufacturing Processes 09/2014;
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    ABSTRACT: Attributes related to the dimensional quality of hot rolled steels are very important in commercial sectors that make direct use of this product, because delay or equipment damage can be avoided when forming in downstream operations. In this research, the steel sheet edge trimming process and its relationship with the defect known as broken edge is experimental and numerically studied. The type of material, horizontal clearance between knives and the energy spent during the cutting process are analyzed in detail. A metal-mechanical study is carried out for obtaining a microstructural hardness and flow stress characterization. Consequently, the edge trimming process is FEM simulated and its results in relation to knife penetration and shear stress lead to determining the energy spent during the cutting process. A mathematical model is determined under the consideration that minimum energy gives the optimum cutting conditions. The model proposes a reliable value for the horizontal clearance (Hc), between knives, taking as the principal factors: energy consumed during the edge trimming process, sheet thickness (Th), carbon content (C) and/or its ultimate tensile strength, expressed as: Hc = α + βTh − γC. A comparison of the recommended numerical results with the best practical conditions is carried out and a high coincidence is successfully found. This model is expected to be easily adopted as a tool where operators can adjust and control the parameters of process, and then, as a result, produce a sheet without edge trimming defects as well as a reduction in efficiency costs.
    Journal of Manufacturing Processes 08/2014;