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1

Analiza metalograficzna przyczyn pękania rury w strefie zgrzewu liniowego podczas kształtowania

Tyrała Dorota, Pawłowski Bogdan

Inżynieria Materiałowa

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2023

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Vol. 44, nr 3

8--11

PL

Celem pracy było określenie przyczyny powstawania pęknięć w partii rur fi 48,3×2,7 mm (stal S355J2H) w obszarze zgrzewu liniowego w trakcie operacji zmniejszania średnicy z 48,3 mm do 38 mm. Część z tych pęknięć nie była widoczna podczas obserwacji makroskopowych, pęknięcia ujawniono dopiero podczas badań z wykorzystaniem mikroskopu świetlnego. W trakcie badań metalograficznych na zgładach nietrawionych nie stwierdzono występowania wad metalurgicznych mogących mieć wpływ na powstawanie i propagacje obserwowanych pęknięć. Badania na zgładach trawionych ujawniły natomiast, że wszystkie badane odcinki rur nie wykazywały mikrostruktury właściwej dla prawidłowo przeprowadzonego procesu zgrzewania prądami wysokiej częstotliwości. Przyczyną powstawania pęknięć wzdłuż linii zgrzewu był nieprawidłowy przebieg procesu zgrzewania, najprawdopodobniej zbyt niska temperatura tego procesu.

EN

The aim of the study was to determine the cause of cracking of pipes fi 48.3×2.7 mm (S355J2H steel) in the seam weld area during the operation of reducing the diameter of 48.3 mm to 38 mm. Some of these cracks were not visible during macroscopic observations, cracks were revealed only during examinations using a light microscope. During the metallographic tests on the non-etched specimens, no metallurgical defects that could affect the formation and propagation of the observed cracks were found. On the other hand, tests on etched specimens revealed that all the examined pipe sections did not show the microstructure appropriate for a proper high-frequency welding process. The reason for the formation of cracks along the weld line is the incorrect course of the HF welding process, most likely too low temperature of this process.

2

Walcowanie poprzeczno-klinowe odkuwki osi kolejowej

Bulzak Tomasz, Winiarski Grzegorz, Wójcik Łukasz

Hutnik, Wiadomości Hutnicze

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2023

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Vol. 90, nr 2

16--20

PL

Artykuł przedstawia wyniki modelowania numerycznego procesu walcowania poprzeczno-klinowego odkuwek osi kolejowych. Na wstępie przedstawiono główny problem, jakim jest pękanie materiału w procesie walcowania poprzeczno-klinowego. Przedstawiono propozycję ograniczenia zjawiska pękania materiału, polegającą na zmianie konstrukcji narzędzi kształtujących. Zaprojektowano trzy warianty narzędzi, których przydatność w procesie walcowania poprzeczno-klinowego osi kolejowych została zweryfikowana na drodze symulacji numerycznych. Symulacje numeryczne przeprowadzono metodą elementów skończonych w oprogramowaniu Simufact Forming. Uzyskane wyniki nie potwierdziły przyjętych założeń. Zastosowanie narzędzi z dwoma kątami kształtującymi wpłynęło na wzrost wartości kryterium pękania, co tym samym zwiększa ryzyko pękania materiału podczas walcowania osi kolejowych.

EN

This paper presents the results of numerical modelling of the cross-wedge rolling process of railway axle forgings. The main problem of material cracking in the cross-wedge rolling process is first presented. A proposal to reduce the phenomenon of material cracking by changing the design of forming tools is presented. Three tool variants were designed, the suitability of which in the process of cross-wedge rolling of railway axles was verified by means of numerical simulations. Numerical simulations were carried out using the finite element method in the Simufact Forming software. The results obtained did not confirm the assumptions made. The use of tools with two forming angles increased the value of the fracture criterion, thereby increasing the risk of material fracture during rolling of railway axles

3

An experimental investigation of fracture modes and delamination behaviour of carbon fiber reinforced laminated composite materials

Musafir Mustafa Abd Alhussein, Ameer Zuhair Jabbar Abdul, Hamzah Ahmed Fadhil

Diagnostyka

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2023

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Vol. 24, No. 1

art. no. 2023101

EN

Mechanically, composite laminates perform exceptionally well in-plane but poorly out-of-plane. Interlaminar damage, known as "delamination," is a major issue for composite laminates. Results from Mode-I and Mode-II experimental testing on twill-woven carbon fiber reinforced (CFRP) laminates are analyzed in this paper. Composite Mode-I fracture toughness was determined using three different methods in accordance with ASTM D5528: modified beam theory, compliance calibration, and a codified compliance calibration. Two methods, the Compliance Calibration Method and the Compliance-Based Beam Method, were used to determine the Mode-II fracture toughness in accordance with ASTM D7905. Stick-slip behavior is quite evident in the composite's ModeI fracture toughness test findings. The MBT technique's 𝐺Ic values for initiation and propagation are 0.533 and 0.679 KJ/m2 , respectively. When comparing the MBT approach to the industry-standard ASTM procedure for determining fracture toughness Mode-I, the MBT method was shown to be highly compatible. Furthermore, the 𝐺IIc values for the CBBM technique are 1.65 KJ/m2 for non-pre cracked and 1.4 KJ/m2 for pre-cracked materials. The CBBM method shows a good method to evaluate fracture toughness Mode-II, due to not needing to monitor the length of the crack during delamination growth to get the value of the fracture toughness.

4

Influence of the specific load on stability and vibrations of the multimember column with internal cracks

Sokół Krzysztof, Kuliński Krzysztof

Bulletin of the Polish Academy of Sciences. Technical Sciences

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2023

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Vol. 71, nr 4

art. no. e146408

EN

Slender systems are mostly studied when Euler’s load or follower load is considered. The use of those types of external loads results in well-known divergence or flutter shape of the characteristic curve. In this study, one takes into account the specific load which allows one to obtain an interesting divergence – pseudo flutter shape of characteristic curves on the external load–vibration frequency plane. The curves can change inclination angle as well as one can observe the change in vibration modes along them. The shape of those curves depends not only on the parameters of the slender system but also on loading heads that induce the specific load. In this study, one considers the slender multimember system in which cracks are present and weaken the host structure. The results of theoretical as well as numerical simulations are focused on the influence of the parameters of the loading heads on vibrations, stability, and loading capacity of the investigated system as well as on the possibility of partial reduction of unwanted crack effect.

5

Novel drawing technology for high area reduction manufacturing of ultra-thin brass wires

Kustra Piotr, Wróbel Mirosław, Dymek Stanisław, Milenin Andrij

Archives of Civil and Mechanical Engineering

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2023

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Vol. 23, no. 3

art. no. e144, 2023

EN

A significant increase in roughness of dieless-drawn wires due to the strain-induced roughness phenomenon has been documented. For small-diameter wires, even a slight surface relief creates stress concentrations that may contribute to the wire breakage during cold drawing. This, in turn, significantly limits the achievable diameter of the product and the efficiency of drawing process. The present study, however, demonstrates that reducing the wire roughness is possible by combining the dieless and conventional drawing methods. Thus, it is possible to improve the process workability threefold when compared to dieless drawing alone, and the product quality is simultaneously improved. In addition, the surface defects typical to the dieless-drawn wires have been significantly reduced, resulting in an increase in the wire strength. This new combined technology enables a significant reduction in the wire diameter and facilitates an economical large-scale production of ultra-thin wires. In addition, based on the classic drawing and dieless drawing process, a brass wire with a diameter of 0.017 mm has been manufactured. Six times thinner than a human hair, it is believed to be the thinnest long brass wire currently manufactured in the world.

6

Pękanie ścian wypełniających w budynku szkieletowym

Kania Tomasz, Matkowski Zygmunt, Nowak Rafał

Materiały Budowlane

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2022

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nr 11

138--140

PL

Coraz większe tempo projektowania i realizacji inwestycji budowlanych sprawia, że występuje coraz więcej problemów związanych z pękaniem ścian wypełniających. Przyczyną uszkodzeń jest m.in. wykonywanie konstrukcji stropowych o dużej rozpiętości oraz nieprawidłowo zrealizowane ich połączenie z elementami konstrukcji nośnej budynku. W artykule przedstawiono analizę przyczyn uszkodzeń ścian nienośnych w budynku wielorodzinnym o konstrukcji szkieletowej zrealizowanym w technologii monolitycznej, żelbetowej. Ściany nienośne wewnątrz mieszkaniowe wykonano z bloczków z betonu komórkowego, a ściany między mieszkaniowe i wypełniające zewnętrzne z pustaków betonowych. Jeszcze przed oddaniem lokali do użytkowania, podczas prowadzenia prac wykończeniowych, stwierdzono ich intensywne zarysowania i pęknięcia. Na podstawie przeprowadzonych pomiarów i analiz przedstawiono błędy wykonania ścian nienośnych, które doprowadziły do ich awarii.

EN

The ever-increasing pace of design and construction projects is causing an increase in problems related to the cracking of infill walls. The causes of their damage include the construction of slender floor structures with long spans as well as improperly implemented connections to elements of the building's load-bearing structure. The article presents an analysis of the causes of damage to non-load-bearing walls in a multifamily building. The frame building was constructed using monolithic reinforced concrete technology. The walls in the apartments were made of aerated concrete. The walls between the apartments and external infilling walls were made of concrete hollow blocks. Even before the premises were put into use, intensive cracking was found when finishing work was carried out. On the basis of measurements and analysis, errors in the construction of non-load-bearing walls were presented, which led to the walls’ failure.

7

Investigation of probabilistic aspects reliability of isotropic bodies with internal defects

Kvit Roman

Journal of Applied Mathematics and Computational Mechanics

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2022

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Vol. 21, nr 3

73--84

EN

A study of the stress state and reliability of an isotropic body with the same material crack resistance and evenly distributed internal defects-cracks under the conditions of homogeneous axisymmetric loading is carried out. Defects are characterized by two independent random variables – a radius and orientation angle. The probability density distribution of the defect radius is chosen in the form of an exponential law. The probability density distribution of the defect orientation angle is chosen in the form of a law that corresponds to the material isotropy. The influence of the loading level, type of stress state and body size (number of defects) on the most probable value, the mean value and the dispersion of failure loading (strength) are investigated.

8

Crack growth diagnostic of ball bearing using vibration analysis

Belaidi S., Lecheb S., Chellil A., Mechakra H., Safi B., Kebir H.

International Journal of Applied Mechanics and Engineering

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2022

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Vol. 27, no. 1

35--45

EN

It is known that supported ball bearings have great effects on the vibrations of the gear transmission system, above in all the presence of local faults as well as the crack growths. For this purpose, this paper focuses on shock and vibration crack growth diagnostic of ball bearing using vibration analysis. Our work is devoted first to a study the static behaviour of the ball bearing by determining the stress, strain and displacement, then its dynamic behaviour by determining the first four natural frequencies. Secondly, a dynamic analysis study of the bearing was carried with defects as a function of crack size and location. The obtained results clearly show that the natural frequencies decrease in a non-linear way with the growth of the length of the crack, on the other hand the stress increases with the presence of the singular points of the crack. Finally, this residual decrease in natural frequencies can be used as an indicator of the state of failure, as well as a parameter used for the diagnosis and screening, and to highlight the fatigue life of the bearing.

9

Zastosowanie rentgenowskiej metody pomiaru naprężeń w diagnostyce przyczyny pękania elementu spawanego turbiny gazowej

Szymański Wojciech

Badania Nieniszczące i Diagnostyka

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2022

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1-4

8--12

PL

W pracy przedstawiono metodykę diagnostyki przyczyn pękania detalu turbiny gazowej w miejscu połączenia spawanego dwóch stopów żarowytrzymałych. Wykonano rozkład naprężeń w okolicy złącza spawanego po wykonaniu elementu, co pozwoliło określić przyczynę pękania. Próby wyżarzania i odprężania wibracyjnego, nie przyniosły spodziewanych efektów. W dalszej części pracy przeprowadzono pomiary naprężeń łączonych spoiną elementów detalu na kolejnych etapach jego wytwarzania, co pozwoliło na określenie, w którym momencie produkcji powstają krytyczne naprężenia będące przyczyną przedwczesnego pękania w czasie pracy turbiny. Poprawa technologii produkcji eliminująca niekorzystny rozkład naprężeń pozwoliła na uzyskanie oczekiwanego czasu pracy turbiny bez awarii.

EN

The paper presents the methodology of diagnostics of the causes of cracking of a gas turbine detail in the place of a welded joint of two heat-resistant alloys. The stress distribution in the area of the welded joint was made after the element was made, which allowed to determine the cause of the cracking. Attempts at annealing and vibration stressing did not bring the expected results. In the further part of the work, measurements of the stresses of the elements connected by welding were carried out at subsequent stages of its production, which allowed to determine at which point in production critical stresses arise, which cause premature fracture during the operation of the turbine. The improvement of the production technology eliminating the unfavourable stress distribution allowed to obtain the expected working time of the turbine without failure.

10

AA5052 failure prediction of electromagnetic flanging process using a combined fracture model

Deng Huakun, Mao Yunfei, Li Guangyao, Zhang Xu, Cui Junjia

Archives of Civil and Mechanical Engineering

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2022

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Vol. 22, no. 2

art. no. e84, 1--17

EN

Electromagnetic forming process could significantly increase the forming limit of aluminum alloy. However, high-speed fracture prediction of aluminum alloys is a major problem in the development of electromagnetic flanging process. In this study, notched specimen tensile tests with high-speed Digital Image Correlation system were conducted under the strain rate range from 0.001 to 100 s-1. A fracture model of AA5052 alloys which combined of an uncoupled fracture model, Gissmo damage evolution model and Johnson-Cook strain rate effect was established. Electromagnetic flanging experiments were conducted to verify the failure criteria effectiveness. Results showed that failure strain was significantly influenced by strain rate under various loading path. Compared with the experiments, the percentage error of established electromagnetic flanging process FEM model was less than 4%. The fracture model established could well predict notched specimen high-speed failure, and also accurately predict sheet failure model of electromagnetic flanging experiments and, thus, verified the effectiveness of the established dynamic failure criteria in electromagnetic flanging process.

11

Microstructure and mechanical properties of Sc-modified AA2519-T62 laser beam welded butt joints

Kosturek Robert, Grzelak Krzysztof, Torzewski Janusz, Wachowski Marcin, Śnieżek Lucjan

Advances in Materials Science

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2022

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Vol. 22, nr 4(74)

57--69

EN

The fundamental aim of the research is to investigate the microstructure and mechanical properties of the AA2519-T62 laser beam welded joints obtained with various values of welding velocity. For the constant value of laser power (3.2 kW) three joints have been produced with various values of welding velocity: 0.8, 1.1, and 1.4 m/min. The joints have been subjected to microstructure analysis (including both light and scanning electron microscope), microhardness measurements, tensile tests, and fractography of tensile samples. The established values of joint efficiency contain within the range of 55-66% with the highest value (66%) reported for the joint obtained with 1.1 m/min welding velocity. The produced welds have noticeable participation of pores, which tends to increase together with the value of welding velocity. In all cases, the failure has occurred in the fusion zone by ductile fracture.

12

Sprawdzenie, czy przeprowadzono test wygrzewania HST [Test wygrzewania szkła hartowanego termicznie]

Calderone Ignatius

Świat Szkła

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2021

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R. 26, nr 3

44--48

13

BREAK – kalibracja teselacji stochastycznych w celu przewidywania pęknięć szkła hartowanego termicznie

Kraus Michael A., Pourmoghaddam Navid, Schneider Jens, Siebert Gerald

Świat Szkła

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2021

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R. 26, nr 10

66--70

14

Unified methodology for strength and stress analysis of structural concrete members

Oukaili Nazar

International Journal of Applied Mechanics and Engineering

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2021

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Vol. 26, no. 1

178--200

EN

In this paper, a methodology is presented for determining the stress and strain in structural concrete sections, also, for estimating the ultimate combination of axial forces and bending moments that produce failure. The structural concrete member may have a cross-section with an arbitrary configuration, the concrete region may consist of a set of subregions having different characteristics (i.e., different grades of concretes, or initially identical, but working with different stress-strain diagrams due to the effect of indirect reinforcement or the effect of confinement, etc.). This methodology is considering the tensile strain softening and tension stiffening of concrete in addition to the tension stiffening of steel bars due to the tensile resistance of the surrounding concrete layer. A comparison of experimental and numerical data indicates that the results, obtained based on this methodology, are highly reliable and highly informative.

15

Corrosion of pipe steels 20 and 17G1S-U in ground electrolytes with a hydrogen indicator close to neutral

Polutrenko M., Maruschak P., Babii A., Prentkovskis O.

Archives of Materials Science and Engineering

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2021

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Vol. 108, nr 1

16--23

EN

Purpose: of this paper is to analyse the mechanism of near-neutral pH corrosion of main gas pipelines. The stages of main gas pipelines in model environments that meet the soil conditions of Ukraine have been studied. Design/methodology/approach: The corrosion rate of steel specimens from steels 17G1S-U and 20 and the influence of borate buffers on their protective properties were evaluated. The influence of corrosion time on changes in pH of model media is shown. Morphological features of surface damages of pipe steels are established. The defect analysis of specimens from steels 17G1S-U and 20 by electron scanning microscopy is carried out. Findings: The effect of borate buffers on the protective properties of the steel grades studied was revealed, and changes in the pH of the model media during corrosion processes were described. The main regularities in corrosion, as well as the surface morphology of damaged specimens, were studied by scanning electron microscopy. Research limitations/implications: Detailed investigation of localised corrosion phenomena induced by inclusions that are present in steels 17G1S-U and 20 is extremely critical. In particular, there is still ambiguity as to whether the localised corrosion initiation induced by non-metallic inclusions is an electrochemical process or a chemical process. Practical implications: The research findings will be used when testing specimens from pipe steels under cyclic loading in the model media studied, as well as for predicting the residual life of gas pipelines with corrosion defects. Their generalization will make it possible to develop the effective methods of ground diagnostics and prediction of SCC of main pipelines. Originality/value: It was found that the corrosion rate is determined by internal (nature and properties of the metal) and external (properties of the aggressive medium and the corrosion process conditions) factors. The protective effect for steel 17G1S in medium NS4 + borate buffer (1: 1) was 61.5%. Steel 20 had the greatest protective effect in medium NS4 + borate buffer (1: 3), which was 87.05%.

16

Analysis of temperature-field and stress-field of steel plate concrete composite shear wall in early stage of construction

Sun Yun, Guo Yaojie

Archives of Civil Engineering

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2021

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Vol. 67, nr 1

351--366

EN

To study the influence of temperature field and stress field on the cracking of the small thickness steel plate concrete composite shear wall (SPCW) in the early stage of construction. The temperature field and stress field of a 400 mm thickness SPCW was monitored and simulated through experimental research and numerical simulation. Moreover, a series of parameter analyses were carried out by using ANSYS to investigate the distribution of temperature field and stress field of SPCW. Based on the analysis results, some suggestions are put forward for controlling the cracking of SPCW in the early stage of construction. The results show that the temperature stress of 400 mm thickness SPCW in the early stage of construction is small, and there is no crack on the wall surface. For SPCW with thickness less than 800mm, the temperature stress caused by hydration heat in the early stage of construction is small, and the wall will not crack. The parameters such as wall thickness, steel plate thickness, boundary condition and stud space significantly influence the temperature field and stress field distribution of the small thickness SPCW in the early stage of construction, and reasonable maintenance measures can avoid cracking.

17

The decisive impact of microstructure on the machinability of pure copper

Sun Xiaoxiang, Ebrahimi Mahmoud, Attarilar Shokouh

Archives of Civil and Mechanical Engineering

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2021

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Vol. 21, no. 3

852--860

EN

Ultrafine-grained (UFG) materials have been of great attention due to their considerable behavior compared to coarse-grained counterparts. Also, the machinability of these UFG materials is of great importance because of the machining significance in manufacturing the final shape of industrial components. Hence, this study dealt with machinability in relation to the microstructure and mechanical properties of the UFG pure copper processed by the twist extrusion. The remarkable microstructure evolution through the dynamic recrystallization mechanisms improved the tensile strengths and hardness of the twist extrusion processed pure copper. Also, the reduction of ductility in the UFG copper compared to the initial state was related to the change of tensile fractography mechanism in which the large and deep dimples transformed into the combined small and shallow dimples with some cleavage planes in the UFG copper. Furthermore, the enhanced machinability of the processed sample was related to its lower thermal conductivity and the development of strain localization within the narrow shear bands which lead to the production of discontinuous short chips. Hence, the formation of the UFG structure is a suitable option to attain the enhanced machinability behavior of copper as one of the most used metals.

18

Investigation of modified friction stir clinching-brazing process of AA2024 Al/AZ31 Mg: metallurgical and mechanical properties

Paidar Moslem, Kazemi Amirreza, Mehrez Sadok, Ojo Olatunji Oladimeji, Nasution Mahyuddin Khairuddin Matyuso, Mironov Sergei Nikolaevich

Archives of Civil and Mechanical Engineering

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2021

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Vol. 21, no. 3

516--532

EN

The weldability of the AA2024-T3 and AZ31 Mg alloys was investigated using the modified friction stir clinching-brazing (MFSC-B) and probe-less friction stir spot brazing (PFSSB) processes. A 50 µm thick Zn foil-interlayer was sandwiched between the dissimilar base materials for the welding processes. The mechanical, microstructure, and weld-fracture behaviors of all joints were studied and compared. Zn-rich interdiffusion-aided lamellar and blocky structures are found at the brazed region/zone of the AA2024-T3/Zn/AZ31 joint irrespective of the welding process due to the sole influence of heat input at the zone. The differential flow in the MFSC-B joint enforces significant inter-material mingling, better distribution of Zn, and more subgrains/dislocation density at the joint as compared to the PFSSB joint. The interlayer inhibited the creation of the β-Al3Mg2 phase while the γ-Al12Mg17 phase could not be prevented in the AA2024-T3/Zn/AZ31 joints due to tool-induced atomic collision and diffusion–reaction mechanisms. Improved tensile/shear failure load is found in the MFSC-B joint (4369 N) as related to their PFSSB counterpart (3018 N) due to improved material flow (intermixing), and intense dislocation density. The MFSC-B process is thus recommended for dissimilar joining of Mg and Al alloys.

19

Fracture limit analysis of DP590 steel using single point incremental forming: experimental approach, theoretical modeling and microstructural evolution

Pandre Sandeep, Morchhale Ayush, Mahalle Gauri, Kotkunde Nitin, Suresh Kurra, Singh Swadesh Kumar

Archives of Civil and Mechanical Engineering

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2021

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Vol. 21, no. 3

138--157

EN

The single point incremental forming (SPIF) process is gaining special attention in the aerospace, biomedical and manufacturing industries for making intricate asymmetric components. In the present study, SPIF process has been performed for forming varied wall angle conical and pyramidal frustums using DP590 steel. Initially, the conventional stretch forming process has been performed for finding the fracture forming limit diagram (FFLD). Further, it has been validated with the limiting strains found using SPIF process. The conical and pyramidal frustums deformed near to the plane strain and biaxial region, respectively. The theoretical FFLD has been predicted using seven different ductile damage models. The effect of sheet anisotropy while predicting the fracture strains has been included using Hill 1948 and Barlat 1989 yielding functions. Among the used damage models, the Bao-Wierzbicki (BW) model along with Barlat 1989 yield criterion displayed the least error of 2.92% while predicting the fracture locus. The stress triaxiality in the different forming region has been thoroughly investigated and it has been found that the higher triaxiality value reveals high rate of accumulated damage which lead to early failure of the material in the respective region. The stress triaxiality and effective fracture strains have also been found to be significantly affected by the anisotropy. The micro-textural studies have also been performed and it has been found that the increase in local misorientations and shift in the textural components from γ-fiber to ε-fiber in the corner region of the frustums worked towards limiting the formability of material and ultimately leading towards the fracture of frustums.

20

Effect of pre-cut hole diameter on deformation mechanics in multi-stage incremental hole flanging of deep drawing quality steel

Gandla Praveen Kumar, Kurra Suresh, Prasad K. Sajun, Panda Sushanta Kumar, Singh Swadesh Kumar

Archives of Civil and Mechanical Engineering

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2021

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Vol. 21, no. 1

260--282

EN

Incremental hole flanging (IHF) is a relatively new sheet metal forming process to produce intricate shapes without using dedicated punches and dies. The present work focuses on understanding the mechanics of the multi-stage IHF process through experimental studies and the finite element approach. The IHF experiments were performed on deep drawing quality steel sheets with a pre-cut hole diameter of 45 mm, 50 mm, 60 mm, and 70 mm. The cylindrical flanges were formed in four stages with an initial wall angle of 60° to a final angle 90° with an angle increment of 10° in each stage. The maximum and minimum hole expansion ratio was found to be 2.06 and 1.17 respectively. The fracture was observed in a blank of 45 mm pre-cut hole diameter in the third stage at 40 mm depth. The fracture forming limit diagram (FFLD) was determined from incrementally formed varying wall angle conical and pyramidal frustums. Consequently, six different ductile damage models incorporating Hill48 anisotropy plastic theory were successfully calibrated. The Ayyada model showed good agreement with experimental FFLD as compared to all other models. The fracture limit determined experimentally and using the Ayyada model was implemented in the finite element simulation of the IHF process to predict the formability in terms of in-plane strain distribution, forming forces, and thickness distribution. The predicted results matched accurately with the experimental data within a 6% error for all investigated conditions. Noticeably, the strain path in IHF had three deformation modes viz. plane strain, bi-axial stretching, and uni-axial tension, which was comprehended using texture analyses. Finally, irrespective of the initial pre-cut hole diameter, the surface roughness was found to decrease with the number of stages of the IHF process.