Jack Jeswiet

• BSc, MSc, PhD PEng
• Professor Emeritus at Queen's University

A green chemistry hydrometallurgical process for recovering one or more metals from a metal-containing material includes leaching the metal-containing material with formic acid, obtaining a leachate comprising the one or more metals as one or more metal formates, and precipitating at least one of the one or more metal formates. The metal-containing...

Single point incremental forming is a promising sheet metal forming technique for small batch production. However, the technique is unable to manufacture vertical walls without significant thickness variation and geometrical errors. Two-point incremental forming has shown the capability to manufacture vertical walls but requires actuators and compl...

More than 60% of household energy consumption in Ontario is for heating. Home heating needs in Ontario are driven by exterior temperatures that fluctuate throughout the day. Ontario’s electricity is generated from a different mix of primary energy sources from hour to hour. Using average hourly data for the electricity generation mix and hourly out...

Incremental sheet metal forming in general and Single Point Incremental Forming (SPIF) specifically have gone through a period of intensive development with growing attention from research institutes worldwide. The result of these efforts is significant progress in the understanding of the underlying forming mechanisms and opportunities as well as...

This chapter contains sections titled: Introduction Surface Treatment Techniques Coating Operations Tribology Evolving Technologies Micro Manufacturing Conclusions

Home heating accounts for most of the residential energy use in Canada. While natural gas, oil-fired furnaces, and electric resistance are the dominant heating system choices, heat pumps have become a viable alternative. Heat pumps with lower minimum operating temperatures and better performance are increasing both their effectiveness and their num...

Donnan Dialysis uses ion exchange membranes to extract and separate cations. The driving force is provided by differences in chemical potential, rather than by electric fields or pressure. A Donnan Dialysis based process to recover lithium, nickel, cobalt, manganese, and organic acid lixiviant from recycled lithium ion battery cathodes is under dev...

The forming tool in single point incremental forming (SPIF) follows a path prescribed by CAM software. As the tool follows this path, thereby deforming the sheet, both friction and deformation occur generating heat. The effect of increasing feed rates and tool rotation speed on resulting temperatures has been studied for AA 5754-H32. A flat tool wa...

This paper proposes how to evaluate environmental impacts in a product Life Cycle Assessment at the premanufacture (mining) stage using Toward Sustainable Mining principles. The material supply chain includes a choice between either recycling or mining where mining remains the primary supplier of materials for manufactured products. Integration of...

The supply chain for metals used in manufacturing is usually from premanufacture (mining). Energy impact needs to be considered, with it being one of the five stressors that impact the environment. In this paper the energy needs for crushing and milling (comminution) are presented. A brief comparison is made with the energy needs for recycling of l...

Heat pump performance is always improving. Lower minimum operating temperatures and better performance curves are increasing both the number of hours of useful service and effectiveness while in use. We estimate the rate of technological development for residential air source heat pumps and their consequent rate of adoption using a system dynamics...

Traditional quality control of resistance spot welds by analysis of the dynamic resistance signature (DRS) relies on manual feature selection to reduce the dimensionality prior to analysis. Manually selected features of the DRS may contain information that is not directly correlated to strength, reducing the accuracy of any classification performed...

Single point incremental forming (SPIF) has higher formability limits than other sheet metal forming processes including stamping, and is therefore a desirable method of forming sheet metal components. To take advantage of this high formability it is necessary to understand how to maximise the limits through manipulation of parameters, increasing t...

Energy efficiency presents enormous opportunities for industry-reducing costs, stimulating economic growth, increasing productivity, and offering a significant reduction in environmental impact. Unfortunately, many companies-especially SMEs (small and medium enterprises)-still shy away from the opportunities that are available to them from energy c...

The product material supply chain starts with stage 1 in manufacturing. In Life Cycle Analysis (LCA) or in an SLCA (streamlined LCA) this is premanufacture. Ideally the first stage starts with recycled material, however most material comes from mining, and will do so for the foreseeable future. The first stage has five elements: material, energy, s...

A high recovery of lithium from recycled lithium ion batteries (LIBs) is essential to ensure the growth and sustainability of the electrical vehicle market. Without recycling, lithium demand is predicted to outstrip supply in 2023. Current industrial processes are focused on recovering cobalt and other valuable metals because, given lithium's curre...

This paper presents an update on single point incremental forming (SPIF) of sheet metal since 2005. It includes a description of the process with new information on the maximum forming angle, ϕmax, for 5052-H32. An in-depth example of the successful design and production of parts is given for industry. This includes discussion on production times a...

Recent publications have discussed the potential for scarcity of materials needed for future engineering designs and manufacture [1,2, 3]. In the case of a recent DOE report [1], materials needed for the production of green energy technologies were deemed as those needing study. A major conclusion of these papers is that there is a need for recycli...

One need not look further than the use of the word sustainable to realise that meaning is critical to our shared understanding of the most pertinent discussions concerning the environment. But the need for clear definitions extends to words we believe to be used correctly, and whose meaning we believe is universal. Fortunately, terminology like “Li...

The broad topic of efficiency is investigated within the context of the general manufacturing sector, which includes anything from computing and electronics to food and textile products, and consumes enormous amounts of energy in order to generate the goods and services we use today. This is unsurprising as it stands to reason that in order to oper...

Improving the energy efficiency of industrial processes and the facilities in which they are carried out is often considered to be one of the most promising ways to begin reducing global greenhouse gas emissions. One of the best ways for organizations to reduce their energy consumption without having to carry out extensive equipment and facility ov...

In this article, large direct current is applied through the tool to improve formability while forming 6061-T6 Al using single-point incremental forming. Special attention is paid to the direct effect of current density, as opposed to bulk resistive heating, to determine whether the electroplastic effect is significant in raising the formability wi...

Because the deformation within single-point incremental forming occurs in a small region around the area of contact, understanding the size and shape of the contact patch is useful to model process conditions. The following presents a new model of contact geometry, wherein contact geometry is derived from the intersection of the tool with the regio...

Single-point incremental forming is a sheet metal forming technique with great potential for use in prototyping and custom manufacture. While this process has undergone considerable development in recent years, designers may benefit from clear design rules to guide the process of designing for and implementing single-point incremental forming. This...

An automotive engine cradle supports many crucial components and systems, such as an engine, transmission, and suspension. Important performance measures for the design of an engine cradle include stiffness, natural frequency, and durability, while minimizing weight is of primary concern. This paper presents an effective and efficient methodology f...

In metal powder compaction, density nonuniformity can be a source of flaws. Material models in finite element analysis for the prediction of density distribution still lack robustness and are computationally expensive. In this work, the Drucker–Prager cap (DPC) material model is implemented into the commercial finite element (FE) software ABAQUS/Ex...

To improve the forming limits and expand the range of potential applications of SPIF, testing was performed on a variety of tool heads, with emphasis on non-standard tool profiles. Two head types have been investigated using a custom 2.5° step curve frustum. The results have been compared to standard hemispherical and flat-bottomed tools. Hemispher...

The LCA of sheet metal forming processes is lacking in studies of sustainability issues and quantification of energy and carbon dioxide (CO2) emissions. This paper summarizes an investigation of the relationship between technical parameters in single point incremental forming (SPIF) and energy use. Using a life cycle analysis (LCA) approach, the as...

The designer is faced often with questions of material selection. To answer these, functional requirements must always be met, and second the cost constraints of the project must not be exceeded, and preferably they are minimized. Sadly, once the functional requirements are met, and the costs minimized, the selection process usually ends. By taking...

This paper aims to provide a systematic overview of the state of the art in energy and resource efficiency increasing methods and techniques in the domain of discrete part manufacturing, with attention for the effectiveness of the available options. For this purpose a structured approach, distinguishing different system scale levels, is applied: st...

In this paper, an initial analysis of cost, energy and carbon dioxide (CO2) emissions that occur in producing a unique aluminium hat using single point incremental forming (SPIF) for two scenarios is performed. The aluminium hat was custom designed and made from Al-3003 O and is formed using a custom steel alloy SPIF tool and vertical computer nume...

The coefficient of friction of three environmentally benign lubricants are tested using two experimental methods, the Ring Test and the bulk upsetting, using a variety of materials and two platen surface finishes. The lubricants tested are methyl esters of: palm oil, used cooking oil (canola) and mineral oil. Extensive testing has been done with re...

This paper demonstrates the use of a new economic model for optimum machining parameter selection in a milling example. In comparison to a recent CIRP paper by the authors, this paper has extensive new data for a more complex part and includes optimization. The example entails acquiring input data for the milling of a sprocket for various speeds an...

Single Point Incremental Forming (SPIF) is a dieless sheet metal forming technique that allows users to form complex asymmetrical shapes without specialized tooling. SPIF uses generalized tools to form complex shapes based on toolpath, rather than tool geometry as seen in stamping. Energy consumption in manufacturing is becoming increasingly import...

In this paper, we propose a machining microeconomic model that can optimize machining parameters and include all energy and environmental costs. A survey of microeconomic machining cost models is covered, with the result that a new cost model has been developed based on life cycle analysis (LCA) methodology. The scope includes the initial part prod...

Effects of forming at high feed rates and tool rotational speeds were studied and analyzed in single point incremental forming (SPIF). Parts formed were examined on the following criteria: external non-contact surface roughness (orange peel effect), thickness distribution and sectional microstructure. Ra and Rz roughness and forming parameters were...

This is a study about the use of compressed air, the energy consumed and the CO2 emitted in two manufacturing facilities connected to a local power grid. Compressed air systems are common to most industries, hence this was chosen for observation of carbon emitted and how this could be part of the reduction of carbon emissions and to achieve carbon...

In future markets, which use either carbon tax or cap and trade, manufacturers will need to estimate their carbon emissions, hence this paper analyzes sites that estimate CO2 output. This comprehensive survey of carbon footprint calculators shows there does not appear to be a standard method for CO2 emission calculations. Initially, 54 websites wer...

This paper optimizes a common metal forming process (upset forming) with respect to: 1) the process; 2) reduction of CO2 emissions; 3) environmentally benign lubricants (palm oil ester and used cooking oil ester). The emphasis is on optimization of these three parameters, with respect to minimizing CO2 emissions, which is not commonly done in manuf...

In recent years, studies into dieless formed sheet surface features, internal roughness due to direct tool contact, and external roughness from indirect contact have been numerous. Much focus has been given to the internal surface finish of SPIF parts, particularly on how to better control the finish by changing forming parameters. Studies by Ham h...

We developed a material user-subroutine in commercial finite element (FE) package ABAQUS/EXPLICIT for the Drucker-Prager Cap material model. Two techniques to improve the stability and one to improve the computational efficiency were proposed and proven to be successful. To improve stability (1) an iterative technique to determine the increment siz...

A Carbon Emission Signature (CES) and a Carbon Emission Label have been proposed for manufactured products in previous CIRP (Collège International pour la Recherche en Productique) annals. This paper considers two things: (1) an example of a CES calculation for assembly with CO2 emissions and (2) the need for a transparent method of calculation. In...

In order to alleviate production costs and increase the environmental performance of solar photovoltaic manufacturing, an eco-industrial park for GW-scale production of PV is proposed. This article quantifies the inputs and outputs for the glass manufacturing component of such a system using standard manufacturing techniques. Utilizing industrial s...

Metal powder compaction and its FE analysis have gained enormous attention in the last decade, especially in automotive gear manufacture. However, no specific material model has been accepted as the standard for metal powders. This paper is an effort to study various material models in different geometries. Two case studies were modeled using ABAQU...

Research was conducted to determine whether parts formed using Single Point Incremental Forming (SPIF) could be distinguished from each other with regard to surface roughness. Each part was formed by perturbing the two forming parameters that are thought to significantly influence roughness, tool size and step size. The surfaces were measured using...

The manufacturing of a product is connected directly to the amount of carbon emitted in producing electrical energy for that manufacturing process. A new, simple Carbon Emission Signature, CES™, is proposed. Knowing the CES for a power grid and the energy needed to make a part, the carbon emitted can be found. Examples of single point turning and o...

Considerable changes have occurred in metal forming in the last decade. A record of these changes can be found in keynote papers presented by the members of the Scientific Technical Committee—Forming, at the CIRP Annual General Meeting each year. The keynote papers are excellent references on important developments in metal forming and are used as...

Traditional sheet metal forming requires expensive dedicated dies, both positive and negative dies, where each die mimics one side of the desired part. Modern manufacturing industry strives to be flexible and to respond to customer needs. This trend toward flexibility requires new sheet metal forming methods. One method is Single Point Incremental...

This paper has three sections: Part I, Green House Gas emissions and environmental impacts as driven by the market; Part II, Design for Environment (DfE), designing to reduce environmental impacts with a set of rules for DfE; and Part III, toxic substances to be avoided in design. All three parts must be addressed by the EcoDesigner in any design s...

Dimensional Accuracy of Single Point Incremental Forming (SPIF) is studied with the use of a Box-Behnken design analysis. The dimensional accuracy of this process is determined by comparing parts manufactured using SPIF with the part drawings used to create the manufacturing toolpaths. Five factors are varied in the manufacturing of the SPIF proces...

In an experimental study of laser sheet bending, a 160 W diode laser is used for two-dimensional sheet bending of low-carbon steel. The variables investigated include metal sheet thickness, laser scan speed, laser power, laser beam width, and laser scan pass number. Bend surface appearances are also analysed. The laser sheet bend results demonstrat...

Using industrial partner experimental data for powder metal compaction, a Finite Element Analysis (FEA) model has been developed for the ejection phase of green parts in the powder metallurgy process. This paper describes development of that model which will be used by industry. The model will provide engineers with the opportunity to study the fri...

New experimental data is presented on Forming Limits in Single Point Incremental Forming (SPIF), which is a sheet metal forming process which does not require dies. A Box-Behnken Design of Experiment is used to develop the experimental plan and analyze data. In former work, the most critical factors affecting Single Point Incremental Forming were f...

Forces are measured in Single Point Incremental Forming with a spindle mounted sensor. Results for AA3003 aluminum cones and pyramids are shown. Forces are measured for parts with a 75° forming angle, at which shear cracks are expected to occur. Forces in the three directions are measured on the spindle with force spikes being observed when the too...

Single Point Incremental Forming (SPIF) is a new method of forming sheet metal for which not all forming limits and forming parameters are yet completely understood. In this paper, a Box-Behnken design of experiment (DOE) is used to execute an experimental study used to determine the forming limits in Single Point Incremental Forming (SPIF). The Bo...

There is a need to create an awareness of Life Cycle Engineering and EcoDesign in Engineering students. Topics covered in an LCE/EcoDesign course will create an awareness of environmental impacts, especially in other design course projects. This paper suggests that an awareness of product impact upon the environment must be created at an early stag...

Single Point Incremental Forming (SPIF) is a modern method of forming sheet metal, where parts can be formed without the use of dedicated dies. The ability of SPIF to form a part is based on various forming parameters. Previous work was not accomplished with the help of design of experiments, thus reducing the number of parameters varied at any tim...

Friction at the workpiece-die boundary, in both bulk forming and sheet forming is, arguably, the single most important physical parameter influencing the processing of metals; yet it remains the least understood. Hence there is a need for basic research into metal-die interface mechanisms. To gain a good understanding of the mechanisms at the inter...

Life Cycle Engineering (LCE) is a label used to describe Environmental Engineering in the areas of Design Engineering and Production Engineering. In our changing society it is important to introduce LCE to all young engineering students at an early stage. This paper presents reasons for the need to do this in the first year of university education....

This paper describes the relation between EcoDesign and Life Cycle Engineering; both include Product Engineering as a focal point. Product Engineering includes both Product Design and Manufacture, two fields which are changing quickly. In addition, this paper shows where future changes can be expected in Life Cycle Engineering and EcoDesign.

The paper reviews the current state of Life Cycle Assessment (LCA) introducing the central elements of the methodology and the latest developments in assessment of the environmental, economic and social impacts along the product chain. The central role of LCA in Integrated Product Policy (IPP) is substantiated describing the different tools of the...

The use of computers in manufacturing has enabled the development of several new sheet metal forming processes, which are based upon older technologies. This paper describes modifications that have been made to traditional forming methods such as conventional spinning and shear forming, forming processes in which deformation is localized. Recent ad...

The use of computers in manufacturing has enabled the development of several new sheet metal forming processes. This paper describes modifications that have been made to traditional forming methods such as conventional spinning and shear forming, where deformation is localized. Recent advances have enabled this localized deformation to be accuratel...

Forces have been measured in Two Point Incremental Forming and Single Point Incremental Forming of Sheet Metal. It is necessary to know the magnitude of these forces when trying to determine if the equipment available is capable of Forming Sheet Metal by either one of the two foregoing processes. The magnitude of forces is also needed when developi...

Single Point Incremental Forming is a new process, which has been developed to make both Rapid Prototyped products and low volume product batches from Sheet Metal. This paper presents a case study of the manufacture of a solar cooker cavity for developing country applications. In the first instance the request was for a rapid prototype, which quick...

Although not standard, Forming Limit Diagrams, FLD’s, are used throughout the automotive industry as a preliminary tool to determine if a sheet metal forming process is capable of forming a good part. FLD’s show a limited range of strains on the diagram; typically the range is 0 to 1 on the major strain axis. A new rapid prototyping process called...

The single-point incremental forming (SPIF) process is described. The maximum draw angle for SPIF is defined and specific values are given for 3003-0 and 5754-0 aluminium. Forming limit diagrams (FLDs) are developed for incremental forming of aluminium sheet, using SPIE Five distinct shapes are used to define the forming limits: a hemisphere, a str...

Forces have been measured in Single Point Incremental Forming of Sheet Metal. It is necessary to know the magnitude of these forces when trying to determine if the equipment available is capable of making parts with the Single Point Incremental Forming process. The magnitude of forces is also needed for developing appropriate models for the new SPI...

Sometimes, products resulting from design for environment (DFE) endeavours are sub-optimisations from an environmental perspective, because the tool determines the process and not vice versa. For a more systematic way of getting the focus right a hierarchy of focusing is introduced:1. What is the function provided and what is the optimal way of pro...

Single-point incremental forming is an innovative sheet metal forming method employing a standard computer numerical controlled (CNC) vertical milling machine and basic tooling. Traditionally the part is formed with a single-pass tool-path technique. A double-pass technique has been proposed as a way to modify the final thickness profile of steep g...

Surface roughness tests were performed on computer numerical controlled (CNC) incrementally formed sheet metal parts using various tool depth increments and spindle speeds. A non-contact method using white light interferometry was selected to avoid scratching the material surface. All parts were formed from annealed Al 3003 sheet to a shape with a...

Neutron diffraction has been used to determine the residual stresses in the weld region of laser-welded tailor-welded blank (TWB) samples. Residual stresses in same gauge and differential gauge TWB samples are examined in the as-welded condition as well as after uniaxial loading to 0.5, 3.0 and 7.0% strain. Results indicate that stress distribution...

The change in material properties for annealed Al 3003 after computer numerical control (CNC) incremental forming was studied through a series of tensile tests. Specific shapes were designed with wall angles of 20-60degrees, in 10degrees increments, to allow for removal of flat specimens of adequate size. A relationship was found, with plots of str...

This paper describes a system for on-line adjustment of the cutting conditions in a turning operation. Cutting conditions are set based on an adaptive model of the cutting operation taking into consideration the gradual wear of the tool. The objective is to control the rough turning operation for a predetermined tool life under varying cutting cond...

The advances made in Rapid Prototyping of non-uniform shapes from sheet metal using CNC Single Point Incremental Forming are discussed. The variety of complex parts for which Rapid Prototypes have been made from sheet metal are presented. Results of tests for maximum draw angle and strain hardening of Aluminum 3003 with increasing draw angle are al...

The use of computers in manufacturing has enabled the development of several new metal forming processes that are based upon older technologies. In this case modifications have been made to traditional forming methods such as conventional spinning and shear forming. These two processes are similar in that the deformation mechanism is localized to a...

Manufacturers of medical devices are held to a higher standard than manufacturers of many other products due to the potential severity of the consequences of introducing inferior or unsafe products to the market-place. In Canada, the medical device industry is regulated by Health Canada under the Medical Device Regulations of the Food and Drug Act....

The forming parameters for incremental forming of aluminium. alloy 3003 sheet are presented. Using two shapes for testing (a conical shape and a pyramid shape) and forming the sheet to various draft angles, the following data have been assembled: tensile tests, strain measurements, strength coefficient K and strain-hardening exponent n. The method...

A new design of friction sensor, intended for use in industrial process applications, such as metal forming, has been developed. The sensor consists of a diaphragm whose outer surface is flush with the surface of the tool and whose inner surface is instrumented with strain gauges. Relative to previous sensor designs, this sensor offers reduced dist...

A method for measuring the properties of laser weld metal in tailor welded automotive blanks is assessed. Tensile specimens in which the weld lies parallel to the axis of tension are pulled to failure and the weld metal properties are determined usingrule of mixtures'' type of calculation. Experiments are performed using two sets of similar gage we...

The use of tailored blanks by the automotive industry is a fact. New applications that use tailored blanks and improvements on existing uses are continuously being created. In order to get the most out of all the advantages of tailored blanks in the quickest and most cost effective manner an understanding of the weld and its behaviour under forming...

The process of single point incremental micro-plastic forming is presented. This process is used to form sheet metal into complicated shapes without the use of either a male or female die. The process uses a single point tool which plastically deforms sheet metal to give a local micro-deformation. By doing this incrementally, and controlling the to...

A fiber optic sensor system is described for non-contact measurement of surface texture. The sensor employs a fiber optic guide and lens arrangement that forms an interferometric cavity between the lens front face and the surface. Changes in the surface topography are manifested as phase changes between the light reflected from the surface and the...

This paper describes a real-time tool condition monitoring system for turning operations. The system uses a combination of static and dynamic neural networks with off-line and on-line training and cutting force components are used as diagnostic signals. The system is capable of monitoring several wear components simultaneously. The wear estimation...

In this paper, the problem of curl in flat rolling is reviewed. A simple method of quantifying curl is described and experimental results are presented. A simulation of curl is also performed using off-the-shelf metal forming software. Using the experimental results, a value called the curl number is obtained. Experiments were run to verify the sim...

This paper describes a the improvement of process where a lubrication system had been designed in an era when environmental regulations were more lax and did not require sophisticated methods of feeding lubricant to the work, in short when "tin can" lubrication methods were adequate. The particular process is pilger rolling and before the improveme...

A sensor which uses strain gauges mounted on a conical cantilever sensing element, has been designed to measure the three forces of interest at the roll/strip interface, namely the normal force, the friction force in the rolling direction and the friction force in the direction transverse to rolling. Successful experiments have been conducted with...

In this paper, a neural network based system for 'on-line' estimation of tool wear in turning operations is introduced. The system monitors the cutting force components and extracts the tool wear information from the changes occurring over the cutting process. A hierarchical structure using multilayered feedforward static and dynamic neural network...

A collaborative work is initiated by the TU Berlin, called Global Production Engineering, which is supported financially by DAAD. The program has the teaching of life cycle assessment (LCA) as one of its primary objectives. This is an important course because of environmental considerations, especially for engineers in the Far East, which is develo...