With the development of manufacturing techniques, the demands have increased on tools with flexible components that can produce parts with different shapes and sizes only by replacing the rigid part of these tools, since the flexible part can match the required geometry. This study is focused on effects of rubber hardness and sheet thickness on the springback developed on the produced parts. Silicone rubber with three hardness (40,60 ,80) Shore A hardness scale was used. The material of workpiece was Aluminum (3003) with three different thicknesses of (0.8,1,1.2) mm and three holding time of (0,10,20) seconds. The results demonstrate that, the springback decreases with any increase in the rubber hardness or sheet thickness. In addition, the holding time showed a significant effect only with a harder rubber.
Most of wire drawing processes is performed at room temperature, causing rising up the heat due to the plastic deformation and the generated friction at the work piece-tool interface. In the poor lubrication conditions, there is a likelihood that both the die and the drawn wire will be damaged. This is because the drawing load is greatly influenced by tool geometry and lubrication conditions, The research work conducted in this paper focuses on drawing of 3 mm diameter Electrolytic tough pitch (ETP) cooper wire to perform 20% reduction in cross sectional area through a conical die. Various parameters have been tested to study the effect of them on the forming load during wire drawing including die angle (4°,6°,8°), bearing distance (1.2, 1.5, 1.8) mm, and lubricant types (Lithium-based greases, soap powder, oil HP). The first phase of this paper is conducted to estimate the coefficient of friction for each lubricant type, Utilizing the experimental values of drawing force in theoretical formals. Based on the estimated values obtained, the second phase was creating numerical model to extend the work to more parameters level as well as check the results validation. The results demonstrated that the drawing force increases with increasing of bearing distance and friction coefficient.
This work aims to provide an experimental investigation into metal removal and micro-hardness through the Magnetic Abrasive Finishing process (MAF) and study the impact of some process parameters (feed rate, coil current, and spindle speed) on these responses with (1008-AISI) workpieces and spherical electromagnetic tool based on Taguchi design of the experiment using Minitab 17 software. The results show that metal removal was strongly affected by the feed rate, while the strongly influential variable on micro-hardness was the coil current. The highest value of metal removal rate is achievable at conditions 10 mm/min, 2.5 A, and 700 RPM for feed rate, coil current, and spindle speed respectively.
This work aims to provide an experimental investigation into metal removal and micro-hardness through the Magnetic Abrasive Finishing process (MAF) and study the impact of some process parameters (feed rate, coil current, and spindle speed) on these responses with (1008-AISI) workpieces and spherical electromagnetic tool based on Taguchi design of the experiment using Minitab 17 software. The results show that metal removal was strongly affected by the feed rate, while the strongly influential variable on micro-hardness was the coil current. The highest value of metal removal rate is achievable at conditions 10 mm/min, 2.5 A, and 700 RPM for feed rate, coil current, and spindle speed respectively.
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