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12 pages, 3564 KiB

Open AccessArticle

Three-Dimensional Micromechanical Modeling of Martensite Particle Size Effects on the Deformation Behavior of Dual-Phase Steels

by Onur Cavusoglu and Serkan Toros

Materials 2024, 17(20), 5004; https://doi.org/10.3390/ma17205004 - 13 Oct 2024

Viewed by 421

Abstract

The objective of this study was to examine the influence of martensite particle size on the formation of stress and strain in microstructures of dual-phase steels. In order to achieve this objective, the 3D representative volume element (RVE) method was utilized. Particle size [...] Read more.

The objective of this study was to examine the influence of martensite particle size on the formation of stress and strain in microstructures of dual-phase steels. In order to achieve this objective, the 3D representative volume element (RVE) method was utilized. Particle size distributions were obtained from the microstructures of DP600 and DP1000 dual-phase steels as they actually exist. Virtual dual-phase steel microstructures were generated according to the above distribution and subsequent validation analyses were performed. In the subsequent phase, microstructures of varying martensite particle sizes (1 µm, 1.98 µm, 3 µm for DP600 and 1.15 µm, 2 µm, 3 µm for DP1000) were formed, and the effects of particle size on deformation behavior under tensile loads were determined. The findings indicated that an increase in martensite particle size resulted in a reduction in tensile strength, accompanied by an increase in deformation amount. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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17 pages, 3315 KiB

Open AccessArticle

Application of the Gradient-Boosting with Regression Trees to Predict the Coefficient of Friction on Drawbead in Sheet Metal Forming

by Sherwan Mohammed Najm, Tomasz Trzepieciński, Salah Eddine Laouini, Marek Kowalik, Romuald Fejkiel and Rafał Kowalik

Materials 2024, 17(18), 4540; https://doi.org/10.3390/ma17184540 - 15 Sep 2024

Viewed by 670

Abstract

Correct design of the sheet metal forming process requires knowledge of the friction phenomenon occurring in various areas of the drawpiece. Additionally, the friction at the drawbead is decisive to ensure that the sheet flows in the desired direction. This article presents the [...] Read more.

Correct design of the sheet metal forming process requires knowledge of the friction phenomenon occurring in various areas of the drawpiece. Additionally, the friction at the drawbead is decisive to ensure that the sheet flows in the desired direction. This article presents the results of experimental tests enabling the determination of the coefficient of friction at the drawbead and using a specially designed tribometer. The test material was a DC04 carbon steel sheet. The tests were carried out for different orientations of the samples in relation to the sheet rolling direction, different drawbead heights, different lubrication conditions and different average roughnesses of the countersamples. According to the aim of this work, the Features Importance analysis, conducted using the Gradient-Boosted Regression Trees algorithm, was used to find the influence of several parameter features on the coefficient of friction. The advantage of gradient-boosted decision trees is their ability to analyze complex relationships in the data and protect against overfitting. Another advantage is that there is no need for prior data processing. According to the best of the authors’ knowledge, the effectiveness of gradient-boosted decision trees in analyzing the friction occurring in the drawbead in sheet metal forming has not been previously studied. To improve the accuracy of the model, five MinLeafs were applied to the regression tree, together with 500 ensembles utilized for learning the previously learned nodes, noting that the MinLeaf indicates the minimum number of leaf node observations. The least-squares-boosting technique, often known as LSBoost, is used to train a group of regression trees. Features Importance analysis has shown that the friction conditions (dry friction of lubricated conditions) had the most significant influence on the coefficient of friction, at 56.98%, followed by the drawbead height, at 23.41%, and the sample width, at 11.95%. The average surface roughness of rollers and sample orientation have the smallest impact on the value of the coefficient of friction at 6.09% and 1.57%, respectively. The dispersion and deviation observed for the testing dataset from the experimental data indicate the model’s ability to predict the values of the coefficient of friction at a coefficient of determination of R² = 0.972 and a mean-squared error of MSE = 0.000048. It was qualitatively found that in order to ensure the optimal (the lowest) coefficient of friction, it is necessary to control the friction conditions (use of lubricant) and the drawbead height. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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16 pages, 7327 KiB

Open AccessArticle

The Structural and Mechanical Properties of Al₂O₃–Ni Composites Obtained by Magnetic Field-Assisted Centrifugal Slip Casting

by Justyna Zygmuntowicz, Magdalena Kosiorek, Marcin Wachowski, Lucjan Śnieżek, Ireneusz Szachogłuchowicz, Paulina Piotrkiewicz, Waldemar Kaszuwara and Katarzyna Konopka

Materials 2024, 17(16), 3902; https://doi.org/10.3390/ma17163902 - 6 Aug 2024

Viewed by 662

Abstract

This study investigates the influence of a magnetic field on the microstructure and properties of Al₂O₃–Ni composites fabricated via centrifugal slip casting at 1500 rpm. Al₂O₃ and Ni powders were combined with water and deflocculants, homogenized, [...] Read more.

This study investigates the influence of a magnetic field on the microstructure and properties of Al₂O₃–Ni composites fabricated via centrifugal slip casting at 1500 rpm. Al₂O₃ and Ni powders were combined with water and deflocculants, homogenized, and then cast into a porous plaster mold surrounded by Nd-Fe-B magnets. The resulting composites, sintered in a reducing atmosphere, exhibited a three-zone structure with varying Ni content due to the combined effects of the magnetic field and centrifugal force. SEM, EDX, and XRD analyses confirmed the distribution and composition of the phases. Hardness tests revealed the highest values at the outermost zone, with a gradual decrease toward the inner zones. Compression tests employing digital image correlation revealed high internal stresses and a significant improvement in compressive strength compared to non-magnetic field methods. This study confirms that magnetic field-assisted centrifugal slip casting significantly enhances the structural, hardness, and compressive strength properties of Al₂O₃–Ni composites, indicating promising potential for advanced applications. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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22 pages, 2629 KiB

Open AccessArticle

Materials and Products Development Based on a Novelty Approach to Quality and Life Cycle Assessment (QLCA)

by Dominika Siwiec and Andrzej Pacana

Materials 2024, 17(15), 3859; https://doi.org/10.3390/ma17153859 - 4 Aug 2024

Viewed by 705

Abstract

The development of materials and the products made from them should respond to new challenges posed by market changes and also by climate change. Therefore, the objective of this investigation was to develop a method that supports the sustainable development of materials and [...] Read more.

The development of materials and the products made from them should respond to new challenges posed by market changes and also by climate change. Therefore, the objective of this investigation was to develop a method that supports the sustainable development of materials and the products made from them based on an aggregated indicator of quality and environmental load in the life cycle (QLCA). The testing and illustration of the QLCA method included a passenger car tyre and nine prototypes. These prototypes were described using eight quality criteria: season, class, size of the load index, speed index, rolling, adhesion, and external noise. Then, customer expectations regarding the importance of the criteria and satisfaction with the indicators in the current and modified states were obtained. Based on the customer assessment, the quality indicators of the prototypes were assessed. This assessment was supported by the weighted sum model (WSM) and the entropy method. Then, life cycle assessment for the reference tyre was performed using the Ecoinvent database in the OpenLCA program. LCA indicators were modelled for other prototypes, taking into account quality changes. As a result of the verification of the method, an aggregated QLCA indicator was estimated, based on which it was possible to select the most favourable (qualitatively and environmentally) prototype out of nine. This was the P4 prototype (QLCA = 0.57). The next position in the ranking was taken by P7 (QLCA = 0.43). The QLCA method can be used to determine the direction of development of materials and products in terms of their sustainable development. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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16 pages, 6346 KiB

Open AccessArticle

Thermo-Mechanical Numerical Simulation of Friction Stir Rotation-Assisted Single Point Incremental Forming of Commercially Pure Titanium Sheets

by Marcin Szpunar, Tomasz Trzepieciński, Robert Ostrowski, Krzysztof Żaba, Waldemar Ziaja and Maciej Motyka

Materials 2024, 17(13), 3095; https://doi.org/10.3390/ma17133095 - 24 Jun 2024

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Abstract

Single point incremental forming (SPIF) is becoming more and more widely used in the metal industry due to its high production flexibility and the possibility of obtaining larger material deformations than during conventional sheet metal forming processes. This paper presents the results of [...] Read more.

Single point incremental forming (SPIF) is becoming more and more widely used in the metal industry due to its high production flexibility and the possibility of obtaining larger material deformations than during conventional sheet metal forming processes. This paper presents the results of the numerical modeling of friction stir rotation-assisted SPIF of commercially pure 0.4 mm-thick titanium sheets. The aim of this research was to build a reliable finite element-based thermo-mechanical model of the warm forming process of titanium sheets. Finite element-based simulations were conducted in Abaqus/Explicit software (version 2019). The formability of sheet metal when forming conical cones with a slope angle of 45° was analyzed. The numerical model assumes complex thermal interactions between the forming tool, the sheet metal and the surroundings. The heat generation capability was used to heat generation caused by frictional sliding. Mesh sensitivity analysis showed that a 1 mm mesh provides the best agreement with the experimental results of total forming force (prediction error 3%). It was observed that the higher the size of finite elements (2 mm and 4 mm), the greater the fluctuation of the total forming force. The maximum temperature recorded in the contact zone using the FLIR T400 infrared camera was 157 °C, while the FE-based model predicted this value with an error of 1.3%. The thinning detected by measuring the drawpiece with the ARGUS non-contact strain measuring system and predicted by the FEM model showed a uniform thickness in the drawpiece wall zone. The FE-based model overestimated the minimum and maximum wall thicknesses by 3.7 and 5.9%, respectively. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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14 pages, 6477 KiB

Open AccessArticle

Selected Errors in Spatial Measurements of Surface Asperities

by Karol Grochalski, Dominika Podbereska, Michał Wieczorowski, Rafał Talar and Wiesław Graboń

Materials 2024, 17(12), 2918; https://doi.org/10.3390/ma17122918 - 14 Jun 2024

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Abstract

This work presents issues related to selected errors accompanying spatial measurements of surface roughness using contact profilometry. The influence of internal heat sources, such as engines or control electronics, on the thermal expansion of the drive responsible for the measurement probe’s movement in [...] Read more.

This work presents issues related to selected errors accompanying spatial measurements of surface roughness using contact profilometry. The influence of internal heat sources, such as engines or control electronics, on the thermal expansion of the drive responsible for the measurement probe’s movement in the X-axis direction was investigated. In terms of starting measurements on a thermally unstable device, the synchronization error of individual profile paths was 16.1 µm. Based on thermographic studies, the time required for full thermal stabilization of this drive was determined to be 6–12 h from when the device was turned on. It was demonstrated that thermal stabilization of the profilometer significantly reduced positioning errors of the measurement probe on the X-axis. Thermal stabilization time should be determined individually for a specific device variant. This research also determined how changes in the center of gravity caused by the measurement probe’s movement affected the overall rigidity of the profilometer structure and the leveling of the tested surface. Laser interferometry was used for this purpose. The determined vulnerability of the profilometer structure was 0.8 µm for a measurement section of 25 mm. Understanding the described relationships will reduce errors associated with conducting measurements and preparing equipment for tests. Additionally, it will enable the correct evaluation of surface geometry. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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20 pages, 11159 KiB

Open AccessArticle

Effect of Zonal Laser Texturing on Friction Reduction of Steel Elements in Lubricated Reciprocating Motion

by Slawomir Wos, Waldemar Koszela, Andrzej Dzierwa and Pawel Pawlus

Materials 2024, 17(10), 2401; https://doi.org/10.3390/ma17102401 - 16 May 2024

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Abstract

During co-action between contact elements in reciprocating motion, different working conditions exist in outer and inner zones of stationary elements. Because the tribological effects of surface texturing depend on the operating conditions, various dimple patterns were created in the middle part of the [...] Read more.

During co-action between contact elements in reciprocating motion, different working conditions exist in outer and inner zones of stationary elements. Because the tribological effects of surface texturing depend on the operating conditions, various dimple patterns were created in the middle part of the steel disc and near the reversal points. The behaviors of variable dimple patterns were compared with those of uniform texturing and untexturing. It was found that the dimple patterns in the middle disc zone depended on the resistance to motion. The best tribological behavior was obtained for a pit area ratio of 13% and diameter of 0.4 mm in the inner zone, and pit area ratio of 3% and diameter of 0.2 mm in the outer zones. Low resistance to motion and the smallest friction variation of all tested sliding pairs were achieved. For the same pit area ratio of 13% in a disc of 0.4 mm, the dimple diameter behaved better than in the 0.2 mm diameter disc. The greatest decrease in the coefficient of friction of 85% compared to untextured sliding pair was achieved for uniform laser texturing with a pit area ratio of 13% and dimple diameter of 0.4 mm, when the normal load was 40 N and frequency of displacement was 20 Hz. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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22 pages, 10485 KiB

Open AccessArticle

Optimization of 2024-T3 Aluminum Alloy Friction Stir Welding Using Random Forest, XGBoost, and MLP Machine Learning Techniques

by Piotr Myśliwiec, Andrzej Kubit and Paulina Szawara

Materials 2024, 17(7), 1452; https://doi.org/10.3390/ma17071452 - 22 Mar 2024

Cited by 4 | Viewed by 1567

Abstract

This study optimized friction stir welding (FSW) parameters for 1.6 mm thick 2024T3 aluminum alloy sheets. A 3 × 3 factorial design was employed to explore tool rotation speeds (1100 to 1300 rpm) and welding speeds (140 to 180 mm/min). Static tensile tests [...] Read more.

This study optimized friction stir welding (FSW) parameters for 1.6 mm thick 2024T3 aluminum alloy sheets. A 3 × 3 factorial design was employed to explore tool rotation speeds (1100 to 1300 rpm) and welding speeds (140 to 180 mm/min). Static tensile tests revealed the joints’ maximum strength at 87% relative to the base material. Hyperparameter optimization was conducted for machine learning (ML) models, including random forest and XGBoost, and multilayer perceptron artificial neural network (MLP-ANN) models, using grid search. Welding parameter optimization and extrapolation were then carried out, with final strength predictions analyzed using response surface methodology (RSM). The ML models achieved over 98% accuracy in parameter regression, demonstrating significant effectiveness in FSW process enhancement. Experimentally validated, optimized parameters resulted in an FSW joint efficiency of 93% relative to the base material. This outcome highlights the critical role of advanced analytical techniques in improving welding quality and efficiency. Full article

(This article belongs to the Special Issue Progressive Technologies and Materials in Mechanical and Materials Engineering)

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