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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.

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; glass – material and mechanical properties in general, glass fiber composites, material processing simulations, fracture mechanics and damage, and applications of glasses in engineering.

As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous expansion of the application of AM materials, subtractive processing has become one of the necessary steps to improve the accuracy and performance of parts. In this paper, the processing process of AM materials is discussed in depth, and the surface integrity problem caused by it is discussed.

Firstly, we listed and analyzed the characterization parameters of metal surface integrity and its influence on the performance of parts and then introduced the application of integrated processing of metal adding and subtracting materials and the influence of different processing forms on the surface integrity of parts. The surface of the trial-cut material is detected and analyzed, and the surface of the integrated processing of adding and subtracting materials is compared with that of the pure processing of reducing materials, so that the corresponding conclusions are obtained.

In this process, we also found some surface integrity problems, such as knife marks, residual stress and thermal effects. These problems may have a potential negative impact on the performance of the final parts. In processing, we can try to use other integrated processing technologies of adding and subtracting materials, try to combine various integrated processing technologies of adding and subtracting materials, or consider exploring more efficient AM technology to improve processing efficiency. We can also consider adopting production process optimization measures to reduce the processing cost of adding and subtracting materials.

With the gradual improvement of the requirements for the surface quality of parts in the production process and the in-depth implementation of sustainable manufacturing, the demand for integrated processing of metal addition and subtraction materials is likely to continue to grow in the future. By deeply understanding and studying the problems of material reduction and surface integrity of AM materials, we can better meet the challenges in the manufacturing process and improve the quality and performance of parts. This research is very important for promoting the development of manufacturing technology and achieving success in practical application.

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.

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.

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.

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).

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.

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.

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.

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.

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.

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

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.

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.

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.

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.

The purpose of this paper is to study the functionality of additively manufactured (AM) parts, mainly depending on their dimensional accuracy and surface finish. However, the products manufactured using AM usually suffer from defects like roughness or uneven surfaces. This paper discusses the various surface quality improvement techniques, including how to reduce surface defects, surface roughness and dimensional accuracy of AM parts.

There are many different types of popular AM methods. Unfortunately, these AM methods are susceptible to different kinds of surface defects in the product. As a result, pre- and postprocessing efforts and control of various AM process parameters are needed to improve the surface quality and reduce surface roughness.

In this paper, the various surface quality improvement methods are categorized based on the type of materials, working principles of AM and types of finishing processes. They have been divided into chemical, thermal, mechanical and hybrid-based categories.

The review has evaluated the possibility of various surface finishing methods for enhancing the surface quality of AM parts. It has also discussed the research perspective of these methods for surface finishing of AM parts at micro- to nanolevel surface roughness and better dimensional accuracy.

This paper represents a comprehensive review of surface quality improvement methods for both metals and polymer-based AM parts.

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.

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.

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.

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.

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.