Experimental and numerical investigations into the deformation and fracture behavior of intermetallics and base materials in as-cast Al-Cu compounds

Greß, Thomas; Gruber, Maximilian; Stahl, Jens; Wittmann, Simon; Steinlehner, Florian; Nardi, Vanessa Glück; Tonn, Babette; Volk, Wolfram

doi:10.1016/j.mtcomm.2020.101278

Cited by 4 publications

(1 citation statement)

References 32 publications

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“…Cold and hot tool steels are also used in the molds of the parts used in these sectors. The cold work steel (X153CrMoV12) is widely used in the industry, especially in cold forming sheet-metal molds, deep drawing molds, molds of highly abrasive plastics applications as well as in machinery and equipment such as bolt rolling rollers and combs, plastic crushing blades, cold rolling rollers, woodworking tools and sections subject to breakage (Greß et al , 2020; Rathmann and Vollertsen, 2020; Aragaw et al , 2020). It is very suitable for cutting and crushing applications owing to its high abrasion resistance and high toughness.…”

Section: Introductionmentioning

confidence: 99%

An investigation on cutting of the cold work steel X153CrMoV12 by WEDM

Ceritbinmez

2021

AEAT

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Purpose Wire electric discharge machining (WEDM) is a non-conventional machining process, which is used for cutting parts of civil and military aircraft, rotorcraft, satellites and spacecraft. The cold work steel X153CrMoV12 is used in molds that are needed to produce plastic and metal parts used in these areas. It is only possible to produce parts with precise dimensions and quality with the use of mold steels with sensitive surfaces. The purpose of this study is to analyze X153CrMoV12 material by cutting it with WEDM method in precise dimensions. Design/methodology/approach The effects of varying cutting parameters on the size of the finished product, surface roughness (SR) and surface hardness were determined by making rough in one pass and precision cuts in different passes. Nikon SMZ745T, Mitutoyo micrometer, Mitutoyo SJ-210 and Insize ISHL-P100 were used for macro-analysis, dimensional control, SR and surface hardness, respectively, to determine the cut qualities. Findings According to the hardness measurement results obtained from the steel surface before cutting and from the cut surfaces after cutting, there was no significant change in the surface hardness owing to the use of heat-treated steel. Increasing the wire tension as a result of the increase in the number of cutting passes and the decrease in the amount of rough stock left for the final cut increased the cut quality. Cutting precision has increased by preventing vibration of the wire with zero upper and lower water pressure required for slag cleaning. Originality/value There are many studies on WEDM in the literature, but there is no similar study emphasizing the importance of the processing parameters such as the number of cutting passes and rough stock amount. In this study, cold work steel with a hardness of 56–60 HRC was machined as rough cut in one pass, rough and fine cut in double pass, double fine cut after one roughing in three passes. As a result of the cuts, 3 µm measurement precision and 0.998 Ra SR were obtained as well as there was no hardness change in the cut surfaces.

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Section: Introductionmentioning

confidence: 99%

An investigation on cutting of the cold work steel X153CrMoV12 by WEDM

Ceritbinmez

2021

AEAT

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Establishing Equal-Channel Angular Pressing (ECAP) for sheet metals by using backpressure: manufacturing of high-strength aluminum AA5083 sheets

Gruber,

Illgen,

Lichte

et al. 2023

Int J Adv Manuf Technol

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Severe plastic deformation (SPD) processes offer the possibility of improving the mechanical properties of metallic materials by grain refinement. However, this great potential has so far mostly been applied on a laboratory scale or on small series. Equal-Channel Angular Pressing (ECAP) also enables to integrate the advantages in industrial processes with large output—so far, mainly for bars or thick plates. In this paper, we investigate the ECAP process for sheet metal. Preliminary investigations have shown that cracks form on the surface when aluminum AA5083 sheets are processed. To solve this problem, we determined the Johnson–Cook fracture criterion for the material and modeled the process numerically. The simulation was carried out with the superposition of a backpressure and subsequently implemented and validated experimentally. The semi-finished sheet metal products from the ECAP investigation were then mechanically characterized with microhardness measurements and tensile tests. In addition, the microstructure was investigated with Electron Back Scatter Diffraction (EBSD). Even comparatively small amounts of backpressure (10 MPa) already result in a significant suppression of the crack formation in the numerical and experimental investigations. The microhardness measurements indicate a more homogeneous strain distribution for a sufficient level of applied backpressure which enables the processing of crack-free sheets in multiple ECAP passes. As with ECAP of bulk materials, tensile tests on the processed sheets show a reduced elongation to failure (− 73%) but a significantly increased yield strength (+ 157%) compared to the initial condition of the material. Distinct substructures are found in the EBSD measurements and explain this behavior. The findings provide the basis for using ECAP on an application-oriented scale and demonstrate an advanced manufacturing method for the production of high-strength aluminum sheets.

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Interfacial characteristics, mechanical properties and fracture behaviour of Al/Mg bimetallic composites by compound casting with different morphologies of Al insert

Jiang

Guan

et al. 2022

International Journal of Cast Metals Research

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Experimental and numerical investigations into the deformation and fracture behavior of intermetallics and base materials in as-cast Al-Cu compounds

Cited by 4 publications

References 32 publications

An investigation on cutting of the cold work steel X153CrMoV12 by WEDM

An investigation on cutting of the cold work steel X153CrMoV12 by WEDM

Establishing Equal-Channel Angular Pressing (ECAP) for sheet metals by using backpressure: manufacturing of high-strength aluminum AA5083 sheets

Interfacial characteristics, mechanical properties and fracture behaviour of Al/Mg bimetallic composites by compound casting with different morphologies of Al insert

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