Advances in Manufacturing

Guest editorial: Molybdenum alloying: more than hardenability

Hardy Mohrbacher

2020, 8(1): 1-2. doi:10.1007/s40436-019-00261-6

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The full text can be downloaded at https://link.springer.com/content/pdf/10.1007/s40436-019-00261-6.pdf

Molybdenum alloying in cast iron and steel

Xiang-Ru Chen, Qi-Jie Zhai, Han Dong, Bao-Hua Dai, Hardy Mohrbacher

2020, 8(1): 3-14. doi:10.1007/s40436-019-00282-1

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Metal casting is an important manufacturing technology for efficiently producing massive components with complex shape. A large share of industrial castings is made from iron and steel alloys, combining attractive properties and low production cost. Upgrading of properties in cast iron and steel is mainly achieved by alloying and in fewer cases by heat treatment. Molybdenum is an important alloying element in that respect, increasing strength, hardness and toughness. It also facilitates particular heat treatments such as austempering. The paper describes the metallurgical functionality of molybdenum alloying in iron-based castings and demonstrates its effectiveness for applications in the automotive and mining industry.

The full text can be downloaded at https://link.springer.com/content/pdf/10.1007/s40436-019-00282-1.pdf

Molybdenum alloying in high-performance flat-rolled steel grades

Pello Uranga, Cheng-Jia Shang, Takehide Senuma, Jer-Ren Yang, Ai-Min Guo, Hardy Mohrbacher

2020, 8(1): 15-34. doi:10.1007/s40436-019-00285-y

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Considerable progress in developing flat-rolled steel grades has been made by the Chinese steel industry over the recent two decades. The increasing demand for high-performance products to be used in infrastructural projects as well as in production of consumer and capital goods has been driving this development until today. The installation of state-of-the-art steel making and rolling facilities has provided the possibility of processing the most advanced steel grades. The production of high-performance steel grades relies on specific alloying elements of which molybdenum is one of the most powerful. China is nearly self-sufficient in molybdenum supplies. This paper highlights the potential and advantages of molybdenum alloying over the entire range of flat-rolled steel products. Specific aspects of steel property improvement with respect to particular applications are indicated.

The full text can be downloaded at https://link.springer.com/content/pdf/10.1007%2Fs40436-019-00285-y.pdf

Editorial: Industrial relevance of molybdenum in China

Tim Outteridge, Nicole Kinsman, Gaetano Ronchi, Hardy Mohrbacher

2020, 8(1): 35-39. doi:10.1007/s40436-019-00270-5

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About 80% of all molybdenum mined in the world (not including units recovered via recycling) is used as an alloying element in iron and steel. In general, the intensity of molybdenum use in China is still lower than in more highly developed regions such as the USA and Europe. This difference is manifest in both carbon steels and stainless steels, suggesting a significant opportunity for more widespread use of molybdenum in the future as China follows its self-reliance policy, calling for more sophisticated materials. Active market development, as being pursued by the International Molybdenum Association (IMOA), is a key asset in that respect. This article summarizes some key facts on molybdenum mining, use and market development in China.

The full text can be downloaded at https://link.springer.com/content/pdf/10.1007%2Fs40436-019-00270-5.pdf

AR-assisted robot welding programming

S. K. Ong, A. Y. C. Nee, A. W. W. Yew, N. K. Thanigaivel

2020, 8(1): 40-48. doi:10.1007/s40436-019-00283-0

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Robotic welding demands high accuracy and precision. However, robot programming is often a tedious and time-consuming process that requires expert knowledge. This paper presents an augmented reality assisted robot welding task programming (ARWP) system using a user-friendly augmented reality (AR) interface that simplifies and speeds up the programming of robotic welding tasks. The ARWP system makes the programming of robot welding tasks more user-friendly and reduces the need for trained programmers and expertise in specific robotic systems. The AR interface simplifies the definition of a welding path as well as the welding gun orientation, and the system; the system can locate the welding seam of a workpiece quickly and generate a viable welding path based on the user input. The developed system is integrated with the touch-sensing capability of welding robots in order to locate the welding path accurately based on the user input, for fillet welding. The system is applicable to other welding processes and methods of seam localization. The system implementation is described and evaluated with a case study.

The full text can be downloaded at https://link.springer.com/content/pdf/10.1007%2Fs40436-019-00283-0.pdf

An automatic optimization method for minimizing supporting structures in additive manufacturing

Xiao-Jun Chen, Jun-Lei Hu, Qing-Long Zhou, Constantinus Politis, Yi Sun

2020, 8(1): 49-58. doi:10.1007/s40436-019-00277-y

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The amount of supporting structure usage has been a major research topic in layer-based additive manufacturing (AM) over the past years as it leads to increased fabrication time and decreased surface quality. Previous studies focused on deformation and topology optimization to eliminate the number of support structures. However, during the actual fabrication process, the properties of shape and topology are essential. Therefore, they should not be modified casually. In this study, we present an optimizer that reduces the number of supporting structures by identifying the prime printing direction. Without rotation, models are projected in each direction in space, and the basis units involved in the generation of support structures are separated. Furthermore, the area of the supporting structures is calculated. Eventually, the prime printing direction with minimal supporting area is obtained through pattern-searching method. The results of the experiment demonstrated that the printing area was reduced by up to 60% for some cases, and the surface quality was also improved correspondingly. Furthermore, both the material consumption and fabrication time were decreased in most cases. In future work, additional factors will be considered, such as the height of the supporting structures and the adhesion locations to improve the efficiency of this optimizer.

The full text can be downloaded at https://link.springer.com/content/pdf/10.1007%2Fs40436-019-00277-y.pdf

Effect of position and force tool control in friction stir welding of dissimilar aluminum-steel lap joints for automotive applications

M. Wasif Safeen, P. Russo Spena, G. Buffa, D. Campanella, A. Masnata, L. Fratini

2020, 8(1): 59-71. doi:10.1007/s40436-019-00290-1

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Widespread use of aluminum alloys for the fabrication of car body parts is conditional to the use of appropriate welding methods, especially if dissimilar welding must be performed with automotive steel grades. Friction stir welding (FSW) is considered to be a reasonable solution to obtain sound aluminum-steel joints. In this context, this work studies the effects of tool position and force control in dissimilar friction stir welding of AA6061 aluminum alloy on DC05 low carbon steel in lap joint configuration, also assessing proper welding parameter settings. Naked eye and scanning electron microscopy (SEM) have been used to detect macroscopic and microscopic defects in joints, as well as to determine the type of intermixture between aluminum and steel. The joint strength of sound joints has been assessed by shear tension test. Results point out that tool force control allows for obtaining joints with better quality and strength in a wider range of process parameters. A process window has been determined for tool force conditions to have joints with adequate strength for automotive purposes.

The full text can be downloaded at https://link.springer.com/content/pdf/10.1007%2Fs40436-019-00290-1.pdf

Mechanical characteristics of oil palm fiber reinforced thermoplastics as filament for fused deposition modeling (FDM)

Mohd Nazri Ahmad, Mohammad Khalid Wahid, Nurul Ain Maidin, Mohd Hidayat Ab Rahman, Mohd Hairizal Osman, Izzati Fatin Alis@Elias

2020, 8(1): 72-81. doi:10.1007/s40436-019-00287-w

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Fibers are increasingly in demand for a wide range of polymer composite materials. This study's purpose was the development of oil palm fiber (OPF) mixed with the thermoplastic material acrylonitrile butadiene styrene (ABS) as a composite filament for fused deposition modeling (FDM). The mechanical properties of this composite filament were then analyzed. OPF is a fiber extracted from empty fruit bunches, which has proved to be an excellent raw material for biocomposites. The cellulose content of OPF is 43%-65%, and the lignin content is 13%-25%. The composite filament consists of OPF (5%, mass fraction) in the ABS matrix. The fabrication procedure included alkalinizing, drying, and crushing the OPF to develop the composite. The OPF/ABS materials were prepared and completely blended to acquire a mix of 250 g of the material for the composition. Next, the FLD25 filament extrusion machine was used to form the OPF/ABS composite into a wire. This composite filament then was used in an FDM-based 3D printer to print the specimens. Finally, the printed specimens were tested for mechanical properties such as tensile and flexural strength. The results show that the presence of OPF had increased the tensile strength and modulus elasticity by approximately 1.9% and 1.05%, respectively. However, the flexural strength of the OPF/ABS composite had decreased by 90.6% compared with the virgin ABS. Lastly, the most significant outcome of the OPF/ABS composite was its suitability for printing using the FDM method.

The full text can be downloaded at https://link.springer.com/content/pdf/10.1007%2Fs40436-019-00287-w.pdf

Development of AZ91/SiC surface composite by FSP: effect of vibration and process parameters on microstructure and mechanical characteristics

Behrouz Bagheri, Mahmoud Abbasi

2020, 8(1): 82-96. doi:10.1007/s40436-019-00288-9

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A surface composite layer enhances the mechanical characteristics of a surface while retaining the properties of the base material. Friction stir processing (FSP) is a method for forming surface metal matrix composites (SMMCs) that reinforce a surface with particles. In the current study, a new method entitled friction stir vibration processing (FSVP) was applied to form SMMCs on the surface of AZ91 magnesium alloy with SiC particles as the reinforcing particles. Contrary to FSP, in FSVP, the workpiece was vibrated normal to the processing line while the tool rotated and traversed. The microstructure and mechanical properties of friction stir (FS) and friction stir vibration (FSV) processed specimens were evaluated. Additionally, the effects of vibration frequency and process parameters on different characteristics of FS and FSV processed specimens were studied. The results showed that the stir zone grains for FSV processed specimens were finer than those for FS processed specimens, and the second phase particles (SiC particles) had a more homogenous distribution in the former specimens than in the latter specimens. This was related to the effect of workpiece vibration during FSVP, which increased the material deformation and led to enhanced dynamic recrystallization and the breakdown of agglomerated SiC particles. The results indicated that the stir zone grain size decreased, and the distribution homogeneity of the SiC particles increased as vibration frequency increased. It was also observed that the stir zone grain size increased, and the mechanical properties of the processed specimens decreased as tool rotation speed increased.

The full text can be downloaded at https://link.springer.com/content/pdf/10.1007%2Fs40436-019-00288-9.pdf

Sensitivity analysis of the surface integrity of monocrystalline silicon to grinding speed with same grain depth-of-cut

Ping Zhou, Zi-Guang Wang, Ying Yan, Ning Huang, Ren-Ke Kang, Dong-Ming Guo

2020, 8(1): 97-106. doi:10.1007/s40436-020-00291-5

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Mechanisms for removal of materials during the grinding process of monocrystalline silicon have been extensively studied in the past several decades. However, debates over whether the cutting speed significantly affects the surface integrity are ongoing. To address this debate, this study comprehensively investigates the effects of cutting speed on surface roughness, subsurface damage, residual stress, and grinding force for a constant grain depth-of-cut. The results illustrate that the changes in the surface roughness and subsurface damage relative to the grinding speed are less obvious when the material is removed in ductile-mode as opposed to in the brittle-ductile mixed mode. A notable finding is that there is no positive correlation between grinding force and surface integrity. The results of this study could be useful for further investigations on fundamental and technical analysis of the precision grinding of brittle materials.

The full text can be downloaded at https://link.springer.com/content/pdf/10.1007%2Fs40436-020-00291-5.pdf

Fabrication and shape detection of a catheter using fiber Bragg grating

Xiang-Yan Chen, Ya-Nan Zhang, Lin-Yong Shen, Jin-Wu Qian, Jia-Ying Fan

2020, 8(1): 107-118. doi:10.1007/s40436-019-00284-z

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Considering the spatial position and shape detection properties of the fiber Bragg grating (FBG) curve sensor used in the human body, the positioning accuracy of the FBG curve sensor plays a major role in the pre-diagnosis and treatment of diseases. We present a new type of shape-sensing catheter (diameter of 2.0 mm and length of 810 mm) that is integrated with an array of four optical fibers, where each contains five nodes, to track the shape. Firstly, the distribution of the four orthogonal fiber gratings is wound around a nitinol wire using novel packaging technology, and the spatial curve shape is rebuilt based on the positioning of discrete points in space. An experimental platform is built, and then a reconstruction algorithm for coordinate point fitting of the Frenet frame is used to perform the reconstruction experiment on millimeter paper. The results show that, compared with those in previous studies, in 2D test, the maximum relative error for the end position is reduced to 2.74%, and in 3D reconstruction experiment, the maximum shape error is 3.43%, which verifies both the applicability of the sensor and the feasibility of the proposed method. The results reported here will provide an academic foundation and the key technologies required for navigation and positioning of noninvasive and minimally invasive surgical robots, intelligent structural health detection, and search and rescue operations in debris.

The full text can be downloaded at https://link.springer.com/content/pdf/10.1007%2Fs40436-019-00284-z.pdf

Thermal error regression modeling of the real-time deformation coefficient of the moving shaft of a gantry milling machine

Wen-Hua Ye, Yun-Xia Guo, Heng-Fei Zhou, Rui-Jun Liang, Wei-Fang Chen

2020, 8(1): 119-132. doi:10.1007/s40436-020-00293-3

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This paper describes a novel modeling method for determining the thermal deformation coefficient of the moving shaft of a machine tool. Firstly, the relation between the thermal deformation coefficient and the thermal expansion coefficient is expounded, revealing that the coefficient of thermal deformation is an important factor affecting the precision of moving shaft feed systems. Then, thermal errors and current boundary and machining conditions are measured using sensors to obtain the first set of parameters for a thermal prediction model. The dynamic characteristics of the positioning and straightness thermal errors of the moving axis of a machine tool are analyzed under different feed speeds and mounting modes of the moving shaft and bearing. Finally, the theoretical model is derived from experimental data, and the axial and radial thermal deformation coefficients at different time and positions are obtained. The expressions for the axial and radial thermal deformation of the moving shaft are modified according to theoretical considerations, and the thermal positioning and straightness error models are established and experimentally verified. This modeling method can be easily extended to other machine tools to determine thermal deformation coefficients that are robust and self-correcting.

The full text can be downloaded at https://link.springer.com/content/pdf/10.1007%2Fs40436-020-00293-3.pdf

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