Search Results (7)

A new manufacturing process has been developed that involves drawing circular sheets of thin metal through a conical die to create square cups. This technique produces deep square cups with a height-to-punch-side length ratio of approximately 2, as well as high dimensional accuracy and a nearly uniform height. The study investigated how various factors, including the sheet material properties and process geometric parameters, affect the limiting drawing ratio (LDR). The researchers used finite element analysis to determine the optimal die design for achieving a high LDR and found that the proposed technique is advantageous for producing long square cups with high dimensional accuracy. Full article

The competition among sheet-metal-forming manufacturers in recent years has become more severe. Many manufacturers have survived by cutting their production costs. Increasing the formability, which could reduce the production costs, is the focus of many manufacturers and engineers. In the present research, to increase the formability over the limiting drawing ratio (LDR) in the cylindrical deep-drawing process, the application of oleophobic coating is proposed. An SUS304 (JIS standard)-stainless-steel cylindrical deep-drawn component was used as the investigated model. First, we applied the oleophobic coating in the sheet-metal-forming process, and tribology tests were carried out to examine the friction coefficients, which were reduced by approximately 60% compared with those of standard lubricant use (Iloform TDN81). Next, deep-drawing tests were performed to investigate the drawing ratio (DR). The LDR recommended in the past could be overcome, and it increased by approximately 12% with the oleophobic coating use. Finally, the deep-drawing mechanism using an extremely low friction coefficient was clarified as well. Based on these results, an oleophobic coating could be applied in the cylindrical deep-drawing process to increase the LDR. The results also clearly expose the multidisciplinary approach that combines an oleophobic coating application and the sheet-metal-forming process. Full article

The liner of a compressed natural gas pressure vessel is manufactured by D.D.I. (deep drawing and ironing), which is a continuous process that uses deep drawing to reduce the diameter of a billet and ironing to reduce the thickness of the billet. In the second stage of the existing D.D.I. process, drawing and two steps of ironing have been performed separately with different dies, which requires a long processing time, high manufacturing cost, and installation space. To solve the above problems, this study suggests a new second stage using a combined redrawing-ironing die. A theoretical formula to calculate the forming load of the combined redrawing-ironing process was established and verified with finite element analysis results. The forming load, maximum thickness reduction ratio in the second stage, and forming defects in the third stage were analyzed by varying the redrawing-ironing ratio in the second stage. The results show that the number of dyes (3 → 1), punch diameter (394.1 mm → 383 mm), and processing time (39.8 s → 20 s) in the second stage were obtained to save production time and cost. Full article

Ti/Al multilayered composites (LMCs) with different layers were prepared by hot-pressing and hot-rolling. The effects of interface on the deep drawability of LMCs were explored. The results indicate that LMCs with more layers have a higher limit-drawing ratio (LDR) and exhibit an excellent deep drawability. The texture strength of the Ti layer gradually weakens with the increase of layers, which leads to the smaller yield ratio (σ_s/σ_b), the plastic strain ratio (r), and the larger strain hardening index (n), thus the deep drawability of LMCs with more layers is enhanced effectively. The Ti/Al interfaces in three, five, and seven layers of LMCs exhibit straight, small wave-like interlocking, and dense serrated structures at the corner of the cylindrical parts, respectively. The component metals become thinner with the increase of layers, and the increased interfacial pressure promotes the formation of an increasingly firm overlapped interfacial structure. The load transfer via the interfaces makes the stress distribution between layers more uniform with the increase of layers, which helps to coordinate deformation. Deflection and tearing occur when the cracks propagate to the interface due to the complex stress state, which hinders and delays the crack penetration, thereby improving the deep drawability of LMCs with more layers. Full article

The facile wet-chemical technique was used to prepare the low-dimensional nano-formulated porous mixed metal oxide nanomaterials (CuO.Mn₂O₃.NiO; CMNO NMs) in an alkaline medium at low temperature. Detailed structural, morphological, crystalline, and functional characterization of CMNO NMs were performed by X-ray photoelectron spectroscopy (XPS), powder X-ray diffraction (XRD), ultraviolet-visible spectroscopy (UV-vis), Fourier-transform infrared spectroscopy (FTIR), field emission scanning electron microscopy (FESEM), and energy-dispersive X-ray spectroscopy (EDS) analyses. An efficient and selective creatine (CA) sensor probe was fabricated by using CMNO NMs decorated onto glassy carbon electrode (GCE) as CMNO NMs/GCE by using Nafion adhesive (5% suspension in ethanol). The relation of current versus the concentration of CA was plotted to draw a calibration curve of the CMNO NMs/GCE sensor probe, which was found to have a very linear value (r² = 0.9995) over a large dynamic range (LDR: 0.1 nM~0.1 mM) for selective CA detection. The slope of LDR by considering the active surface area of GCE (0.0316 cm²) was applied to estimate the sensor sensitivity (14.6308 µAµM⁻¹ cm⁻²). Moreover, the detection limit (21.63 ± 0.05 pM) of CMNO MNs modified GCE was calculated from the signal/noise (S/N) ratio at 3. As a CA sensor probe, it exhibited long-term stability, good reproducibility, and fast response time in the detection of CA by electrochemical approach. Therefore, this research technique is introduced as a promising platform to develop an efficient sensor probe for cancer metabolic biomarker by using nano-formulated mixed metal oxides for biochemical as well as biomedical research for the safety of health care fields. Full article

As a major sheet metal process for fabricating cup or box shapes, the deep drawing process is commonly applied in various industrial fields, such as those involving the manufacture of household utensils, medical equipment, electronics, and automobile parts. The limiting drawing ratio (LDR) is the main barrier to increasing the formability and production rate as well as to decrease production cost and time. In the present research, the multi draw radius (MDR) die was proposed to increase LDR. The finite element method (FEM) was used as a tool to illustrate the principle of MDR based on material flow. The results revealed that MDR die could reduce the non-axisymmetric material flow on flange and the asymmetry of the flange during the deep drawing process. Based on this material flow characteristic, the cup wall stretching and fracture could be delayed. Furthermore, the cup wall thicknesses of the deep drawn parts obtained by MDR die application were more uniform in each direction along the plane, at 45°, and at 90° to the rolling direction than those obtained by conventional die application. In the present research, a proper design for the MDR was suggested to achieve functionality of the MDR die as related to each direction along the plane, at 45°, and at 90° to the rolling direction. The larger draw radius positioned for at 45° to the rolling direction and the smaller draw radius positioned for along the plane and at 90° to the rolling direction were recommended. Therefore, by using proper MDR die application, the drawing ratio could be increased to be 2.75, an increase in LDR of approximately 22.22%. Full article

The concept of Zener–Hollomon (Z) based Forming Limit Surface (Z-FLS)—which has minor strain, major strain, and ln(Z) as its three axes—was initially proposed in a previous study. In the Z-FLS diagram, strain rate and temperature effects on the major limit strain are reflected by ln(Z). In the current study, the concept of Z-FLS is revisited to provide a practical approach to construct Z-FLS. A Z-FLS then is constructed for magnesium alloy AZ31B sheet material using available experimental forming limit curves. The constructed Z-FLS is used to identify fracture in a non-isothermal warm cup forming process, which was modeled as a coupled thermo-mechanical process. Based on the Z-FLS, the determined limiting draw ratio (LDR) matches well with the published experimental results. Full article