An Experimental and Numerical Analysis of the Compression of Bimetallic Cylinders

Abstract

This paper investigates the upsetting of bimetallic cylinders with an aluminum alloy center and a brass ring. The influence of the center-ring shape factor and type of assembly fit (interference and clearance), and the effect of friction on the compression force and ductile damage are comprehensively analyzed by means of a combined numerical-experimental approach. Results showed that the higher the shape factor, the lower the forces required, whereas the effect of friction is especially important for cylinders with the lowest shape factors. The type of assembly fit does not influence the compression force. The accumulated ductile damage in the compression of bimetallic cylinders is higher than in single-material cylinders, and the higher the shape factor, the lower the damage for the same amount of stroke. The highest values of damaged were found to occur at the middle plane, and typically in the ring. Results also showed that an interference fit was more favorable for preventing fracture of the ring than a clearance fit. Microstructural analysis by scanning electron microscopy revealed a good agreement with the finite element predicted distribution of ductile damage.

Selection of Die Material and Its Impact on the Multi-Material Extrusion of Bimetallic AZ31B–Ti6Al4V Components for Aeronautical Applications

“…This method is widely used to predict the damage, mainly in cold formation processes, because of its simplicity and very little material data required for calculations. This criterion is based on the hypothesis that the accumulation of damages occurs only when at least one of the principal stress components is tensile, as represented in Equation (1). Considering the heat transfer across the billet, die, and the extrusion tooling, all parts were meshed with tetrahedral elements.…”

“…There are several studies about multi-material formation such as Camacho et al [1] analyzing the effect of shape factors and different assembly fit tolerances on the ductile damage and the microstructure resultant in minting of bimetallic cylinders made of a brass UNS C38500 ring and aluminum alloy UNS A92011 center. Additionally, Zhang et al [2] used hot rolling to manufacture an Al/Mg/Al composite with a trilaminate structure.…”

Prediction of Mechanical Properties by Artificial Neural Networks to Characterize the Plastic Behavior of Aluminum Alloys

“…In metal forming, the plastic behavior of metallic alloys is directly related to their formability, that is the material's ability to undergo plastic deformation. In fact, for the study of forming processes, the plastic behavior of metals is typically implemented in finite element simulation [1,2] and other analytical methods [3] by the so-called flow curves. In engineering applications, the plastic behavior has been traditionally characterized by simplified models; apart from well-known models such as Hollomon's power law and the Swift model [4], a linear approximation is the easiest way to model the plastic behavior through the mechanical properties' yield strength (YS) and ultimate tensile strength (UTS), especially when strain hardening has an important role such as in cold forming conditions.…”

Special Issue of the Manufacturing Engineering Society 2019 (SIMES-2019)

“…In this Special Issue of the journal Materials, 29 contributions to cutting-edge advances in different fields of the manufacturing engineering have been collected. In particular, in additive manufacturing and 3D printing [4][5][6][7][8][9][10][11]; sustainable and green manufacturing [12][13][14][15][16]; metrology and quality in manufacturing [17][18][19][20][21]; advances and innovations in manufacturing processes [22][23][24][25]; manufacturing of new materials [26][27][28]; design, modeling, and simulation in manufacturing engineering [29,30] industry 4.0 [31] and manufacturing engineering and society [32]. Among all of them, the topic additive manufacturing and 3D printing stands out for the number of contributions it has had in this Special Issue showing the interest that this topic arouses, currently, among researchers, the industry and the public in general.…”

“…The next topics by the number of contributions are sustainable and green manufacturing and metrology and quality in manufacturing with five contributions each. The first one gathers four works about new sustainable lubrication/cooling techniques used in removal processes [12][13][14][15] and the other about reusing waste in ecological cement [16]. The second one collects research about the optimization of laser tracker location on verification process [17], estimation of an upper bound to the value of the step potentials from grounding resistance measurements [18], enhanced positioning algorithm by mesh elements, recalculation and angle error orientation [19], industrial calibration procedure for confocal microscopes [20] and, finally, the development and validation of a calibration gauge for length measurement systems [21].…”