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A CRITICAL stage in the process of making aircraft occurs with alarming frequency in the history of aviation.

The purpose of this paper is to propose a computational approach in order to help establish the effect of various self-piercing rivet (SPR) process and material parameters on the quality and the mechanical performance of the resulting SPR joints.

Toward that end, a sequence of three distinct computational analyses is developed. These analyses include: (a) finite-element modeling and simulations of the SPR process; (b) determination of the mechanical properties of the resulting SPR joints through the use of three-dimensional, continuum finite-element-based numerical simulations of various mechanical tests performed on the SPR joints; and (c) determination, parameterization and validation of the constitutive relations for the simplified SPR connectors, using the results obtained in (b) and the available experimental results. The availability of such connectors is mandatory in large-scale computational analyses of whole-vehicle crash or even in simulations of vehicle component manufacturing, e.g. car-body electro-coat paint-baking process. In such simulations, explicit three-dimensional representation of all SPR joints is associated with a prohibitive computational cost.

It is found that the approach developed in the present work can be used, within an engineering optimization procedure, to adjust the SPR process and material parameters (design variables) in order to obtain a desired combination of the SPR-joint mechanical properties (objective function).

To the authors’ knowledge, the present work is the first public-domain report of the comprehensive modeling and simulations including: self-piercing process; virtual mechanical testing of the SPR joints; and derivation of the constitutive relations for the SPR connector elements.

A review of CFRP dealing with its processing, properties and some of the ways in which it could be used in conjunction with conventional materials. The importance of the utilization of carbon fibres in commercially useful as well as experimental structures is discussed. This may be achieved by using the fibres in conjunction with conventional sheet metal components, as a preliminary step toward the 100 per cent reinforced plastic structure. A few such applications are described, together with a brief summary of the fibre processing and properties as an aid to preliminary design studies.

MUCH ingenuity has been devoted of late years to the problem of rapid and secure fastenings for sheet‐metal work, and numbers of devices have been evolved to replace the slower and more cumbersome traditional methods. A particularly interesting American development in this line takes the form of a threaded rivet of the type shown in fig. 1. The shank portion of this rivet is made somewhat thinner so that it can be upset by a suitable heading tool (hand or power). This heading tool transmits a pull on the threaded portion so that a bulge forms on the plain shank portion immediately above the threads and below the sheet or sheets to which the rivet is applied, and the pull on the threads is continued until the expanding metal seats itself firmly against the work to be fastened. The pull‐up stud of the heading tool is then removed from the threads, and the fixing is complete with the rivet threads clean, ready for the attachment of another member by means of a screw in the manner shown by fig. 2, giving at least six full threads for this purpose, no matter how thin the metal sheet.

To introduce an innovative method for the design of supporting elements to be applied to the free‐form components during the dimensional control.

This paper shows an innovative procedure based on reverse engineering and rapid prototyping techniques for the realization of fixtures fitting the geometry of free‐form elements. The application of the procedure have been made on a sheet metal free‐form element. After the design and manufacturing of the supporting elements, some uniformly distributed measurements have been made on the sheet metal component. A coordinate measuring machine (CMM) has been used in order to get dimensional information and to give the IT class location of the component.

The use of the CMMs for the dimensional control of the production elements requires the availability of an adequate supporting system above all if the control concerns free‐form components with complex forms. This influences considerably the final quality of the measurements mainly if the control concerns free‐form components with complex forms, not bound to classic geometric entities. The supporting systems commonly used foresee the utilization of standard elements (clamps, magnets, suction cups and plates and others) ideal for the parts with regular geometry but that can cause inconveniences if applied to free‐form elements and long times for the part supporting. The supporting elements of our paper fit to the geometry of free‐form component.

For the production of the supporting elements, the chosen technique has been the selective laser sintering with the use of the Pa‐Al powders (alumide). This material has a limited mechanical resistance such to guarantee a control up to 500 parts. For this reason, in a future research we would produce these fixtures using sintered metal materials.

The possibility to guarantee a correct dimensional control in the case of free form components using fixtures that fit to the geometry of free form components.

The paper shows an innovative procedure to get fixturing elements that fit to the geometry of free‐form component and provide stability and immobility to the component during the inspection phase.

The purpose of this paper is to develop the method of taking the eddy current losses in the laminated magnetic circuits into account during implicit transient calculations. The nonlinear magnetization characteristic of iron and the hysteresis losses can also be considered in the simulations done with the developed method.

The paper presents complex equivalent magnetic permeability derived from the presumed angular frequency in a laminated magnetic circuit. On this basis, the synthesis of a magnetic permeability as a function of the Laplace variable “s” is presented. After transformation of the variable “s” to a variable “z” of the Z transformation, it is possible to conduct discrete time calculation of transient states of magnetic circuits including the eddy current losses. An iterative process is developed to take the saturation of the magnetic circuit in these calculations into account. As regards hysteresis losses, the scalar model of magnetic hysteresis by Juhani Tellinen was implemented. The new method is validated by calculations of a two-coil transformer.

It is important to take into account the losses in sheet metal directly in the implicit transient calculations. This possibility is provided by the presented method based on the synthesis of the equivalent magnetic permeability μ^(s). The presented method was proved to be correct and efficient. The calculated sheet metal losses were compared with the results presented in literature. Good conformance of results was attained.

The method enables calculation of eddy current and hysteresis losses in laminated magnetic circuits during calculations of transient states. It does not need, unlike the previous methods, previously provided information (“a priori”) about the content of higher harmonics in waveforms. The method takes into account mutual dependence of transient waveforms of currents in the analysed system and losses of laminated magnetic circuit, expressed by eddy currents and hysteresis losses. Its implementation comes down to using in calculations a filter of the IIR type and corresponds to its calculation complexity. The author plans to use the presented method in the finite elements method transient calculations.

A new approach is a synthesis of the equivalent magnetic permeability in Laplace domain, which creates an equivalent RC circuit for permeability. Analytic equations for parameters of this equivalent circuit are original. A method for considering nonlinear magnetization characteristic and hysteresis losses was presented. In calculations of transient states of systems with magnetic circuits, one can use the developed equivalent circuit of magnetic permeability in a form of the IIR filter. Operator magnetic permeability includes fractional derivative of Laplace’s variable “vs”. Therefore, the equivalent IIR filter includes “history” of the processes that take place in the laminated magnetic circuit to the current, calculated time moment. This “history” in terms of its content is limited only by the degree of the applied IIR filter. It enables to calculate “step by step”, without previous (“a priori”) knowledge about harmonic components of the whole waveforms. It was necessary in the previously used methods, when determining parameters of magnetic permeability. The method proposed in the paper allows for calculations with taking into account direct dependence of an electric part of the system on its magnetic part.

The purpose of this paper was to offer more reliable dry electrode materials for long-term measuring and determine how repeated machine washing affects the measured impedance and surface resistance of the sample electrodes. The aim was to manufacture electrodes that could be used for the measurement of ECG. Skin friendly, metal sheet type, electrodes could be a solution.

In addition to two conventional electrodes already used in heart rate belts, the authors prepared and tested three different sheet metal electrodes. Three 20-mm-diameter electrodes were manufactured from the following materials: silvered knit, conductive polymer, stainless steel, silver and platinum. Electrode impedance was measured at seven frequencies from 1 Hz to 1 MHz, by placing two electrodes face-to-face. Measurements were taken on unused electrodes and after multiple machine washes at 40°C.

Analysis of the measurements indicates that with every material tested, the impedances are elevated after repeated washes. All metallic materials have impedances in the range of 0.01 to 4.5 Ω. Metal sheet electrodes can be integrated comfortably into the textile, and they endure textile maintenance without loss of electrical properties.

Metal sheet electrodes function well in long-term vital signs monitoring, provide a reliable signal and are resistant to maintenance. For the reasons described in this research, they can be used as a long-term wearable sensor.

Novel electrode material for long-term measuring research is important in many disciplines such as health care and apparel manufacturing. These findings suggest that pure metal electrodes are better than conductive textiles in long-term measuring.

Riveting deformation is inevitable because of local relatively large material flows and typical compliant parts assembly, which affect the final product dimensional quality and fatigue durability. However, traditional approaches are concentrated on elastic assembly variation simulation and do not consider the impact of local plastic deformation. This paper aims to present a successive calculation model to study the riveting deformation where local deformation is taken into consideration.

Based on the material constitutive model and friction coefficient obtained by experiments, an accurate three-dimensional finite element model was built primarily using ABAQUS and was verified by experiments. A successive calculation model of predicting riveting deformation was implemented by the Python and Matlab and was solved by the ABAQUS. Finally, three configuration experiments were conducted to evaluate the effectiveness of the model.

The model predicting results, obtained from two simple coupons and a wing panel, showed that it was a good compliant with the experimental results, and the riveting sequences had a significant effect on the distribution and magnitude of deformation.

The proposed model of predicting the deformation from riveting process was available in the early design stages, and some efficient suggestions for controlling deformation could be obtained.

A new predicting model of thin-walled sheet metal parts riveting deformation was presented to help the engineers to predict and control the assembly deformation more exactly.

DRAWING of metals occurs in innumerable ways, both hot and cold. Here, however, we are concerned only with the cold drawing operations used to form vast tonnages of steel, and large quantities of non‐ferrous metals, as tube and wire, and for the forming of sheet metals (especially by deep drawing).