Journal of Materials Processing Technology

Publications in this journal

• Article: Modeling of velocity-dependent chip flow angle and experimental analysis when machining 304L austenitic stainless steel with groove coated-carbide tools

  F. Koné, C. Czarnota, B. Haddag, M. Nouari
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  ABSTRACT: This paper presents an analysis of experimental cutting forces and the study of the chip flow angle when machining 304L austenitic steel with a groove coated tool under dry condition. Experiments were conducted on a wide range of cutting conditions with a particular attention to ensure a great confidence in the obtained results. A detailed analysis of experimental cutting forces and the identification of empirical cutting force equations similar to that usually used for flat tools are proposed. The main focus of this work is on the study of chip flow angle deduced here from experimental cutting forces, considering that the chip flow direction is collinear to the friction force. From a comparison between experiments and two often used approaches, it appears that the experimental chip flow angle estimation, based on neglecting the complex tool geometry and adopting a zero rake angle, is bounded by the two considered modelings that renders useful the proposed study. From experiments it is also observed an increase of the chip flow angle as the cutting velocity is increased. A velocity-dependent modeling with two distinct strategies of identification is then proposed in order to capture the cutting velocity effect on the chip flow angle.
  Journal of Materials Processing Technology 01/2013;
• Article: Contact conditions on nugget development during resistance spot welding of Zn coated steel sheets using rounded tip electrodes

  R. Raoelison, A. Fuentes, Ph. Rogeon, P. Carré, T. Loulou, D. Carron, F. Dechalotte
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  ABSTRACT: This paper investigates the influence of coating on the nugget development during resistance spot welding of Zn coated steel sheets using rounded tip electrodes. The study relies on an experimental observation of zinc behaviour coupled with a numerical Electro-Thermo-Metallurgical–Mechanical analysis. The electro-thermal contact surface enlargement due to zinc ejection at sheet/sheet and electrode/sheet interfaces is found to have a negligible effect on the nugget development. The numerical analysis shows that the dispersion on the efficient weld size, attributable to the zinc effect, is below 10%.
  Journal of Materials Processing Technology 08/2012; Volume 212,(Issue 8, August 2012,):Pages 1663-1669.
• Article: A Scientific Application Oriented Classification for Metal Transfer Modes in GMA Welding

  SCOTTI, PONOMAREV, LUCAS
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  ABSTRACT: In this work, metal transfer in solid wire GMA welding was studied. Several experiments with different combinations of gas-wire-parameters were carried out to observe metal transfer and to characterize the various transfer modes. A laser shadograph system with synchronized electrical signals and high speed filming were used. New modes were observed and their particular characteristics described for completeness. A classification for metal transfer, oriented to scientific personnel (researchers, scholars and students), is proposed, in which the modes are independent of the type of shielding gas or welding power source.
  Journal of Materials Processing Technology 06/2012; 212(6):1406-1413.
• Article: Effects of superimposed high-frequency vibration on deformation of aluminum in micro/meso-scale upsetting

  Zhehe Yao, Gap-Yong Kim, LeAnn Faidley, Qingze Zou, Deqing Mei, Zichen Chen
  Journal of Materials Processing Technology 01/2012; 212:640-646.
• Article: Porous structures fabrication by continuous and pulsed laser metal deposition for biomedical applications: modelling and experimental investigation

  M N Ahsan, C P Paul, L M Kukreja, A J Pinkerton
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  ABSTRACT: The use of porous surface structures is gaining popularity in biomedical implant manufacture due to its ability to promote increased osseointegration and cell proliferation. Laser direct metaldeposition (LDMD) is a rapid manufacturing technique capable of producing such a structure. In this work LDMD with a diode laser in continuous mode and with a CO2laser in pulsed modes are used to produce multi-layer porousstructures. Gas-atomized Ti–6Al–4V and 316L stainless steel powders are used as the deposition material. The porousstructures are compared with respect to their internal geometry, pore size, and part density using a range of techniques including micro-tomography. Results show that the two methods produce radically different internal structures, but in both cases a range of part densities can be produced by varying process parameters such as laser power and powder mass flow rate. Prudent selection of these parameters allows the interconnected pores that are considered most suitable for promoting osseointegration to be obtained. Analytical models of the processes are also developed by using Wolfram Mathematica software to solve interacting, transient heat, temperature and mass flow models. Measured and modelled results are compared and show good agreement.
  Journal of Materials Processing Technology 04/2011; 211(4):602-609.
• Article: Influence of shallow and deep cryogenic treatment on the residual state of stress of 4140 steel

  D Senthilkumar, I Rajendran, M Pellizzari, Juha Siiriainen
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  ABSTRACT: The present research work studies the effect of cryogenic treatment on the residual stress state in 4140 steel. Two kinds of cryogenic treatment, namely shallow (SCT, −80 °C × 5 h) and deep cryogenic treatment (DCT, −196 °C × 24 h) were carried out between quenching and tempering in conventional heat treatment process. The results evidenced an increase in the compressive residual stress in steel are subjected to cryogenic treatment before tempering. X-ray diffractometry revealed that residual stresses are relieved during tempering, according to the redistribution of carbon in martensite and the precipitation of transition carbides. While conventional heat treatment (CHT) and shallow cryogenic treatment (SCT) promote a tensile state of residual stress, DCT shows a compressive residual stress.
  Journal of Materials Processing Technology 03/2011; 211(3):396-401.
• Source

  Available from: elsevierscitech.com

  Article: Slip-line field model of micro-cutting process with round tool edge effect

  Xiaoliang Jin, Yusuf Altintas
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  ABSTRACT: Journal of Materials Processing Technology j o u r n a l h o m e p a g e : w w w . e l s e v i e r . c o m / l o c a t e / j m a t p r o t e c a b s t r a c t This paper presents a slip-line field model which considers the stress variation in the material deformation region due to the tool edge radius effect. The Johnson–Cook constitutive model is applied to obtain the shear flow stress and hydrostatic pressure as functions of strain, strain-rate, and temperature in the primary shear zone. The friction parameters between the rake face and chip are identified from cutting tests. The sticking and sliding contact zones between the tool and chip are considered in the secondary shear zone. The total cutting forces are evaluated by integrating the forces along the entire chip-rake face contact zone and the ploughing force caused by the round edge. The proposed model is experimentally verified by a series of cutting force measurements conducted during micro-turning tests. Micro-cutting process is analyzed from a series of slip-line field simulations.
  Journal of Materials Processing Technology 01/2011; 211:339-355.
• Source

  Available from: metalmanu.com

  Article: A wire cutting test to check the temperature distribution in inductively heated cylindrical aluminium billets at semi-solid material state

  K.-D Bouzakis, A Tsouknidas, G Maliaris
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  ABSTRACT: Journal of Materials Processing Technology j o u r n a l h o m e p a g e : w w w . e l s e v i e r . c o m / l o c a t e / j m a t p r o t e c a b s t r a c t A fast test has been developed to evaluate the homogeneity of the temperature field within aluminium cylindrical billets heated up to their semi-solid state. This method is based on the evaluation of force measurements during cutting of the heated specimens by a thin wire, considering that the shear stress of thixo-tropic Al-alloys is significantly deteriorated at thixo temperatures. The obtained results were explained by FEM supported calculations of the occurring thermal field within the billet. Moreover, the measured cutting forces versus the wire displacement were verified by a FEM based simulation of the introduced test. The developed method enables a fast assessment of the specimen heating uniformity and contributes to an undisturbed conduct of semi-solid high-pressure die casting.
  Journal of Materials Processing Technology 01/2010; 210:166-173.
• Article: Acceleration of groove formation in silicon using catalytic wire electrodes for development of a slicing technique

  MOHAMED SHAKER SALEM ; LEE Chia-Lung ; IKEDA Shigeru ; MATSUMURA Michio
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  ABSTRACT: A novel electrochemical technique for silicon slicing in which anodic potential is applied to a platinum wire, keeping it in contact with silicon, is proposed. Since silicon was dissolved in a solution containing hydrogen fluoride at the site of contact with the platinum wire electrode, a goove was formed in the silicon. The grooving speed depended on the concentration of hydrogen fluoride and additives in the solution. A grooving speed of 0.85 mm/h was obtained at room temperature using an electrolyte composed of 30wt% hydrofluoric acid, 1 mM iodine, and 0.03 vol% glycerol. Iodine acted as a catalyst for the oxidaton of silicon, and glycerol prevented the filling of grooves with gases. Further increase in grooving speed to 1.0 mm/h was achieved by applying pulsed potentials oscillating between 1 and 2 V vs. Ag/AgCl in the same electrolyte.
  Journal of Materials Processing Technology 01/2010; 210:330.
• Source

  Available from: korea.ac.kr

  Article: Numerical simulations of capillary spreading of a particle-laden droplet on a solid surface

  Jun Hyun, Jeong, Ryol Wook, Hwang, Chongyoup Kim, See Jo Kim
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  ABSTRACT: Journal of Materials Processing Technology j o u r n a l h o m e p a g e : w w w . e l s e v i e r . c o m / l o c a t e / j m a t p r o t e c a b s t r a c t We present a direct numerical simulation technique and some results for the capillary spreading of a particulate droplet on a solid surface which is of great importance in the industrial inkjet printing tech-nology as an alternative to the conventional lithography process for precise particle delivery. Since the spreading of particulate droplets is quite complicated in nature, the present work focuses on 2D capillary spreading behavior with full consideration of hydrodynamic interactions as a preliminary study for the particle effect on spreading. To understand the micro-structural phenomena underlying the process, we present a finite-element based computational scheme by combining the level-set method for an accurate interface description with the interfacial tension and the equilibrium contact angle, and the fictitious-domain method for suspended particles with implicit treatment of the hydrodynamic interactions. We investigated droplet spreading by capillary force in a Newtonian fluid and discussed effects of the pres-ence of particles on the spreading behavior along with the particle movement. The amount of spread of a particulate droplet appears smaller than that of a homogeneous fluid droplet during the spread process and this reduced rate of spreading has been interpreted the results in conjunction with the distribution of the shear rate, the angular velocity of particles, and the kinetic energy.
  Journal of Materials Processing Technology 01/2010; 210:297-305.
• Article: A. Karrech, A. C. Seibi, “Analytical Model for the Expansion of Tubes under Tension,” Journal of Materials Processing Technology, Vol. 210, 2010, pp: 356 – 362.

  A. Karrech, A. C. Seibi
  Journal of Materials Processing Technology 01/2010; 210:356-362.
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  Available from: elsevierscitech.com

  Article: Selective Laser Melting of thin wall parts using pulse shaping

  K A Mumtaz, N Hopkinson
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  ABSTRACT: Journal of Materials Processing Technology j o u r n a l h o m e p a g e : w w w . e l s e v i e r . c o m / l o c a t e / j m a t p r o t e c a b s t r a c t Pulse shaping is a technique used to temporally distribute energy within a single laser pulse. This provides the user an added degree of control over the heat delivered to the laser material interaction zone. Pulses that induce a gradual heating or a prolonged cooling effect can be generated with peak power/pulse energy combinations specifically tailored to control melt pool properties and eventual part formation. This investigation used a pulsed 550 W Nd:YAG laser to produce thin wall Inconel 625 ® parts using pulse shapes that delivered a variety of different energy distributions. Parts built with and without pulse shape control were measured for width, top and side surface roughness. The efficacy of pulse shaping control is discussed including potential benefits for use within the Selective Laser Melting process. Pulse shaping was shown to reduce spatter ejection during processing, improve the top surface roughness of parts and minimise melt pool width.
  Journal of Materials Processing Technology 01/2010; 210:279-287.
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  Available from: forging.org

  Article: Effect of forging strain rate and deformation temperature on the mechanical properties of warm-worked 304L stainless steel

  N T Switzner, C J Van Tyne, M C Mataya
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  ABSTRACT: Journal of Materials Processing Technology j o u r n a l h o m e p a g e : w w w . e l s e v i e r . c o m / l o c a t e / j m a t p r o t e c a b s t r a c t Stainless steel 304L forgings were produced with four different types of production forging equipment – hydraulic press, mechanical press, screw press, and high-energy rate forging (HERF). Each machine imparted a different nominal strain rate during the deformation. The final forgings were done at the warm working (low hot working) temperatures of 816 • C, 843 • C, and 871 • C. The objectives of the study were to characterize and understand the effect of industrial strain rates (i.e. processing equipment), and deformation temperature on the mechanical properties for the final component. Some of the compo-nents were produced with an anneal prior to the final forging while others were deformed without the anneal. The results indicate that lower strain rates produced lower strength and higher ductility com-ponents, but the lower strain rate processes were more sensitive to deformation temperature variation and resulted in more within-part property variation. The highest strain rate process, HERF, resulted in slightly lower yield strength due to internal heating. Lower processing temperatures increased strength, decreased ductility but decreased within-part property variation. The anneal prior to the final forging produced a decrease in strength, a small increase in ductility, and a small decrease of within-part property variation.
  Journal of Materials Processing Technology 01/2010; 210:998-1007.