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Article
Publication date: 1 May 1994

N. Brännberg and J. Mackerle

This paper gives a review of the finite element techniques (FE)applied in the area of material processing. The latest trends in metalforming, non‐metal forming and powder…

Abstract

This paper gives a review of the finite element techniques (FE) applied in the area of material processing. The latest trends in metal forming, non‐metal forming and powder metallurgy are briefly discussed. The range of applications of finite elements on the subjects is extremely wide and cannot be presented in a single paper; therefore the aim of the paper is to give FE users only an encyclopaedic view of the different possibilities that exist today in the various fields mentioned above. An appendix included at the end of the paper presents a bibliography on finite element applications in material processing for the last five years, and more than 1100 references are listed.

Details

Engineering Computations, vol. 11 no. 5
Type: Research Article
ISSN: 0264-4401

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Article
Publication date: 1 August 1999

Jaroslav Mackerle

This paper gives a bibliographical review of the finite element methods (FEMs) applied to the analysis of ceramics and glass materials. The bibliography at the end of the…

Abstract

This paper gives a bibliographical review of the finite element methods (FEMs) applied to the analysis of ceramics and glass materials. The bibliography at the end of the paper contains references to papers, conference proceedings and theses/dissertations on the subject that were published between 1977‐1998. The following topics are included: ceramics material and mechanical properties in general, ceramic coatings and joining problems, ceramic composites, ferrites, piezoceramics, ceramic tools and machining, material processing simulations, fracture mechanics and damage, applications of ceramic/composites in engineering; glassmaterial and mechanical properties in general, glass fiber composites, material processing simulations, fracture mechanics and damage, and applications of glasses in engineering.

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Engineering Computations, vol. 16 no. 5
Type: Research Article
ISSN: 0264-4401

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Article
Publication date: 23 June 2021

Radhwan Bin Hussin, Safian Bin Sharif, Shayfull Zamree Bin Abd Rahim, Mohd Azlan Bin Suhaimi, Mohd Tanwyn Bin Mohd Khushairi, Abdellah Abdellah EL-Hadj and Norshah Afizi Bin Shuaib

Rapid tooling (RT) integrated with additive manufacturing technologies have been implemented in various sectors of the RT industry in recent years with various kinds of…

Abstract

Purpose

Rapid tooling (RT) integrated with additive manufacturing technologies have been implemented in various sectors of the RT industry in recent years with various kinds of prototype applications, especially in the development of new products. The purpose of this study is to analyze the current application trends of RT techniques in producing hybrid mold inserts.

Design/methodology/approach

The direct and indirect RT techniques discussed in this paper are aimed at developing a hybrid mold insert using metal epoxy composite (MEC) in increasing the speed of tooling development and performance. An extensive review of the suitable development approach of hybrid mold inserts, material preparation and filler effect on physical and mechanical properties has been conducted.

Findings

Latest research studies indicate that it is possible to develop a hybrid material through the combination of different shapes/sizes of filler particles and it is expected to improve the compressive strength, thermal conductivity and consequently increasing the hybrid mold performance (cooling time and a number of molding cycles).

Research limitations/implications

The number of research studies on RT for hybrid mold inserts is still lacking as compared to research studies on conventional manufacturing technology. One of the significant limitations is on the ways to improve physical and mechanical properties due to the limited type, size and shape of materials that are currently available.

Originality/value

This review presents the related information and highlights the current gaps related to this field of study. In addition, it appraises the new formulation of MEC materials for the hybrid mold inserts in injection molding application and RT for non-metal products.

Details

Rapid Prototyping Journal, vol. 27 no. 6
Type: Research Article
ISSN: 1355-2546

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Article
Publication date: 1 August 1998

Jaroslav Mackerle

This paper gives a review of the finite element techniques (FE) applied in the area of material processing. The latest trends in metal forming, non‐metal forming, powder…

Abstract

This paper gives a review of the finite element techniques (FE) applied in the area of material processing. The latest trends in metal forming, non‐metal forming, powder metallurgy and composite material processing are briefly discussed. The range of applications of finite elements on these subjects is extremely wide and cannot be presented in a single paper; therefore the aim of the paper is to give FE researchers/users only an encyclopaedic view of the different possibilities that exist today in the various fields mentioned above. An appendix included at the end of the paper presents a bibliography on finite element applications in material processing for 1994‐1996, where 1,370 references are listed. This bibliography is an updating of the paper written by Brannberg and Mackerle which has been published in Engineering Computations, Vol. 11 No. 5, 1994, pp. 413‐55.

Details

Engineering Computations, vol. 15 no. 5
Type: Research Article
ISSN: 0264-4401

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Article
Publication date: 12 May 2021

P.S. Liu and X.M. Ma

The purpose of this paper is to provide a summarization and review of the present author's main investigations on failure modes of reticular metal foams under different…

Abstract

Purpose

The purpose of this paper is to provide a summarization and review of the present author's main investigations on failure modes of reticular metal foams under different loadings in engineering applications.

Design/methodology/approach

With the octahedral structure model proposed by the present authors themselves, the fundamentally mechanical relations have been systematically studied for reticular metal foams with open cells in their previous works. On this basis, such model theory is continually used to investigate the failure mode of this kind of porous materials under compression, bending, torsion and shearing, which are common loading forms in engineering applications.

Findings

The pore-strut of metal foams under different compressive loadings will fail in the tensile breaking mode when it is brittle. While it is ductile, it will tend to the shearing failure mode when the shearing strength is half or nearly half of the tensile strength for the corresponding dense material and to the tensile breaking mode when the shearing strength is higher than half of the tensile strength to a certain value. The failure modes of such porous materials under bending, torsional and shearing loads are also similarly related to their material species.

Originality/value

This paper presents a distinctive method to conveniently analyze and estimate the failure mode of metal foams under different loadings in engineering applications.

Details

Multidiscipline Modeling in Materials and Structures, vol. 17 no. 4
Type: Research Article
ISSN: 1573-6105

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Article
Publication date: 1 December 2005

S.H. Masood and W.Q. Song

Presents development and characterisation of a new metal/polymer composite material for use in fused deposition modelling (FDM) rapid prototyping process with the aim of…

Abstract

Purpose

Presents development and characterisation of a new metal/polymer composite material for use in fused deposition modelling (FDM) rapid prototyping process with the aim of application to direct rapid tooling. The work represents a major development in reducing the cost and time in rapid tooling.

Design/methodology/approach

The material consists of iron particles in a nylon type matrix. The detailed formulation and characterisation of the thermal properties of the various combinations of the new composites are investigated experimentally. Results are compared with other metal/polymer composites used in rapid tooling.

Findings

The feedstock filaments of this composite have been produced and used successfully in the unmodified FDM system for direct rapid tooling of injection moulding inserts. Thermal properties are found to be acceptable for rapid tooling applications for injection moulding.

Originality/value

Introduces an entirely new metal based composite material for direct rapid tooling application using FDM RP system with desired thermal properties and characteristics. This will reduce the cost and time of manufacturing tooling inserts and dies for injection moulding.

Details

Assembly Automation, vol. 25 no. 4
Type: Research Article
ISSN: 0144-5154

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Article
Publication date: 30 November 2018

Chuansheng Wang, Ning Cai, Dewei Zhang, Jinxiu Zhang, Tianhao Chang, Shaoming Li, Yuqi Chao and Jiquan Hu

This purpose of this study was to develop a 3D printer based on powder particle. The best degreasing and sintering process of a blank body was investigated to obtain a…

Abstract

Purpose

This purpose of this study was to develop a 3D printer based on powder particle. The best degreasing and sintering process of a blank body was investigated to obtain a metal product with high precision and high surface finish. This process will greatly reduce the difficulty and cost of forming a complex metal product with high application value.

Design/methodology/approach

Stainless steel powder and polymer materials were mixed using a rubber mixing machine. The powders were granulated to prepare a mixed material. A powder feed 3D printer was used at low temperature (about 200°C) to print and degrease the body. A series of sintering experiments were performed to study the different sintering temperatures, and the physical and mechanical properties of the sample sintered under various conditions were compared to determine the best degreasing and sintering process.

Findings

The reaction at 1,370°C was the optimal route for the metal billet degreasing. The resulting metal products had fine structure and stable performance compared with the products with traditional powder metallurgy composition.

Originality/value

Most 3D printed metal powder materials rely on imports, which are expensive and increase the manufacturing cost. These drawbacks limit the application and development of metal 3D printing technology to a certain extent. The successful study of this molding method greatly reduces the difficulty and cost of forming complex metal products with high application value. This report will provide valuable guidance for sintering process and forming methods.

Details

Rapid Prototyping Journal, vol. 25 no. 3
Type: Research Article
ISSN: 1355-2546

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Article
Publication date: 1 December 1957

Phosphating mild steel causes the surface to be etched into a network of microscopic channels 0.0004 to 0.0008 in. deep, the phosphate crystals being located on the…

Abstract

Phosphating mild steel causes the surface to be etched into a network of microscopic channels 0.0004 to 0.0008 in. deep, the phosphate crystals being located on the intervening high spots. With this type of surface, running‐in is both rapid and safe and low friction conditions are soon established. The phosphate crystals do not act as a solid lubricant in the same sense as graphite or M0S2; initial friction is higher and final friction is much lower. Friction of MoS2, for example decreases with rubbing by a factor of 4, from 0.2 to 0.05, whereas the friction of phosphated steel decreased by a factor of 60, from 0.3 to 0.005. In addition, the final friction of the run‐in phosphated surface depended on temperature and pressure in a manner characteristic of ‘thin film’ fluid lubrication, not ‘boundary’ or ‘solid’ lubrication.

Details

Industrial Lubrication and Tribology, vol. 9 no. 12
Type: Research Article
ISSN: 0036-8792

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Article
Publication date: 31 October 2018

Jibing Chen, Nong Wan, Juying Li and Zhanwen He

Metal green parts fabricated by indirect selective laser sintering (SLS) have lower mechanical properties, and thus, they cannot satisfy practical application. To enhance…

Abstract

Purpose

Metal green parts fabricated by indirect selective laser sintering (SLS) have lower mechanical properties, and thus, they cannot satisfy practical application. To enhance their performance, two polymer resins were compounded as a modified material to infiltrate into the metal parts by SLS.

Design/methodology/approach

The viscosity and glass-transition temperature were tested by a viscometer and differential scanning calorimetry, respectively. The microstructure and morphology of the interface of parts by polymer resin infiltrated were observed to be using scanning electron microscopy. The tensile strength of sample parts was tested, too. The temperature tolerances of two mass ratio polymer materials were tested and compared by thermo-gravimetric analysis (TGA).

Findings

Compared to those without being polymer material infiltrated, the results of test showed that the tensile strength of the metallic parts is enhanced obviously, about four times. In addition, the analysis of TGA showed that the resin of mass ratio of 2:1 can be endured up to 200° and can be used as infiltrating materials for metal parts.

Originality/value

Therefore, plastic injection mold and function part can be manufactured by this method.

Details

Rapid Prototyping Journal, vol. 24 no. 9
Type: Research Article
ISSN: 1355-2546

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Article
Publication date: 1 December 2004

Jaroslav Mackerle

Sheet metal forming is a process of shaping thin sheets of metal by applying pressure through male or female dies or both. In most of used sheet‐formating processes the…

Abstract

Sheet metal forming is a process of shaping thin sheets of metal by applying pressure through male or female dies or both. In most of used sheet‐formating processes the metal is subjected to primarily tensile or compressive stresses or both. During the last three decades considerable advances have been made in the applications of numerical techniques, especially the finite element methods, to analyze physical phenomena in the field of structural, solid and fluid mechanics as well as to simulate various processes in engineering. These methods are useful because one can use them to find out facts or study the processes in a way that no other tool can accomplish. Finite element methods applied to sheet metal forming are the subjects of this paper. The reason for writing this bibliography is to save time for readers looking for information dealing with sheet metal forming, not having an access to large databases or willingness to spend own time with uncertain information retrieval. This paper is organized into two parts. In the first one, each topic is handled and current trends in the application of finite element techniques are briefly mentioned. The second part, an Appendix, lists papers published in the open literature. More than 900 references to papers, conference proceedings and theses/dissertations dealing with subjects that were published in 1995‐2003 are listed.

Details

Engineering Computations, vol. 21 no. 8
Type: Research Article
ISSN: 0264-4401

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