The springback failure of ultra-high strength boron steel (22MnB5) in hot press forming (HPF) process was characterized under bending and membrane conditions. Hot press forming for U–shaped parts with ultra-high strength boron steel were experimented and simulated to study the effect of initial blank temperatures on springback failure in the automotive industry. The results specify the various preheated temperature of 22MnB5 blank effect toward springback occurrences with reference to hot press forming dies design. ANSYS Workbench was used to verify finite element (FE) simulations of the processes in order to consolidate the knowledge of springback. The validated numerical simulation model were used in analyzing the stress and strain distributions along the formed part in the FE models, it was found that the springback angle was related in averaging value throughout quenching, regardless of the forming conditions. Springback failure mainly caused dimension deviation in hot press form parts due to the impact of thermal restoring moments and quenching rate of hot press forming process.
Weight reduction and material substitution were increasing trends in the automotive industry due to the growing demand for more fuel-efficient vehicles to reduce energy consumption nowadays. The characteristic properties of aluminium alloy which includes high strength stiffness to weight ratio, good corrosion resistance, and high recycling potential make it the ideal candidate to replace the other materials (Steel or copper) currently used in cars. The replacement to aluminium alloy parts is on par to the weight reduction demand within automotive industry. The focus on lightweight had also brought the attention on the high strength Aluminium alloy. Its high mechanical properties and excellent strength to weight ratio had made it suitable for car frame parts. In order to improve its mechanical properties, the heat treatment technique make it the suitable process to implement in aluminium alloy for produce the car body parts. The process of heat treatment was same as hot stamping technique which is this process was to improve its mechanical properties. Hence, in order to define and identified the heat treatment technique available, this paper had reviewed on the development of forming process and heat treatment condition applied toward aluminium alloy throughout the years.
Abstract-In the new global economy, consumption has become a central issue for many fields of industries. This project work studied on the effectiveness of pulse duration of supercritical carbon dioxide (SCCO 2 ) in machining performance in terms of cutting temperature, cutting force and surface roughness in turning AISI 1045 medium carbon steel by uncoated cemented carbide insert. Pulse mode reduces the quantity used for cutting fluids because of the decrease of spray duration. The minimization of cutting fluids also brings economic benefits by way of saving the carbon dioxide and lubricant costs. The encouraging result includes the reduction of lubricant flow rate consumption and machining cost while maintaining significant performance, such as cutting temperature, cutting force and surface roughness. The performance of SCCO 2 pulse cooling is comparable with continuous cooling with only 34% maximum increment in temperature, 3.64% increment of cutting force, 14% increment of surface roughness and 36.18% increment of tool life.Keyword-Cryogenic coolant, Lathe, Pulse, Supercritical carbon dioxide, Sustainable machining I. INTRODUCTION In past decades, rapid development in manufacturing technology are emerging in many ways. Product quality and cost reduction are an important components in the manufacturing activities. They are some of the main key roles in obtaining the effectiveness of machining processes. Previous studies have reported that the main consideration is usually the overall machining cost, which depends most strongly in tool life [1]. The tool life and the tool wear rate are both affected by high cutting force and temperature during machining operation.In the turning process, the temperature at the critical point is normally controlled by the cutting fluids during the material removal process. Flood coolant is commonly used technique for various machining applications. However, this method uses very large amounts of cutting thus becomes a liability especially on the health and environmental hazards [2]. Therefore, near dry machining was introduced as an alternative to the flood coolant. Reports showed that the performance of near dry machining is superior to that of flood coolant [3][4][5][6][7][8]. However, in recent days, cryogenic technique was introduced to remove the heat from the cutting zone by using liquid nitrogen as a cooling gas. Besides that, carbon dioxide gas can be used as the cryogenic coolant where the gas needs to be pressurized up to the supercritical phase.Supercritical carbon dioxide (SCCO 2 ) cooling technique is one of the novel techniques that could minimize the generation of cutting temperature and proven to benefit the economical aspect by substituting the aqueous emulsion and the mineral oil, which are currently being used in the metalworking industries. Sprays of rapidly expanding SCCO 2 cool and lubricate the machining processes by delivering a mixture of dry ice and lubricant deep into the cutting zone [9,10]. From previous researches, SCCO 2 cooling technique has shown...
Available forming process applied for heat treatable aluminium alloy were reviewed and presented in this paper. The reviews emphasized on the heat treatment, application and contribution of the forming methods. Forming methods discussed includes traditional, warm forming, hydroforming, superplastic forming, hot forming with in-die quench (HFQ) and hot press forming (HPF). The effects of forming processes towards heat treatable aluminium alloy were presented through the understanding on each process strengthening phenomena and the heat treating phenomena. These were to ensure better understanding on heat treatable aluminium alloy composition changes throughout forming process. Finally, concluding remarks the underline challenges of forming heattreatable aluminium alloy and subsequently highlights the potential work that can be applied in order to ensure a more efficient and sustainable manufacturing agenda for heat treatable aluminium alloy.
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