Search results for: thermoplastic forming

Authors: Shuo Tian, Xuepiao Bai, Jianqin Shang, Pengtao Gai, Yuansong Zeng

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Shot peen forming is an essential forming process for aircraft metal wing panel. With the development of computer simulation technology, scholars have proposed a numerical simulation method of shot peen forming based on stress field. Three shot peen forming indexes of crater diameter, shot speed and surface coverage are required as simulation parameters in the stress field method. It is necessary to establish the relationship between simulation and experimental process parameters in order to simulate the deformation under different shot peen forming parameters. The shot peen forming tests of the 2024-T351 aluminum alloy workpieces were carried out using uniform test design method, and three factors of air pressure, feed rate and shot flow were selected. The second-order response surface model between simulation parameters and uniform test factors was established by stepwise regression method using MATLAB software according to the results. The response surface model was combined with the stress field method to simulate the shot peen forming deformation of the workpiece. Compared with the experimental results, the simulated values were smaller than the corresponding test values, the maximum and average errors were 14.8% and 9%, respectively.

Keywords: shot peen forming, process parameter, response surface model, numerical simulation

Procedia PDF Downloads 87

Authors: K. Almi, S.Lakel, A. Benchabane, A. Kriker

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The fiber–matrix compatibility can be improved if suitable enforcements are chosen. Whenever the reinforcements have more thermal stability, they can resist to the main processes for wood–thermoplastic composites. This paper is an investigation of effect of different treatment process on the mechanical proprieties and on the thermal stability of date palm leaflets fibers with a view to improve the date palm fiber proprieties used as reinforcement of thermoplastic materials which main processes require extrusion, hot press. To compare the effect of alkali and acid treatment on the date palm leaflets fiber properties, different treatment were used such as Sodium hydroxide NaOH solution, aluminium chloride AlCl3 and acid treatment with HCL solution. All treatments were performed at 70°C for 4h and 48 h. The mechanical performance (tensile strength and elongation) is affected by immersion time in alkaline and acid solutions. The reduction of the tensile strength and elongation of fibers at 48h was higher in acid treatment than in alkali treatment at high concentration. No significant differences were observed in mechanical and thermal proprieties of raw fibers and fibers submerged in AlCl3 at low concentration 1% for 48h. Fibers treated by NaOH at 6% for 4h showed significant increase in the mechanical proprieties and thermal stability of date palm leaflets fibers. Hence, soda treatment is necessary to improve the fibers proprieties and consequently optimize the composite performance.

Keywords: date palm fibers, surface treatments, thermoplastic composites, thermal analysis

Procedia PDF Downloads 342

Authors: Ali Moarrefzadeh

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In metalworking, rolling is a metal forming process in which metal stock is passed through a pair of rolls. Rolling is classified according to the temperature of the metal rolled. If the temperature of the metal is above its recrystallization temperature, then the process is termed as hot rolling. If the temperature of the metal is below its recrystallization temperature, the process is termed as cold rolling. In terms of usage, hot rolling processes more tonnage than any other manufacturing process, and cold rolling processes the most tonnage out of all cold working processes. This article describes the use of advanced tubing inspection NDT methods for boiler and heat exchanger equipment in the petrochemical industry to supplement major turnaround inspections. The methods presented include remote field eddy current, magnetic flux leakage, internal rotary inspection system and eddy current.

Keywords: hot forming, cold forming, metal, rolling, simulation

Procedia PDF Downloads 529

Authors: Kyo Jin An, Bukyo Seo, Young-Chul Park

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The current trend in car market is increase of parts of automobile and weight in vehicle. It comes from improvement of vehicle performance. Outer tie rod is a part of component of steering system and it is lighter than the others. But, weight lightening is still required for improvement of car mileage. So, we have presented a model of aluminized outer tie rod, but the process of fabrication has to be checked to manufacture the product. Therefore, we have anticipated forming load, die stress and abrasion to use the program of forging interpretation in the part of hot forging process of outer tie rod in this study. Also, we have implemented the experiments design to use the table of orthogonal arrays to reduce the forming load.

Keywords: forming load, hot forging, orthogonal array, outer tie rod (OTR), multi–step forging

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Authors: M. A. Aleem, M. S. Awan

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Flat spiral coil for electromagnetic forming system has been modelled in FEMM 4.2 software. Copper strip was chosen as the material for designing the actuator coil. Relationship between height to width ratio (S-factor) of the copper strip and coil’s performance has been studied. Magnetic field intensities, eddy currents, and Lorentz force were calculated for the coils that were designed using six different 'S-factor' values (0.65, 0.75, 1.05, 1.25, 1.54 and 1.75), keeping the cross-sectional area of strip the same. Results obtained through simulation suggest that actuator coil with S-factor ~ 1 shows optimum forming performance as it exerts maximum Lorentz force (84 kN) on work piece. The same coils were fabricated and used for electromagnetic sheet forming experiments. Aluminum 6061 sheets of thickness 1.5 mm have been formed using different voltage levels of capacitor bank. Smooth forming profiles were obtained with dome heights 28, 35 and 40 mm in work piece at 800, 1150 and 1250 V respectively.

Keywords: FEM modelling, electromagnetic forming, spiral coil, Lorentz force

Procedia PDF Downloads 286

Authors: W. V. W. H. Wickramaarachchi, S. Walpalage, S. M. Egodage

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Thermoplastic elastomer (TPE) is a multifunctional polymeric material which possesses a combination of excellent properties of parent materials. Basically, TPE has a rubber phase and a thermoplastic phase which gives processability as thermoplastics. When the rubber phase is partially or fully crosslinked in the thermoplastic matrix, TPE is called as thermoplastic elastomer vulcanizate (TPV). If the rubber phase is non-crosslinked, it is called as thermoplastic elastomer olefin (TPO). Nowadays TPEs are introduced into the commercial market with different products. However, the application of TPE as a roofing material is limited. Out of the commercially available roofing products from different materials, only single ply roofing membranes and plastic roofing sheets are produced from rubbers and plastics. Natural rubber (NR) and high density polyethylene (HDPE) are used in various industrial applications individually with some drawbacks. Therefore, this study was focused to develop both TPO and TPV blends from NR and HDPE at different compositions and then to identify the best blend composition to use as a roofing material. A series of blends by varying NR loading from 10 wt% to 50 wt%, at 10 wt% intervals, were prepared using a twin screw extruder. Dicumyl peroxide was used as a crosslinker for TPV. The standard properties for a roofing material like tensile properties tear strength, hardness, impact strength, water absorption, swell/gel analysis and thermal characteristics of the blends were investigated. Change of tensile strength after exposing to UV radiation was also studied. Tensile strength, hardness, tear strength, melting temperature and gel content of TPVs show higher values compared to TPOs at every loading studied, while water absorption and swelling index show lower values, suggesting TPVs are more suitable than TPOs for roofing applications. Most of the optimum properties were shown at 10/90 (NR/HDPE) composition. However, high impact strength and gel content were shown at 20/80 (NR/HDPE) composition. Impact strength, as being an energy absorbing property, is the most important for a roofing material in order to resist impact loads. Therefore, 20/80 (NR/HDPE) is identified as the best blend composition. UV resistance and other properties required for a roofing material could be achieved by incorporating suitable additives to TPVs.

Keywords: thermoplastic elastomer, natural rubber, high density polyethylene, roofing material

Procedia PDF Downloads 126

Authors: Kamil Dydek, Szymon Demski, Kamil Majchrowicz, Paulina Kozera, Bogna Sztorch, Dariusz Brząkalski, Zuzanna Krawczyk, Robert Przekop, Anna Boczkowska

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Thanks to their excellent properties, i.e. high stiffness and strength in relation to their weight, corrosion resistance, and low thermal expansion, Carbon Fiber Reinforced Polymers (CFRPs) are a group of materials readily used in many industrial sectors, e.g. aviation, automotive, wind energy. Conventional CFRPs also have their disadvantages, namely, relatively low electrical conductivity and brittle cracking. To counteract this, a thermoplastic acrylic resin was proposed, which was further modified by the addition of organosilicon compounds and multi-walled carbon nanotubes (MWCNTs). The addition of the organosilicon compounds was aimed at improving the dispersion of the MWCNTs and obtaining good adhesion between the resin and the carbon fibre, where the MWCNTs were used as a conductive filler. In addition, during the fabrication of laminates using the infusion method, thermoplastic nonwovens doped with MWCNTs were placed between the carbon reinforcement layers to achieve a synergistic effect with an increase in electrical and mechanical properties.

Keywords: CFRP, acrylic resin, organosilicon compounds, mechanical properties, electrical properties

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Authors: Nesrine Gaaliche

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This study provides a finite element dynamic model for analyzing rolling bearing system vibration response. The vibration responses of polypropylene bearings with and without defects are studied using FE analysis and compared to experimental data. The viscoelastic behavior of thermoplastic is investigated in this work to evaluate the influence of material flexibility and damping viscosity. The vibrations are detected using 3D dynamic analysis. Peak vibrations are more noticeable in an inner ring defect than in an outer ring defect, according to test data. The performance of thermoplastic bearings is compared to that of metal parts using vibration signals. Both the test and numerical results show that Polypropylene bearings exhibit less vibration than steel counterparts. Unlike bearings made from metal, polypropylene bearings absorb vibrations and handle shaft misalignments. Following validation of the overall vibration spectrum data, Von Mises stresses inside the rings are assessed under high loads. Stress is significantly high under the balls, according to the simulation findings. For the test cases, the computational findings correspond closely to the experimental results.

Keywords: viscoelastic, FE analysis, polypropylene, bearings

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Authors: A. Anbu Raj, V. Mugendiren

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Sheet metal forming is a vital manufacturing process used in automobile, aerospace, agricultural industries, etc. Incremental forming is a promising process providing a short and inexpensive way of forming complex three-dimensional parts without using die. The aim of this research is to study the forming behaviour of AA 5052, Aluminium Alloy, using incremental forming and also to study the FLD of cone shape AA 5052 Aluminium Alloy at room temperature and various annealing temperature. Initially the surface roughness and wall thickness through incremental forming on AA 5052 Aluminium Alloy sheet at room temperature is optimized by controlling the effects of forming parameters. The central composite design (CCD) was utilized to plan the experiment. The step depth, feed rate, and spindle speed were considered as input parameters in this study. The surface roughness and wall thickness were used as output response. The process performances such as average thickness and surface roughness were evaluated. The optimized results are taken for minimum surface roughness and maximum wall thickness. The optimal results are determined based on response surface methodology and the analysis of variance. Formability Limit Diagram is constructed on AA 5052 Aluminium Alloy at room temperature and various annealing temperature by using optimized process parameters from the response surface methodology. The cone has higher formability than the square pyramid and higher wall thickness distribution. Finally the FLD on cone shape and square pyramid shape at room temperature and the various annealing temperature is compared experimentally and simulated with Abaqus software.

Keywords: incremental forming, response surface methodology, optimization, wall thickness, surface roughness

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Authors: Zamira Sattinova, Tassybek Bekenov

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The article is devoted to modeling the technology of hot casting of beryllium oxide ceramics. The stages of ultrasonic activation of beryllium oxide slurry in the plant vessel to improve the rheological property, hot casting in the moulding cavity with cooling and solidification of the casting are described. Thermoplastic slurry (hereinafter referred to as slurry) shows the rheology of a non-Newtonian fluid with yield and plastic viscosity. Cooling-solidification of the slurry in the forming cavity occurs in the liquid, taking into account crystallization and solid state. In this work is the method of calculation of hot casting of the slurry using the method of effective molecular viscosity of viscoplastic fluid. It is shown that the slurry near the cooled wall is in a state of crystallization and plasticity, and the rest may still be in the liquid phase. Nonuniform distribution of temperature, density and concentration of kinetically free binder takes place along the cavity section. This leads to compensation of shrinkage by the influx of slurry from the liquid into the crystallization zones and plasticity of the castings. In the plasticity zone, the shrinkage determined by the concentration of kinetically free binder is compensated under the action of the pressure gradient. The solidification mechanism, as well as the mechanical behavior of the casting mass during casting, the rheological and thermophysical properties of the thermoplastic BeO slurry due to ultrasound exposure have not been well studied. Nevertheless, experimental data allow us to conclude that the effect of ultrasonic vibrations on the slurry mass leads to it: a change in structure, an increase in technological properties, a decrease in heterogeneity and a change in rheological properties. In the course of experiments, the effect of ultrasonic treatment and its duration on the change in viscosity and ultimate shear stress of the slurry depending on temperature (55-75℃) and the mass fraction of the binder (10 - 11.7%) have been studied. At the same time, changes in these properties before and after ultrasound exposure have been analyzed, as well as the nature of the flow in the system under study. The experience of operating the unit with ultrasonic impact has shown that at the same time, the casting capacity of the slurry increases by an average of 15%, and the viscosity decreases by more than half. Experimental study of physicochemical properties and phase change with simultaneous consideration of all factors affecting the quality of products in the process of continuous casting is labor-intensive. Therefore, an effective way to control the physical processes occurring in the formation of articles with predetermined properties and shapes is to simulate the process and determine its basic characteristics. The results of the calculations show the whole stage of hot casting of beryllium oxide slurry, taking into account the change in its state of aggregation. Ultrasonic treatment improves rheological properties and increases the fluidity of the slurry in the forming cavity. Calculations show the influence of velocity, temperature factors and structural data of the cavity on the cooling-solidification process of the casting. In the calculations, conditions for molding with shrinkage of the slurry by hot casting have been found, which makes it possible to obtain a solidifying product with a uniform beryllium oxide structure at the outlet of the cavity.

Keywords: hot casting, thermoplastic slurry molding, shrinkage, beryllium oxide

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Authors: Chi-Chung Marven Chick, Chu-Po Ho, Sau-Chuen Joe Au, Wing-Fai Sidney Wong, Chi-Wai Kan

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Recently, 3D printing becomes popular process for manufacturing, especially has special attention in textile applications. However, there are various types of 3D printing materials, including plastic, resin, rubber, ceramics, gold, platinum, silver, iron, titanium but not all these materials are suitable for textile application. Generally speaking, 3D printing of textile mainly uses thermoplastic polymers such as acrylonitrile butadiene styrene (ABS), polylactide (PLA), polycaprolactone (PCL), thermoplastic polyurethane (TPU), polyethylene terephthalate glycol-modified (PETG), polystyrene (PS), polypropylene (PP). Due to the characteristics of the polymers, 3D printed textiles usually have low air permeability and poor comfortable. Therefore, in this paper, we will review the possible materials suitable for textile application with desired physical and mechanical properties.

Keywords: 3D printing, 3D printing materials, textile, properties

Procedia PDF Downloads 63

Authors: H. G. Noh, H. G. Park, B. S. Kang, J. Kim

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Electromagnetic forming process (EMF) is one of high-velocity forming processes using Lorentz force. Advantages of EMF are summarized as improvement of formability, reduction in wrinkling, non-contact forming. In this study, numerical simulations were conducted to determine the practical parameters for EMF process. A 2-D axis-symmetric electromagnetic model was considered based on the spiral type forming coil. In the numerical simulation, RLC circuit coupled with spiral coil was made to consider the design parameters such as system input current and electromagnetic force. In order to deform the sheet in the patter shape die, two types of spiral shape coil were considered to deform the pattern shape sheet. One is a spiral coil that has 6turns with dead zone at centre point. Another is a normal spiral coil without dead zone that has 8 turns. In the electric analysis, input current and magnetic force were compared and then plastic deformation was treated in the mechanical analysis for two coil cases. Deformation behaviour of dead zone coil case has good agreement with pattern shape die. As a result, deformation behaviour could be controlled by giving dead zone at centre of the coil in spiral shape coil case.

Keywords: electromagnetic forming, spiral coil, Lorentz force, manufacturing

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Authors: H. Hosseini, B. V. Berdyshev, I. Iskopintsev

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This paper presents a rheological model for producing shape-memory thermoplastic polymers. Shape-memory occurs as a result of internal rearrangement of the structural elements of a polymer. A non-linear viscoelastic model was developed that allows qualitative and quantitative prediction of the stress-strain behavior of shape-memory polymers during heating. This research was done to develop a technique to determine the maximum possible change in size of heat-shrinkable products during heating. The rheological model used in this work was particularly suitable for defining process parameters and constructive parameters of the processing equipment.

Keywords: elastic deformation, heating, shape-memory polymers, stress-strain behavior, viscoelastic model

Procedia PDF Downloads 323

Authors: Anna Dziubinska

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The applications of magnesium alloys in transport include all kinds of vehicle wheels for cars, motorcycles, bicycles, trolleys, etc. Modern technologies of manufacturing products from these materials have been noticeably improved recently, creating new possibilities for their application. Continuously developed technologies for forming Mg alloys must not be overlooked, which make it possible to manufacture products with better properties compared to those obtained by casting only. The article reviews the specialized literature on magnesium wheel forming and presents a concept of technology for forging magnesium wheels for light vehicles from cast preforms. The research leading to these results has received funding from the Norway Grants 2014-2021 via the National Centre for Research and Development.

Keywords: forming, forging, magnesium alloy, wheels, vehicles

Procedia PDF Downloads 141

Authors: Adeshina Fadeyibi

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Application of pure thermoplastic film in food packaging is greatly limited because of its poor service performance, often enhanced by the addition of organic or inorganic particles in the range of 1–100 nm. Thus, this study was conducted to develop cassava starch zinc-nanocomposite films for applications in food packaging. Three blending ratios of 1000 g cassava starch, 45–55 % (w/w) glycerol and 0–2 % (w/w) zinc nanoparticles were formulated, mixed and mechanically homogenized to form the nanocomposite. Thermoplastic were prepared, from a dispersed mixture of 24 g of the nanocomposite and 600 ml of distilled water, and heated to 90oC for 30 minutes. Plastic molds of 350 ×180 mm dimension and 8, 10 and 12 mm depths were used for film casting and drying at 60oC and 80 % RH for 24 hour. The average thicknesses of the dried films were found to be 15, 16 and 17 µm. The films were characterized based on their barrier, thermal, mechanical and structural properties. The results show that the oxygen and water vapor barrier properties increased with glycerol concentration and decreased with thickness; but the full width at half maximum (FWHM) and d- spacing increased with thickness. The higher degree of d- spacing obtained is a consequence of higher polymer intercalation and exfoliation. Also, only 2 % weight degradation was observed when the films were exposed to temperature between 30–60oC; indicating that they are thermally stable and can be used for packaging applications in the tropics. The mechanical properties of the film were higher than that of the pure thermoplastic but comparable with the LDPE films. The information on the characterized attributes and optimization of the cassava starch zinc-nanocomposite films justifies their alternative application to pure thermoplastic and conventional films for food packaging.

Keywords: synthesis, characterization, casaava Starch, nanocomposite film, packaging

Procedia PDF Downloads 119

Authors: Yiğit Gürler, İbrahim Şimşek, Müge Savaştaer, Ayberk Karakuş, Alper Taşdemirci

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316L steel is frequently used in the industry due to its easy formability and accessibility in sheet metal forming processes. Numerical and experimental studies are frequently encountered in the literature to examine the mechanical behavior of 316L stainless steel during the forming process. 316L stainless steel is the most common material used in the production of plate heat exchangers and plate heat exchangers are produced by plastic deformation of the stainless steel. The motivation in this study is to determine the appropriate material model during the simulation of the sheet metal forming process. For this reason, two different material models were examined and Ls-Dyna material cards were created using material test data. These are MAT133_BARLAT_YLD2000 and MAT093_SIMPLIFIED_JOHNSON_COOK. In order to compare results of the tensile test & hydraulic bulge test performed both numerically and experimentally. The obtained results were evaluated comparatively and the most suitable material model was selected for the forming simulation. In future studies, this material model will be used in the numerical modeling of the sheet metal forming process.

Keywords: 316L, mechanical characterization, metal forming, Ls-Dyna

Procedia PDF Downloads 334

Authors: Kittichai Thanasupsin, Satis Sukniam

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Pavement marking is an essential task of road construction and maintenance. One of several benefits of pavement markings has been used to provide information about road alignment and road conditions ahead. In some cases, retro-reflectivity of road marking at night may not meet the standard. This degradation may be caused by internal factors such as the size of glass beads and the number of glass beads or external factors such as traffic volume, lane width, vehicle weight, and so on. This research aims to investigate the reflective efficiency of thermoplastic road marking with the glass beads. Ratios of glass beads, ranging from 359 to 553 grams per square meter on an asphaltic concrete, have been tested. The reflective efficiency data was collected at the beginning and at a specific time interval for a total of 8 months. It was found that the difference in glass beads quantity affects the rate of retro-reflectivity but does not affect the diffuse reflectivity. It was also found that other factors affect retro-reflectivity, such as duration, the position of road marking, traffic density, the quantity of glass beads, and dirt coating on top. The dirt coating on top is the most crucial factor that deteriorating retro-reflectivity.

Keywords: thermoplastic pavement marking, retro-reflectivity, diffuse reflectivity, asphalt concrete

Procedia PDF Downloads 133

Authors: Yujeong Shin, Seong Jin Cho, Jin Ho Kim

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In the textile-weaving machine, the reed is the core component to separate thousands of strands of yarn and to produce the fabric in a continuous high-speed movement. In addition, the reed affects the quality of the fiber. Therefore, the wire forming analysis of the main raw materials of the reed needs to be considered. Roll-forming is a key technology among the manufacturing process of reed wire using textile machine. A simulation of roll-forming line in accordance with the reduction rate is performed using LS-DYNA. The upper roller, fixed roller and reed wire are modeled by finite element. The roller is set to be rigid body and the wire of SUS430 is set to be flexible body. We predict the variation of the cross-sectional shape of the wire depending on the reduction ratio.

Keywords: textile machine, reed, rolling, reduction ratio, wire

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Authors: Jorge Prada, Christina Cordes, Carsten Harms, Walter Lang

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The development of microfluidic-based biosensors over the last years has shown an increasing employ of thermoplastic polymers as constitutive material. Their low-cost production, high replication fidelity, biocompatibility and optical-mechanical properties are sought after for the implementation of disposable albeit functional lab-on-chip solutions. Among the range of thermoplastic materials on use, the Cyclo-Olefin Copolymer (COC) stands out due to its optical transparency, which makes it a frequent choice as manufacturing material for fluorescence-based biosensors. Moreover, several processing techniques to complete a closed COC microfluidic biosensor have been discussed in the literature. The reported techniques differ however in their implementation, and therefore potentially add more or less complexity when using it in a mass production process. This work introduces and reports results on the application of a purely thermal bonding process between COC substrates, which were produced by the hot-embossing process, and COC foils containing screen-printed circuits. The proposed procedure takes advantage of the transition temperature difference between two COC grades foils to accomplish the sealing of the microfluidic channels. Patterned heat injection to the COC foil through the COC substrate is applied, resulting in consistent channel geometry uniformity. Measurements on bond strength and bursting pressure are shown, suggesting that this purely thermal bonding process potentially renders a technique which can be easily adapted into the thermoplastic microfluidic chip production workflow, while enables a low-cost as well as high-quality COC biosensor manufacturing process.

Keywords: biosensor, cyclo-olefin copolymer, hot embossing, thermal bonding, thermoplastics

Procedia PDF Downloads 240

Authors: Seyfullah Madakbaş, Ferhat Şen, Memet Vezir Kahraman

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The aim of this study was to improve thermal stability, mechanical and surface properties of thermoplastic polyurethane (TPU) with the addition of BaTiO3. The TPU/ BaTiO3 composites having various ratios of TPU and BaTiO3 were prepared. The chemical structure of the prepared composites was investigated by FT-IR. FT-IR spectra of TPU/ barium titanate composites show that they successfully were prepared. Thermal stability of the samples was evaluated by thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC). The prepared composites showed high thermal stability, and the char yield increased as barium titanate content increased. The glass transition temperatures of the composites rise with the addition of barium titanate. Mechanical properties of the samples were characterized with stress-strain test. The mechanical properties of the TPU were increased with the contribution of the contribution of the barium titanate it increased. Hydrophobicity of the samples was determined by the contact angle measurements. The contact angles have the tendency to increase the hydrophobic behavior on the surface, when barium titanate was added into TPU. Moreover, the surface morphology of the samples was investigated by a scanning electron microscopy (SEM). SEM-EDS mapping images showed that barium titanate particles were dispersed homogeneously. Finally, the obtained results prove that the prepared composites have good thermal, mechanical and surface properties and that they can be used in many applications such as the electronic devices, materials engineering and other emergent.

Keywords: barium titanate, composites, thermoplastic polyurethane, scanning electron microscopy

Procedia PDF Downloads 329

Authors: Karla D. Vazquez-Valdez, Bradley P. Wynne

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In the last decades manufacturing needs have been changing, leading to the study of manufacturing methods that were underdeveloped, such as incremental forming processes like shear forming. These processes use rotating tools in constant local contact with the workpiece, which is often also rotating, to generate shape. This means much lower loads to forge large parts and no need for expensive special tooling. Potential has already been established by demonstrating manufacture of high-value products, e.g., turbine and satellite parts, with high dimensional accuracy from difficult to manufacture materials. Thus, huge opportunities exist for these processes to replace the current method of manufacture for a range of high value components, e.g., eliminating lengthy machining, reducing material waste and process times; or the manufacture of a complicated shape without the development of expensive tooling. However, little is known about the exact deformation conditions during processing and why certain materials are better than others for shear forming, leading to a lot of trial and error before production. Three alloys were used for this study: Ti-54M, Jethete M154, and IN718. General Microscopy and Electron Backscatter Diffraction (EBSD) were used to measure strains and orientation maps during shear forming. A Design of Experiments (DOE) analysis was also made in order to understand the impact of process parameters in the properties of the final workpieces. Such information was the key to develop a reliable Finite Element Method (FEM) model that closely resembles the deformation paths of this process. Finally, the potential of these three materials to be shear spun was studied using the FEM model and their Forming Limit Diagram (FLD) which led to the development of a rough methodology for testing the shear spinnability of various metals.

Keywords: shear forming, damage, principal strains, forming limit diagram

Procedia PDF Downloads 163

Authors: Eshwara Prasad Koorapati, R. Raman Goud, Swadesh Kumar Singh

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In the present work forming limit diagrams and strain distribution profile diagrams for extra deep drawing steel at room and elevated temperatures have been determined experimentally by conducting stretch forming experiments by using designed and fabricated warm stretch forming tooling setup. With the help of forming Limit Diagrams (FLDs) and strain distribution profile diagrams the formability of Extra Deep Drawing steel has been analyzed and co-related with mechanical properties like strain hardening coefficient (n) and normal anisotropy (r−).Mechanical properties of EDD steel from room temperature to 4500 C were determined and discussed the impact of temperature on the properties like work hardening exponent (n) anisotropy (r-) and strength coefficient of the material. Also, the fractured surfaces after stretching have undergone the some metallurgical investigations and attempt has been made to co-relate with the formability of EDD steel sheets. They are co-related and good agreement with FLDs at various temperatures.

Keywords: FLD, micro hardness, strain distribution profile, stretch forming

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Authors: Selma Saadia, Nacira Naar, Ahmed Benaboura

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This work is dedicated to the elaboration of composites (PP/PANI) with Polypropylene (PP) as thermoplastic polymer and the polyaniline (PANI) as electric charge doped with sulfanilic acid (PANI-As). These realized formulations are intended for the antistatic domain. The used conductive polymer is synthesized by the method self-curling which proved the obtaining of the nanoparticles of PANI in regular morphological forms. The PANI and PP composites are fabricated into a film by a twin-screw extruding. Several methods of characterization are proposed: spectroscopic, thermal, and electric. The realized composites proved a pseudo-homogeneous aspect and the threshold percolation study, showed that the formulation with 7% of PANI presents a better formulation which can be used in the antistatic domain.

Keywords: extruding, PANI, Polypropylene, sulfanilic acid, self-Curling

Procedia PDF Downloads 244

Authors: Mir Mohammad Badrul Hasan, Anwar Abdkader, Chokri Cherif

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With the increasing demand and use of carbon fibre reinforced composites (CFRC), disposal of the carbon fibres (CF) and end of life composite parts is gaining tremendous importance on the issue especially of sustainability. Furthermore, a number of processes (e. g. pyrolysis, solvolysis, etc.) are available currently to obtain recycled CF (rCF) from end-of-life CFRC. Since the CF waste or rCF are neither allowed to be thermally degraded nor landfilled (EU Directive 1999/31/EC), profitable recycling and re-use concepts are urgently necessary. Currently, the market for materials based on rCF mainly consists of random mats (nonwoven) made from short fibres. The strengths of composites that can be achieved from injection-molded components and from nonwovens are between 200-404 MPa and are characterized by low performance and suitable for non-structural applications such as in aircraft and vehicle interiors. On the contrary, spinning rCF to yarn constructions offers good potential for higher CFRC material properties due to high fibre orientation and compaction of rCF. However, no investigation is reported till yet on the direct comparison of the mechanical properties of thermoplastic CFRC manufactured from virgin CF filament yarn and spun yarns from staple rCF. There is a lack of understanding on the level of performance of the composites that can be achieved from hybrid yarns consisting of rCF and PA6 fibres. In this drop back, extensive research works are being carried out at the Textile Machinery and High-Performance Material Technology (ITM) on the development of new thermoplastic CFRC from hybrid yarns consisting of rCF. For this purpose, a process chain is developed at the ITM starting from fibre preparation to hybrid yarns manufacturing consisting of staple rCF by mixing with thermoplastic fibres. The objective is to apply such hybrid yarns for the manufacturing of load bearing textile reinforced thermoplastic CFRCs. In this paper, the development of innovative multi-component core-sheath hybrid yarn structures consisting of staple rCF and polyamide 6 (PA 6) on a DREF-3000 friction spinning machine is reported. Furthermore, Unidirectional (UD) CFRCs are manufactured from the developed hybrid yarns, and the mechanical properties of the composites such as tensile and flexural properties are analyzed. The results show that the UD composite manufactured from the developed hybrid yarns consisting of staple rCF possesses approximately 80% of the tensile strength and E-module to those produced from virgin CF filament yarn. The results show a huge potential of the DREF-3000 friction spinning process to develop composites from rCF for high-performance applications.

Keywords: recycled carbon fibres, hybrid yarn, friction spinning, thermoplastic composite

Procedia PDF Downloads 255

Authors: Saif N. Al-Bahry, Yahya M. Al-Wahaibi, Abdulkadir E. Elshafie, Ali S. Al-Bemani, Sanket J. Joshi

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Environmental pollution is a global problem and best possible solution is identifying and utilizing native microorganisms. One possible application of microbial product -biosurfactant is in bioremediation of hydrocarbon contaminated sites. We have screened forty two different petroleum contaminated sites from Oman, for biosurfactant producing spore-forming bacterial isolates. Initial screening showed that out of 42 soil samples, three showed reduction in surface tension (ST) and interfacial tension (IFT) within 24h of incubation at 40°C. Out of those 3 soil samples, one was further selected for isolation of bacteria and 14 different bacteria were isolated in pure form. Of those 14 spore-forming, rod shaped bacteria, two showed highest reduction in ST and IFT in the range of 70mN/m to < 35mN/m and 26.69mN/m to < 9mN/m, respectively within 24h. These bacterial biosurfactants may be utilized for bioremediation of oil-spills.

Keywords: bioremediation, hydrocarbon pollution, spore-forming bacteria, bio-surfactant

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Authors: M. Kamal M. Shah, Al Fareez Bin Aslie, O. Irma Wani, J. Sahari

Abstract:

Wood plastic composites (WPC) were made using matrix of polypropylene (PP) thermoplastic resin with wood fiber from Artocarpus Odoratissimus as filler. The purpose of this project is to investigate the fracture properties of Artocarpus odoratissimus composite with PP. The WPC were manufactured by hot-press technique with varying formulations which are 10:0 (100% pure PP), 50:50 (40 g of wood fiber and 40 g of PP) and 60:40 (48 g of wood fiber and 32 g of PP). The mechanical properties were investigated. Tensile and flexural were carried out according to ASTM D 638 and ASTM D 790. The results were analysed to calculate the tensile strength. Tensile strength at break is ranged from 13.2 N/mm2 to 21.7 N/mm2 while, the flexural strength obtained is varying from 14.7 N/mm2 to 31.1 N/mm2. The results of the experiment showed that tensile and flexural properties of the composite were increased with the adding of wood fiber material. Finally, the Scanning Electron Microscope (SEM), have been done to study the fracture behavior of the WPC specimens.

Keywords: Artocarpus odoratissimus, polypropylene thermoplastic, wood fiber, WPC

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Authors: Nattaporn Khanoonkon, Rangrong Yoksan, Amod A. Ogale

Abstract:

Polyethylene (PE) is one of the most petroleum-based thermoplastic materials used in many applications including packaging due to its cheap, light-weight, chemically inert and capable to be converted into various shapes and sizes of products. Although PE is a commercially potential material, its non-biodegradability caused environmental problems. At present, bio-based polymers become more interesting owing to its bio-degradability, non-toxicity, and renewability as well as being eco-friendly. Thermoplastic starch (TPS) is a bio-based and biodegradable plastic produced from the plasticization of starch under applying heat and shear force. In many researches, TPS was blended with petroleum-based polymers including PE in order to reduce the cost and the use of those polymers. However, the phase separation between hydrophobic PE and hydrophilic TPS limited the amount of TPS incorporated. The immiscibility of two different polarity polymers can be diminished by adding compatibilizer. PE-based compatibilizers, e.g. polyethylene-grafted-maleic anhydride, polyethylene-co-vinyl alcohol, etc. have been applied for the PE/TPS blend system in order to improve their miscibility. Until now, there is no report about the utilization of starch-based compatibilizer for PE/TPS blend system. The aims of the present research were therefore to synthesize a new starch-based compatibilizer, i.e. stearic acid-grafted starch (SA-g-starch) and to study the effect of SA-g-starch on chemical interaction, morphological properties, tensile properties and water vapor as well as oxygen barrier properties of the PE/TPS blend films. PE/TPS blends without and with incorporating SA-g-starch with a content of 1, 3 and 5 part(s) per hundred parts of starch (phr) were prepared using a twin screw extruder and then blown into films using a film blowing machine. Incorporating 1 phr and 3 phr of SA-g-starch could improve miscibility of the two polymers as confirmed from the reduction of TPS phase size and the good dispersion of TPS phase in PE matrix. In addition, the blend containing SA-g-starch with contents of 1 phr and 3 phr exhibited higher tensile strength and extensibility, as well as lower water vapor and oxygen permeabilities than the naked blend. The above results suggested that SA-g-starch could be potentially applied as a compatibilizer for the PE/TPS blend system.

Keywords: blend, compatibilizer, polyethylene, thermoplastic starch

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Authors: Sukhila Krishnan, Smita Mohanty, Sanjay K. Nayak

Abstract:

Polylactide (PLA) and thermoplastic starch (TPS) are the most promising bio-based materials presently available on the market. Polylactic acid is one of the versatile biodegradable polyester showing wide range of applications in various fields and starch is a biopolymer which is renewable, cheap as well as extensively available. The usual increase in the cost of petroleum-based commodities in the next decades opens bright future for these materials. Their biodegradability and compostability was an added advantage in applications that are difficult to recycle. Currently, thermoplastic starch (TPS) has been used as a substitute for synthetic plastic in several commercial products. But, TPS shows some limitations mainly due to its brittle and hydrophilic nature, which has to be resolved to widen its application.The objective of the work we report here was to initiate chemical modifications on TPS and to build up a process to control its chemical structure using a solution process which can reduce its water sensitive properties and then blended it with PLA to improve compatibility between PLA and TPS. The method involves in cleavage of starch amylose and amylopectin chain backbone to plasticize with glycerol and water in batch mixer and then the prepared TPS was reacted in solution with diisocyanates i.e, 4,4'-Methylenediphenyl Diisocyanate (MDI).This diisocyanate was used before with great success for the chemical modification of TPS surface. The method utilized here will form an urethane-linkages between reactive isocyanate groups (–NCO) and hydroxyl groups (-OH) of starch as well as of glycerol. New polymer synthesised shows a reduced crystallinity, less hydrophilic and enhanced compatibility with other polymers. The TPS was prepared by Haake Rheomix 600 batch mixer with roller rotors operating at 50 rpm. The produced material is then refluxed for 5hrs with MDI in toluene with constant stirring. Finally, the modified TPS was melt blended with PLA in different compositions. Blends obtained shows an improved mechanical properties. These materials produced are characterized by Fourier Transform Infrared Spectra (FTIR), DSC, X-Ray diffraction and mechanical tests.

Keywords: polylactic acid, thermoplastic starch, Methylenediphenyl Diisocyanate, Polylactide (PLA)

Procedia PDF Downloads 384

Authors: Hatem Mrad, Alban Notin, Mohamed Bouazara

Abstract:

Sheet metal forming process has a multiple successive steps starting from sheets fixation to sheets evacuation. Often after forming operation, the sheet has defects requiring additional corrections steps. For example, in the drawing process, the formed sheet may have several defects such as springback, localized thinning and bends. All these defects are directly dependent on process, geometric and material parameters. The prediction and elimination of these defects requires the control of most sensitive parameters. The present study is concerned with a reliable parametric study of deep forming process in order to control the localized thinning. The proposed approach will be based on stochastic finite element method. Especially, the polynomial Chaos development will be used to establish a reliable relationship between input (process, geometric and material parameters) and output variables (sheet thickness). The commercial software Abaqus is used to conduct numerical finite elements simulations. The automatized parametrical modification is provided by coupling a FORTRAN routine, a PYTHON script and input Abaqus files.

Keywords: sheet metal forming, reliability, localized thinning, parametric simulation

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Authors: P. Homola, L. Novakova, V. Kafka, M. P. Oscoz

Abstract:

Shear spinning is closely related to the asymmetric incremental sheet forming (AISF) that could significantly reduce costs incurred by the fabrication of complex aeronautical components with a minimal environmental impact. The spinning experiments were carried out on commercially pure titanium (Ti-Gr2) and Ti-6Al-4V (Ti-Gr5) alloy. Three forming modes were used to characterize the titanium alloys properties from the point of view of different spinning parameters. The structure and properties of the materials were assessed by means of metallographic analyses and micro-hardness measurements. The highest value wall angle failure limit was achieved using spinning parameters mode for both materials. The feed rate effect was observed only in the samples from the Ti-Gr2 material, when a refinement of the grain microstructure with lower feed rate and higher tangential speed occurred. Ti-Gr5 alloy exhibited a decrease of the micro-hardness at higher straining due to recovery processes.

Keywords: incremental forming, metallography, shear spinning, titanium alloys

Procedia PDF Downloads 236