Search results for: cold formed steel sheet

Authors: Yasar Pala, Safa Senaysoy, Emre Calis

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In this paper, structural behavior and improvement of buckling behavior of cold formed steel uprights with open cross-section used storage rack system are studied. As a first step, in the case of a stiffener having an inclined part on the flange, experimental and nonlinear finite element analysis are carried out for three different upright lengths. In the uprights with long length, global buckling is observed while distortional buckling and local buckling are observed in the uprights with medium length and those with short length, respectively. After this point, the study is divided into two groups. One of these groups is the case where the stiffener on the flange is folded at 90°. For this case, four different distances of the stiffener from the web are taken into account. In the other group, the case where different depth of stiffener on the web is considered. Combining experimental and finite element results, the cross-section giving the ultimate critical buckling load is selected.

Keywords: steel, upright, buckling, modes, nonlinear finite element analysis, optimization

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Authors: M. Atef Gabr, M. H. Abdel Latif, Ramadan El Gamsy

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Sandwich panels comprise a thick, light-weight plastic foam such as polyurethane (PU) sandwiched between two relatively thin faces. One or both faces may be flat, lightly profiled or fully profiled. Until recently sandwich panel construction in Egypt has been widely used in cold-storage buildings, cold trucks, prefabricated buildings and insulation in construction. Recently new techniques are used in mass production of Sandwich Materials such as Reaction Injection Molding (RIM) and Vacuum bagging technique. However, in recent times their use has increased significantly due to their widespread structural applications in building systems. Structural sandwich panels generally used in Egypt comprise polyurethane foam core and thinner (0.42 mm) and high strength about 550 MPa (yield strength) flat steel faces bonded together using separate adhesives and By RIM technique. In this paper, we will use a new technique in sandwich panel preparation by using different face sheet materials in combination with polyurethane foam to form sandwich panel structures. Previously, PU Foam core with same thin 2 faces material was used, but in this work, we use different face materials and thicknesses for the upper face sheet such as Galvanized steel sheets (G.S),Aluminum sheets (Al),Fiberglass sheets (F.G) and Aluminum-Rubber composite sheets (Al/R) with polyurethane foam core 10 mm thickness and 45 Kg/m3 Density and Galvanized steel as lower face sheet. Using Aluminum-Rubber composite sheets as face sheet is considered a hybrid composite sandwich panel which is built by Hand-Layup technique by using PU glue as adhesive. This modification increases the benefits of the face sheet that will withstand different working environments with relatively small increase in its weight and will be useful in several applications. In this work, a 3-point bending test is used assistant professor to measure the most important factor in sandwich materials that is strength to weight ratio(STW) for different combinations of sandwich structures and make a comparison to study the effect of changing the face sheet material on the mechanical behavior of PU sandwich material. Also, the density of the different prepared sandwich materials will be measured to obtain the specific bending strength.

Keywords: hybrid sandwich panel, mechanical behavior, PU foam, sandwich panel, 3-point bending, flexural strength

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Authors: Hari Krishnan K. P., Anil Kumar M. V.

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The Direct Strength Method (DSM) is used for the computation of the design strength of members whose behavior is governed by any form of buckling. DSM based semiempirical equations have been successfully used for cold-formed steel (CFS) members subjected to compression, bending, and shear. The DSM equations for the strength of a CFS member are based on the parameters accounting for strength [yield load (Py), yield moment (My), and shear yield load (Vy) for compression, bending, and shear respectively] and stability [buckling load (Pcr), buckling moment (Mcr), and shear buckling load (Vcr) for compression, bending and shear respectively]. The buckling of column and beam shall be governed by local, distortional, or global buckling modes and their interaction. Recently DSM-based methods are extended for the web crippling strength of CFS beams also. Numerous DSM-based expressions were reported in the literature, which is the function of loading case, cross-section shape, and boundary condition. Unlike members subjected to axial load, bending, or shear, no unified expression for the design web crippling strength irrespective of the loading case, cross-section shape, and end boundary conditions are available yet. This study, based on nonlinear finite element analysis results, shows that the slenderness of the web, which shall be represented either using web height to thickness ratio (h=t) or Pcr has negligible contribution to web crippling strength. Hence, the results in this paper question the suitability of DSM based approach for the web crippling strength of CFS beams.

Keywords: cold-formed steel, beams, DSM-based procedure, interior two flanged loading, web crippling

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Authors: Mohammed Tahir, Jonas Lagergren

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Vancron 40, a nitrided powder metallurgical tool Steel, is used in cold work applications where the predominant failure mechanisms are adhesive wear or galling. Typical applications of Vancron 40 are among others fine blanking, cold extrusion, deep drawing and cold work rolls for cluster mills. Vancron 40 positive results for cold work rolls for cluster mills and as a tool for some severe metal forming process makes it competitive compared to other type of work rolls that require higher precision, among others in cold rolling of thin stainless steel, which required high surface finish quality. In this project, three roll materials for cold rolling of stainless steel strip was examined, Vancron 40, Narva 12B (a high-carbon, high-chromium tool steel alloyed with tungsten) and Supra 3 (a Chromium-molybdenum tungsten-vanadium alloyed high speed steel). The purpose of this project was to study the depth profiles of the ironed stainless steel strips, emergence of galling and to study the lubrication performance used by steel industries. Laboratory experiments were conducted to examine scratch of the strip, galling and surface roughness of the roll materials under severe tribological conditions. The critical sliding length for onset of galling was estimated for stainless steel with four different lubricants. Laboratory experiments result of performance evaluation of resistance capability of rolls toward adhesive wear under severe conditions for low and high reductions. Vancron 40 in combination with cold rolling lubricant gave good surface quality, prevents galling of metal surfaces and good bearing capacity.

Keywords: Vancron 40, cold rolling, adhesive wear, galling, surface finish, lubricant, stainless steel

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Authors: Shahid Hussain Abro, F. Mufadi, A. Boodi

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Microstructural study and phase transformation in steels is a basic and important step during the design of structural steel. There are huge efforts and study has been done so far on phase transformations, due to so many steel grades available commercially the phase development in steel has different consequences. In the present work an effort has been made to study the effect of heating rate on microstructural features of cold heading quality steel. The SEM, optical microscopy, and heat treatment techniques have been applied to observe the microstructural features in the experimental steel. It was observed that heating rate has the strong influence on phase transformation of CHQ steel under investigation. Heating rate increases the austenite formation kinetics with respect to holding time, and this austenite has been transformed to martensite upon cooling. Heating rate also plays a vital role on nucleation sites of austenite formation in the experimental steel.

Keywords: CHQ steel, austenite formation, heating rate, nucleation

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Authors: Muhamad Sani Buang, Shahrul Azam Abdullah, Juri Saedon

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There is not much effective guideline on development of design parameters selection on springback for advanced high strength steel sheet metal in U-channel process during cold forming process. This paper presents the development of predictive model for springback in U-channel process on advanced high strength steel sheet employing Response Surface Methodology (RSM). The experimental was performed on dual phase steel sheet, DP590 in U-channel forming process while design of experiment (DoE) approach was used to investigates the effects of four factors namely blank holder force (BHF), clearance (C) and punch travel (Tp) and rolling direction (R) were used as input parameters using two level values by applying Full Factorial design (24). From a statistical analysis of variant (ANOVA), result showed that blank holder force (BHF), clearance (C) and punch travel (Tp) displayed significant effect on springback of flange angle (β2) and wall opening angle (β1), while rolling direction (R) factor is insignificant. The significant parameters are optimized in order to reduce the springback behavior using Central Composite Design (CCD) in RSM and the optimum parameters were determined. A regression model for springback was developed. The effect of individual parameters and their response was also evaluated. The results obtained from optimum model are in agreement with the experimental values

Keywords: advance high strength steel, u-channel process, springback, design of experiment, optimization, response surface methodology (rsm)

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Authors: Agnese Natali, Francesco Morelli, Walter Salvatore, José Humberto Matias de Paula Filho, Patrick Pol

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In the framework of the evaluation of the applicability of high strength steel to produce thin-walled elements to be used in Automated Rack Supported Warehouses, an experimental campaign is carried outto evaluate the structural performance of typical profile shapes adopted for such purposes and made of high strength steel. Numerical models are developed to fit the observed failure modes, stresses, and deformation patterns, and proper directions are proposed to simplify the numerical simulations to be used in further applications and to evaluate the mechanical behavior and performance of profiles.

Keywords: Steel racks, Automated Rack Supported Warehouse, thin walled cold-formed elements, high strength steel.

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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

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Authors: Tatsuhiko Aizawa, Hiroshi Morita

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The tool steels such as SKD11 and SKH51 have been utilized as punch and die substrates for cold stamping, forging, and fine blanking processes. The heat-treated SKD11 punches with the hardness of 700 HV wrought well in the stamping of SPCC, normal steel plates, and non-ferrous alloy such as a brass sheet. However, they suffered from severe damage in the fine blanking process of smaller holes than 1.5 mm in diameter. Under the high aspect ratio of punch length to diameter, an elastoplastic bucking of slender punches occurred on the production line. The heat-treated punches had a risk of chipping at their edges. To be free from those damages, the blanking punch must have sufficient rigidity and strength at the same time. In the present paper, the small-hole blanking punch with a dual toughness structure was proposed to provide a solution to this engineering issue in production. The low-temperature plasma nitriding process was utilized to form the nitrogen supersaturated thick layer into the original SKD11 punch. Through the plasma nitriding at 673 K for 14.4 ks, the nitrogen supersaturated layer, with the thickness of 50 μm and without nitride precipitates, was formed as a high nitrogen steel (HNS) layer surrounding the original SKD11 punch. In this two-zone structured SKD11 punch, the surface hardness increased from 700 HV for the heat-treated SKD11 to 1400 HV. This outer high nitrogen SKD11 (HN-SKD11) layer had a homogeneous nitrogen solute depth profile with a nitrogen solute content plateau of 4 mass% till the border between the outer HN-SKD11 layer and the original SKD11 matrix. When stamping the brass sheet with the thickness of 1 mm by using this dually toughened SKD11 punch, the punch life was extended from 500 K shots to 10000 K shots to attain a much more stable production line to yield the brass American snaps. Furthermore, with the aid of the masking technique, the punch side surface layer with the thickness of 50 μm was modified by this high nitrogen super-saturation process to have a stripe structure where the un-nitrided SKD11 and the HN-SKD11 layers were alternatively aligned from the punch head to the punch bottom. This flexible structuring promoted the mechanical integrity of total rigidity and toughness as a punch with an extremely small diameter.

Keywords: high nitrogen supersaturation, semi-dry cold stamping, solid solution hardening, tool steel dies, low temperature nitriding, dual toughness structure, extremely small diameter punch

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Authors: Jungkyun Na, Jaesang Lee, Yang Mo Koo

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In this study to find a replacement for expensive secondary recrystallization in GO electrical steel production, effect of heat treatment on the formation of columnar grain and Goss texture is investigated. The composition of the sample is Fe-2.0Si-0.2C. This process involves repeating of cold rolling and decarburization as a replacement for secondary recrystallization. By cold-rolling shear band is made and Goss grain grows from shear band by decarburization. By doing another cold rolling, some Goss texture is newly formed from the shear band, and some Goss texture is retained in microbands. To determine whether additional heat treatment with H2 atmosphere is needed on decarburization process for growth of Goss texture, comparing between decarburization and heat treatment with H2 atmosphere is performed. Also, to find optimum condition for heat treatment, heat treatment with various time and temperature is performed. It was found that increase in the number of cold rolling and heat treatment increases Goss texture. Both high Goss texture and good columnar structure is achieved at 900℃, and this temperature is within a+r phase region. Heat treatment at a temperature higher than a+r phase region caused carbon diffusion and this made layer with Goss grain decrease.

Keywords: electrical steel, Goss texture, columnar structure, normal grain growth

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Authors: Zeradam Yeshiwas, A. Krishnaia

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The aim of this study is to verify the resulting surface roughness of parts formed by the Single-Point Incremental Forming (SPIF) process for an ISO 3574 Drawing Quality Cold Rolled CR2 Steel. The chemical composition of drawing quality Cold Rolled CR2 steel is comprised of 0.12 percent of carbon, 0.5 percent of manganese, 0.035 percent of sulfur, 0.04 percent phosphorous, and the remaining percentage is iron with negligible impurities. The experiments were performed on a 3-axis vertical CNC milling machining center equipped with a tool setup comprising a fixture and forming tools specifically designed and fabricated for the process. The CNC milling machine was used to transfer the tool path code generated in Mastercam 2017 environment into three-dimensional motions by the linear incremental progress of the spindle. The blanks of Drawing Quality Cold Rolled CR2 steel sheets of 1 mm of thickness have been fixed along their periphery by a fixture and hardened high-speed steel (HSS) tools with a hemispherical tip of 8, 10 and 12mm of diameter were employed to fabricate sample parts. To investigate the surface roughness, hyperbolic-cone shape specimens were fabricated based on the chosen experimental design. The effect of process parameters on the surface roughness was studied using three important process parameters, i.e., tool diameter, feed rate, and step depth. In this study, the Taylor-Hobson Surtronic 3+ surface roughness tester profilometer was used to determine the surface roughness of the parts fabricated using the arithmetic mean deviation (Rₐ). In this instrument, a small tip is dragged across a surface while its deflection is recorded. Finally, the optimum process parameters and the main factor affecting surface roughness were found using the Taguchi design of the experiment and ANOVA. A Taguchi experiment design with three factors and three levels for each factor, the standard orthogonal array L9 (3³) was selected for the study using the array selection table. The lowest value of surface roughness is significant for surface roughness improvement. For this objective, the ‘‘smaller-the-better’’ equation was used for the calculation of the S/N ratio. The finishing roughness parameter Ra has been measured for the different process combinations. The arithmetic means deviation (Rₐ) was measured via the experimental design for each combination of the control factors by using Taguchi experimental design. Four roughness measurements were taken for a single component and the average roughness was taken to optimize the surface roughness. The lowest value of Rₐ is very important for surface roughness improvement. For this reason, the ‘‘smaller-the-better’’ Equation was used for the calculation of the S/N ratio. Analysis of the effect of each control factor on the surface roughness was performed with a ‘‘S/N response table’’. Optimum surface roughness was obtained at a feed rate of 1500 mm/min, with a tool radius of 12 mm, and with a step depth of 0.5 mm. The ANOVA result shows that step depth is an essential factor affecting surface roughness (91.1 %).

Keywords: incremental forming, SPIF, drawing quality steel, surface roughness, roughness behavior

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Authors: Maziar Ramezani, Thomas Neitzert, Timotius Pasang

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This paper aims at experimental and numerical investigation of springback behavior of sheet metals during L-bending process with emphasis on Stribeck-type friction modeling. The coefficient of friction in Stribeck curve depends on sliding velocity and contact pressure. The springback behavior of mild steel and aluminum alloy 6022-T4 sheets was studied experimentally and using numerical simulations with ABAQUS software with two types of friction model: Coulomb friction and Stribeck friction. The influence of forming speed on springback behavior was studied experimentally and numerically. The results showed that Stribeck-type friction model has better results in predicting springback in sheet metal forming. The FE prediction error for mild steel and 6022-T4 AA is 23.8%, 25.5% respectively, using Coulomb friction model and 11%, 13% respectively, using Stribeck friction model. These results show that Stribeck model is suitable for simulation of sheet metal forming especially at higher forming speed.

Keywords: friction, L-bending, springback, Stribeck curves

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Authors: A. Soualem

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The design of multi stage deep drawing processes requires the evaluation of many process parameters such as the intermediate die geometry, the blank shape, the sheet thickness, the blank holder force, friction, lubrication etc..These process parameters have to be determined for the optimum forming conditions before the process design. In general sheet metal forming may involve stretching drawing or various combinations of these basic modes of deformation. It is important to determine the influence of the process variables in the design of sheet metal working process. Especially, the punch and die corner for deep drawing will affect the formability. At the same time the prediction of sheet metals springback after deep drawing is an important issue to solve for the control of manufacturing processes. Nowadays, the importance of this problem increases because of the use of steel sheeting with high stress and also aluminum alloys. The aim of this paper is to give a better understanding of the springback and its effect in various sheet metals forming process such as expansion and restraint deep drawing in the cup drawing process, by varying radius die, lubricant for two commercially available materials e.g. galvanized steel and Aluminum sheet. To achieve these goals experiments were carried out and compared with other results. The original of our purpose consist on tests which are ensured by adapting a U-type stretching-bending device on a tensile testing machine, where we studied and quantified the variation of the springback.

Keywords: springback, deep drawing, expansion, restricted deep drawing

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Authors: S. P. Rana

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Objectives: For the manufacture of a very thin strip or a strip with a high-quality finish, the stainless steel sheet that is called billet is re-rolled in re-rolling mill to make stainless steel sheet of 18 gauges. The rolls of re-rolling mill exert tremendous pressure over the sheet and there is likely chance of breaking of stainless steel strip from the sheet. The objective of the study was to minimise the number of accidents in steel re-rolling mills due to ejection of stainless steel strip and to minimize the pollution caused by the pickling process used in these units. Methods: Looking into the high rate of frequency and severity of accidents as well as pollution hazard in re-rolling and pickling mills, it becomes essential to make necessary arrangements for prevention of accidents in such type of industry. The author carried out survey/inspections of a large number of re-rolling and pickling mills and allied units. During the course of inspection, the working of these steel re-rolling and pickling mills was closely studied and monitored. A number of accidents involving re-rolling mills were investigated and subsequently remedial measures to prevent the occurrence of such accidents were suggested. Assessment of occupational safety and health system of these units was carried out and compliance level of the statutory requirements was checked. The workers were medically examined and monitored to ascertain their health conditions. Results: Proper use of safety gadgets by workers, machine guarding and regular training brought down the risk to an acceptable level and discharged effluent pollution was brought down to permissible limits. The fatal accidents have been reduced by 83%. Conclusions: Effective enforcement and implementation of the directions/suggestions given to the managements of such units brought down the no. of accidents to a rational level. The number of fatal accidents has reduced by 83% during the study period. The effective implementation of pollution control device curtailed the pollution level to an acceptable level.

Keywords: re-rolling mill, hazard, accident, health hazards

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Authors: Minoo Tavakoli, Alireza Kiani Rashid, Abbas Afrasiabi

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An aluminum coating deposited on mild steel substrate by electric arc spray and diffused to the base steel material by diffusion treatment at 800 and 900°C for 1 and 3 hours in a static air. Alloy layers formed by diffusion at both temperatures were investigated, and their features were compared with those of pack cementation aluminized steel. High-temperature oxidation tests were carried out in air at 600 °C for 145 hours. Results indicated that the aluminide coatings obtained from this process have significantly improved the high-temperature oxidation resistance in both methods due to the Al2O3 scale formation. Furthermore, it showed that the isothermal oxidation resistance of arc spray technique is better than pack cementation method. This can be attributed to voids that formed at the intermetallic layer /Al layer interface which is increased in the pack cementation method.

Keywords: electric arc spray, pack cementation, oxidation resistance, aluminized steel

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Authors: Bunty Tomar, Shiva S.

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Fabrication of steel and copper-based functionally graded material (FGM) through cold metal transfer-based wire arc additive manufacturing is a novel exploration. Components combining Cu and steel show significant usage in many industrial applications as they combine high corrosion resistance, ductility, thermal conductivity, and wear resistance to excellent mechanical properties. Joining steel and copper is challenging due to the mismatch in their thermo-mechanical properties. In this experiment, a functionally graded material (FGM) structure of pure copper (Cu) and 316L stainless steel (SS) was successfully developed using cold metal transfer-based wire arc additive manufacturing (CMT-WAAM). The interface of the fabricated samples was characterized under optical microscopy, field emission scanning electron microscopy, and X-ray diffraction techniques. Detailed EBSD and TEM analysis was performed to analyze the grain orientation, strain distribution, grain boundary misorientations, and formation of metastable and intermetallic phases. Mechanical characteristics of deposits was also analyzed using tensile and wear testing. This works paves the way to use CMT-WAAM to fabricate steel/copper FGMs.

Keywords: wire arc additive manufacturing (waam), cold metal transfer (cmt), metals and alloys, mechanical properties, characterization

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Authors: Maryam Hasanali, Syed Mohammad Mojtabaei, Iman Hajirasouliha, G. Charles Clifton, James B. P. Lim

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Cold-formed steel (CFS) elements are increasingly being used as main load-bearing components in the modern construction industry, including low- to mid-rise buildings. In typical multi-storey buildings, CFS structural members act as beam-column elements since they are exposed to combined axial compression and bending actions, both in moment-resisting frames and stud wall systems. Current design specifications, including the American Iron and Steel Institute (AISI S100) and the Australian/New Zealand Standard (AS/NZS 4600), neglect the beneficial effects of warping-restrained boundary conditions in the design of beam-column elements. Furthermore, while a non-linear relationship governs the interaction of axial compression and bending, the combined effect of these actions is taken into account through a simplified linear expression combining pure axial and flexural strengths. This paper aims to evaluate the reliability of the well-known Direct Strength Method (DSM) as well as design proposals found in the literature to provide a better understanding of the efficiency of the code-prescribed linear interaction equation in the strength predictions of CFS beam columns and the effects of warping-restrained boundary conditions on their behavior. To this end, the experimentally validated finite element (FE) models of CFS elements under compression and bending were developed in ABAQUS software, which accounts for both non-linear material properties and geometric imperfections. The validated models were then used for a comprehensive parametric study containing 270 FE models, covering a wide range of key design parameters, such as length (i.e., 0.5, 1.5, and 3 m), thickness (i.e., 1, 2, and 4 mm) and cross-sectional dimensions under ten different load eccentricity levels. The results of this parametric study demonstrated that using the DSM led to the most conservative strength predictions for beam-column members by up to 55%, depending on the element’s length and thickness. This can be sourced by the errors associated with (i) the absence of warping-restrained boundary condition effects, (ii) equations for the calculations of buckling loads, and (iii) the linear interaction equation. While the influence of warping restraint is generally less than 6%, the code suggested interaction equation led to an average error of 4% to 22%, based on the element lengths. This paper highlights the need to provide more reliable design solutions for CFS beam-column elements for practical design purposes.

Keywords: beam-columns, cold-formed steel, finite element model, interaction equation, warping-restrained boundary conditions

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Authors: Agnese Natali, Francesco Morelli, Walter Salvatore

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Automated Rack Supported Warehouses (ARSWs) are structures currently designed as steel racks. Even if there are common characteristics, there are differences that don’t allow to adopt the same design approach. Aiming to highlight the factors influencing the design and the behavior of ARSWs, a set of 5 structures designed by 5 European companies specialized in this field is used to perform both a critical analysis of the design approaches and the assessment of the seismic performance, which is used to point out the criticalities and the necessity of new design philosophy.

Keywords: steel racks, automated rack supported warehouse, thin walled cold-formed elements, seismic assessment

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Authors: H. Selcuk Halkacı, Mevlüt Türköz, Ekrem Öztürk, Murat Dilmec

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Various attempts concerning the low formability issue for lightweight materials like aluminium and magnesium alloys are being investigated in many studies. Advanced forming processes such as hydroforming is one of these attempts. In last decades sheet hydroforming process has an increasing interest, particularly in the automotive and aerospace industries. This process has many advantages such as enhanced formability, the capability to form complex parts, higher dimensional accuracy and surface quality, reduction of tool costs and reduced die wear compared to the conventional sheet metal forming processes. There are two types of sheet hydroforming. One of them is hydromechanical deep drawing (HDD) that is a special drawing process in which pressurized fluid medium is used instead of one of the die half compared to the conventional deep drawing (CDD) process. Another one is sheet hydroforming with die (SHF-D) in which blank is formed with the act of fluid pressure and it takes the shape of die half. In this study, transition of cup height according to cup diameter between the processes was determined by performing simulation of the processes in Finite Element Analysis. Firstly SHF-D process was simulated for 40 mm cup diameter at different cup heights chancing from 10 mm to 30 mm and the cup height to diameter ratio value in which it is not possible to obtain a successful forming was determined. Then the same ratio was checked for a different cup diameter of 60 mm. Then thickness distributions of the cups formed by SHF-D and HDD processes were compared for the cup heights. Consequently, it was found that the thickness distribution in HDD process in the analyses was more uniform.

Keywords: finite element analysis, HDD, hydroforming sheet metal forming, SHF-D

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Authors: Cai-Wan Chang-Jian, Han-Ting Tsai

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In the processing industry of metal forming, rolling is the most used method of processing. In a cold rolling factory of stainless steel, there occurs a product defect on temper rolling process within cold rolling. It is called 'roll marks', which is a phenomenon of undesirable flatness problem. In this research, we performed a series of experimental measurements on the roll marks, and we used optical sensors to measure it and compared the vibration frequency of roll marks with the vibration frequency of key components in the skin pass mill. We found there is less correlation between the above mentioned data. Finally, we took measurement on the motor driver in rolling mill. We found that the undulation frequency of motor could match with the frequency of roll marks, and then we have confirmed that the motor’s undulation caused roll marks.

Keywords: roll mark, plane strain, rolling mill, stainless steel

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Authors: Sang Hwan Bak, Min Jung Kim, Dong Bok Lee

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Fe-2%Mn-0.5%Si-0.2C steel was welded and corroded at 600, 700 and 800oC for 20 h in 1 atm of N2/H2S/H2O-mixed gas in order to characterize the high-temperature corrosion behavior of the welded joint. Corrosion proceeded fast and almost linearly. It increased with an increase in the corrosion temperature. H2S formed FeS owing to sulfur released from H2S. The scales were fragile and nonadherent.

Keywords: Fe-Mn-Si steel, corrosion, welding, sulfidation, H2S gas

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Authors: Sellidj Abdelaziz, Lebaili Soltane

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A cobalt-based alloy type Co-Cr-Ni-WC was deposited by plasma transferred arc projection (PTA) on a stainless steel valve. The alloy is characterized at the equilibrium by a solid solution Co (γ) mainly dendritic, and eutectic carbides M₇C₃ and ηM₆C. At the deposit/substrate interface, this microstructure is modified by the fast cooling mode of the alloy when applied in the liquid state on the relatively cold steel substrate. The structure formed in this case is heterogeneous and metastable phases can occur and evolve over temperature service. Coating properties and reliability are directly related to microstructures formed during deposition. We were interested more particularly in this microstructure formed during the solidification of the deposit in the region of the interface joining the soldered couple and its evolution during cyclic heat treatments at temperatures similar to those of the thermal environment of the valve. The characterization was carried out by SEM-EDS microprobe CAMECA, XRD, and micro hardness profiles. The deposit obtained has a linear and regular appearance that is free of cracks and with little porosity. The morphology of the microstructure represents solidification stages that are relatively fast with a temperature gradient high at the beginning of the interface by forming a plane front solid solution Co (γ). It gradually changes with the decreasing temperature gradient by getting farther from the junction towards the outer limit of the deposit. The matrix takes the forms: cellular, mixed (cells and dendrites) and dendritic. Dendritic growth is done according to primary ramifications in the direction of the heat removal which takes place in the direction perpendicular to the interface, towards the external surface of the deposit, following secondary and tertiary undeveloped arms. The eutectic carbides M₇C₃ and ηM₆C formed are very thin and are located in the intercellular and interdendritic spaces of the solid solution Co (γ).

Keywords: Co-Ni-Cr-W-C alloy, solid deposit, microstructure, carbides, cyclic heat treatment

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Authors: Hatem Mrad, Alban Notin, Mohamed Bouazara

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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: Usha Sivasankaran, Seetha Raman

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Experimental work on Double skin Concrete Filled tubes (DSCFT) are a variation of CFT (Concrete- filled steel tubular) with a hollow core formed by two concentric steel tubes in – filled with concrete. Six Specimens with three different volume fractions of steel fibres are cast and tested. Experiments on circular steel tubes in – filled with steel fibre reinforced concrete (SFRC) and normal concrete have been performed to investigate the contribution of steel fibres to the load bearing capacity of Short Composite Columns. The main Variable considered in the test study is the percentage of steel fibres added to the in –filled concrete. All the specimens were tested under axial compression until failure state realisation. This project presents the percentage Variation in the compression strengths of the 3 types of Composite members taken under Study. The results show that 1.5% SFRC in filled steel columns exhibit enhanced ultimate load carrying capacity.

Keywords: composite columns, optimization of steel, double skin, DSCFT

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Authors: Abdolreza Heidari Noosh Abad, Amir Abedi, Davood Mirahmadi khaki

Abstract:

The high strength and flexibility of TRIP steels are the major reasons for them being widely used in the automobile industry. Deep drawing is regarded as a common metal sheet manufacturing process is used extensively in the modern industry, particularly automobile industry. To investigate the potential of deep drawing characteristic of materials, steel sheet anisotropy is studied and expressed as R-Value. The TRIP steels have a multi-phase microstructure consisting typically of ferrite, bainite and retained austenite. The retained austenite appears to be the most effective phase in the microstructure of the TRIP steels. In the present research, Taguchi method has been employed to study investigates the effect of austempering temperature parameters on the anisotropy property of the TRIP steel. To achieve this purpose, a steel with chemical composition of 0.196C -1.42Si-1.41Mn, has been used and annealed at 810oC, and then austempered at 340-460oC for 3, 6, and 9 minutes. The results shows that the austempering temperature has a direct relationship with R-value, respectively. With increasing austempering temperature, residual austenite grain size increases as well as increased solubility, which increases the amount of R-value. According to the results of the Taguchi method, austempering temperature’s p-value less than 0.05 is due to effective on R-value.

Keywords: Taguchi method, hot rolling, thermomechanical process, anisotropy, R-value

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Authors: Amol Rakhunde, Namdeo Hedaoo

Abstract:

Cold bituminous emulsion mixes (CBEM) are preferred due to their low cost for the construction of low volume roads in India. Due to the low strength of CBEM’s, the strength is generally increased by the addition of Ordinary Portland Cement (OPC) and hydrated lime. To improve the performance of CBEM’s, the use of industrial waste material is also an alternative. Steel slag is by product of steel industry which is sustainable construction material. Due to limited modes of practice of utilization steel slag, huge amount of steel slag dumped in yards of each steel industry and engaging of important agricultural land and gave pollution to whole environment. The effective use of steel slag as additives in CBEM’s has ultimate benefits such improvement in strength of CBEM’s, waste disposal steel slag, saving natural aggregate and lowering cost of roadways. Studies carried out in the past have shown a significant improvement in the strength of CBEM’s prepared with the replacement of natural aggregate with industrial waste materials such as fly ash and ground granulated blast furnace slag. In this study, effect of modified mix which is mixes prepared with steel slag compared with the control mix and the mixes prepared with OPC. Experimental work was carried out on the sample of control mix, OPC mix, and modified mix. For modified mix, aggregate was replaced with steel slag by 10%, 20%, 30% and 40% of weight of aggregate of same size as of steel slag in aggregate gradation. For OPC mix, filler was replaced by 1%, 2% and 3% of weight of total aggregate with OPC. Optimum emulsion content of each mix obtained by using Marshall stability test and comparison of stability values were carried out. Marshall stability, indirect tensile strength test, and retained stability tests are performed on control mixes, OPC mixes and modified mixes. Significant improvement in Marshall stability retained stability and indirect tensile strength of modified mix compared to control mix and OPC mix.

Keywords: CBEM, indirect tensile strength test, Marshall stability test, OPC, optimum emulsion content, retained stability test, steel slag

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Authors: Lei Zhu, Nan Li

Abstract:

Cold stamping has been widely applied in the automotive industry for the mass production of a great range of automotive panels. Predicting the springback to ensure the dimensional accuracy of the cold-stamped components is a critical step. The main approaches for the prediction and compensation of springback in cold stamping include running Finite Element (FE) simulations and conducting experiments, which require forming process expertise and can be time-consuming and expensive for the design of cold stamping tools. Machine learning technologies have been proven and successfully applied in learning complex system behaviours using presentative samples. These technologies exhibit the promising potential to be used as supporting design tools for metal forming technologies. This study, for the first time, presents a novel application of a Convolutional Neural Network (CNN) based surrogate model to predict the springback fields for variable U-shape cold bending geometries. A dataset is created based on the U-shape cold bending geometries and the corresponding FE simulations results. The dataset is then applied to train the CNN surrogate model. The result shows that the surrogate model can achieve near indistinguishable full-field predictions in real-time when compared with the FE simulation results. The application of CNN in efficient springback prediction can be adopted in industrial settings to aid both conceptual and final component designs for designers without having manufacturing knowledge.

Keywords: springback, cold stamping, convolutional neural networks, machine learning

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Authors: Yuksel Akinay, Fatih Hayat

Abstract:

The influence of the alloying element on mechanical properties and micro structures of the Fe-22Mn-0.6C-0,6Si twinning induced plasticity (TWIP) steel were investigated at different temperatures. This composition was fabricated by a vacuum induction melting method. This steel was homogenized at 1200◦C for 8h. After heat treatment it was hot-rolled at 1100◦C to 6 mm thickness. The hot rolled plates were cold rolled to 3 mm and annealed at 700 800 and 900 °C for 60 and 150 minute and then air-cooled. X-ray diffractometry (XRD), optic microscope and field emission scanning electron microscope (FESEM), hardness and tensile tests were used to analyse the relationship between mechanical properties and micro structure after annealing process. The results show that, the excellent mechanical properties were obtained after heat treatment process. The tensile strength of material was decreased and the ductility of material was improved with increasing annealing temperature. Ni element were increased the mechanical resistance of specimens and because of carbide precipitation the hardness of specimen annealed at 700 C is higher than others.

Keywords: high manganese, heat treatment, SEM, XRD, cold-rolling

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Authors: Mohammed Mohsin Ali H., Mohamed Haneef

Abstract:

The connecting rod transmits the piston load to the crank causing the latter to turn, thus converting the reciprocating motion of the piston into a rotary motion of the crankshaft. Connecting rods are subjected to forces generated by mass and fuel combustion. This study investigates and compares the fatigue behavior of forged steel, powder forged and ASTM a 514 steel cold quenched connecting rods. The objective is to suggest for a new material with reduced weight and cost with the increased fatigue life. This has entailed performing a detailed load analysis. Therefore, this study has dealt with two subjects: first, dynamic load and stress analysis of the connecting rod, and second, optimization for material, weight and cost. In the first part of the study, the loads acting on the connecting rod as a function of time were obtained. Based on the observations of the dynamic FEA, static FEA, and the load analysis results, the load for the optimization study was selected. It is the conclusion of this study that the connecting rod can be designed and optimized under a load range comprising tensile load and compressive load. Tensile load corresponds to 360^o crank angle at the maximum engine speed. The compressive load is corresponding to the peak gas pressure. Furthermore, the existing connecting rod can be replaced with a new connecting rod made of ASTM a 514 steel cold quenched that is 12% lighter and 28% cheaper.

Keywords: connecting rod, ASTM a514 cold quenched material, static analysis, fatigue analysis, stress life approach

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Authors: E. Stepanova, N. Popov, S. Demakov, S. Stepanov

Abstract:

This paper examines the so-called invar-type behavior of metastable titanium alloy subjected to cold rolling. The effect was shown to occur due to the anisotropy of thermal expansion of titanium orthorhombic martensite. By means of X-ray diffraction analysis and dilatometry analyses, the influence of crystallographic texture of orthorhombic martensite on the coefficient of thermal expansion of sheets of metastable titanium alloy VT23 was examined. Anisotropy of the coefficient of thermal expansion has been revealed. It was lower in the rolling plane and higher along the transverse direction of the cold-rolled sheet comparing to the coefficient of thermal expansion of the unprocessed alloy.

Keywords: invar-type, cold rolling, metastable titanium alloy, texture

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