Acoustic condition monitoring for cold metal forming

One of the most important objectives of cold metal forming research is to develop techniques that enable better manufacturing efficiencies. Within this monitoring of tooling condition is vital to providing high quality manufacturing. The objective of this research is to determine the signature derived from Acoustic Emission (AE) sensors, in order to establish the current condition of a machine tool, as applied to bolt-making. From here we aim to develop and implement an on-line condition monitoring tool for the cold forming process. A review of the literature has shown that much research into AE has been successfully applied in metal cutting operations; such as milling, drilling and turning, but little research has been done related to metal forming. This appears to be due to the complexity of obtaining consistent signals using Acoustic Emission systems, because the presence of noise in many forms. This paper will detail many of the AE signals acquired and analysed through our research. The extensive results indicate this form of condition monitoring is not suitable for metal forming in its current configuration. Further tests are proposed to enable such research to move forward, so a condition monitoring system can be established.

Knowledge based optimisation techniques for sheet metal forming die design

A knowledge based optimism technique has been developed to predict solutions for quality issues found in an initial draw die design. Post processing of the initial design yields all the features applying forces, and major quality issues. Using the geometric relationship between the two, a knowledge-base is interrogated to determine the possible corrective actions. These actions are then passed through a fast semi-analytical model to determine the level of change required. Results from a 2D forming are presented to highlight the advantage of the new algorithms over current optimisation techniques.

Statistical analysis of finite element modeling in sheet metal forming and springback analysis

This work focuses on development of a method to statistically study forming and springback problems of TRansformation Induced Plasticity (TRIP) through an industrial case study. A Design of Experiments (DOE) approach was used to study the sensitivity of predictions to four user input parameters in implicit and explicit sheet metal forming codes. Numerical results were compared to experimental measurements of parts stamped in an industrial production line. The accuracy of forming strain predictions for TRIP steel were comparable with conventional steel, but the springback predictions of TRIP steel were far less accurate. The statistical importance of selected parameters for forming and springback prediction is also discussed. Changes of up to ±10% in Young's modulus and coefficient of friction were found to be insignificant in improving or deteriorating the statistical correlation of springback accuracies.

The role of the gift wrap stall at christmas

The pressure to wrap a gift can cause anxiety for the giver. At Christmas, many shopping centres have gift wrap stalls to assist their customers with the wrapping. In this paper we explore the purpose of a gift wrap stall and the role it plays in Christmas gift shopping. Data were collected through observation as it allowed insights into the phenomena that could not otherwise be obtained. Findings include the nature of a gift wrap stall, the mood surrounding the gift wrap stall, the types of gifts wrapped, the level of decision making involved, the role of the staff and issues relating to trust, the waiting times for gift wrapping, the giver’s gift wrap skills, and enquiries into the gift wrap service. This research makes an insightful contribution to a novel topic in the field of consumer behaviour as it allows us to better understand gift wrapping and its role in gift exchange.

Contact pressure evolution at the die radius in sheet metal stamping

The contact conditions at the die radius are of primary importance to the wear response for many sheet metal forming processes. In particular, a detailed understanding of the contact pressure at the wearing interface is essential for the application of representative wear tests, the use of wear resistant materials and coatings, the development of suitable wear models, and for the ultimate goal of predicting tool life. However, there is a lack of information concerning the time-dependant nature of the contact pressure response in sheet metal stamping. This work provides a qualitative description of the evolution and distribution of contact pressure at the die radius for a typical channel forming process. Through an analysis of the deformation conditions, contact phenomena and underlying mechanics, it was identified that three distinct phases exist. Significantly, the initial and intermediate stages resulted in severe and localised contact conditions, with contact pressures significantly greater than the blank material yield strength. The final phase corresponds to a larger contact area, with steady and smaller contact pressures. The proposed contact pressure behaviour was compared to other results available in the literature and also discussed with respect to tool wear.

To wrap or not to wrap? What is expected? Some initial findings from a study of gift wrapping

This paper aims to explore and discuss the expectations surrounding the decision to wrap a gift. Gift wrapping can enable an object to be turned into a gift through the development of meaning that symbolises it as a gift. There are two key expectations surrounding the use of gift wrapping. The first expectation is that receivers prefer gifts to be wrapped and the second expectation is that the gift meets individual and social expectations of what a gift should look like. Data was gathered using three qualitative techniques; observation, interviews and projective workshops. These initial findings form part of a larger research study into gift wrapping.

Preparation of bioactive porous titanium-molybdenum alloy through powder metallurgy

Porous Ti-Mo alloy samples with different porosities from 52% to 72% were successfully fabricated by the space-holder sintering method. The pore size of the porous Ti-Mo alloy samples were ranged from 200 to 500 μm. The plateau stress and elastic modulus of the porous Ti-Mo alloy samples increases with the decreasing of the porosity. Moreover, an apatite coating on the Ti-Mo alloy after an alkali and heat treatment was obtained through soaking into a simulated body fluid (SBF). The porous Ti-Mo alloy provides promising potential for new implant materials with new bone tissue ingrowth ability, bioactivity and mechanical properties mimicking those of natural bone.

Ultrafine ferrite formation in steels through thermomechanical processing

The main aim of this study was to investigate the critical conditions for the formation of ultrafine grain structures using hot torsion and wedge rolling techniques. In addition, the effect of thermomechanical parameters and steel composition on the critical conditions for ultrafine grain structure formation has been systematically evaluated.

Effects of aging bake hardenable steel in sheet metal forming

Bake hardening steels are being used as body panels in modern cars. These steels are stronger through an ageing process after baking in the paint ovens, which allows the thickness of the steel to be reduced without reducing the denting performance. The current study examined whether the steel ages at room temperature prior to forming which would deteriorate the formability. The work developed a new test and provided insight into acceptable levels of natural ageing which could be tolerated in the manufacturing process.

Thermodynamics and kinetics of the formation of Al2 O3/ MgAl2O4/MgO in Al-Silica metal matrix composite

The formation of Al₂O₃, MgAl₂O₄, and MgO has been widely studied in different Al base metal matrix composites, but the studies on thermodynamic aspects of the Al₂O₃/ MgAl₂O₄/MgO phase equilibria have been limited to few systems such as Al/Al₂O₃ and Al/SiC. The present study analyzes the Al₂O₃/MgAl₂O₄ and MgAl₂O₄/MgO equilibria with respect to the temperature and the Mg content in Al/SiO2 system using an extended Miedema model. There is a linear and parabolic variation in Mg with respect to the temperature for MgAl₂O₄/MgO and Al₂O₃/MgAl₂O₄ equilibria, respectively, and the influence of Si and Cu in the two equilibria is not appreciable. The experimental verification has been limited to MgAl₂O₄/MgO equilibria due to the high Mg content (≥0.5 wt pct) required for composite processing. The study has been carried out on two varieties of Al/SiO₂ composites, i.e., Al/Silica gel and Al/Micro silica processed by liquid metallurgy route (stir casting route). MgO is found to be more stable compared to MgAl₂O₄ at Mg levels ≥5 and 1 wt pct in Al/Silica gel and Al/Micro silica composites, respectively, at 1073 K. MgO is also found to be more stable at lower Mg content (3 wt pct) in Al/Silica gel composite with decreasing particle size of silica gel from 180 micron to submicron and nanolevels. The MgO to MgAl₂O₄ transformation has taken place through a series of transition phases influenced by the different thermodynamic and kinetic parameters such as holding temperature, Mg concentration in the alloy, holding time, and silica particle size.

Ionic liquid electrolyte for lithium metal batteries : physical, electrochemical, and interfacial studies of N-Methyl-N-butylmorpholinium Bis(fluorosulfonyl)imide

The ionic liquid (IL) N-methyl-N-butylmorpholinium bis(fluorosulfonyl)imide (C₄mmor FSI) is examined from physical and electrochemical perspectives. Pulsed field gradient NMR spectroscopy shows that ion diffusivities are low compared with similar, non-ethereal ILs. Ionicity values indicate that above room temperature, less than 50% of ions contribute to conductivity.

Lithium cycling in symmetrical cells using a C₄mmor FSI-based electrolyte is best demonstrated at elevated temperatures. Specific capacities of 130 mAh g⁻¹ are achieved in a Li−LiFePO₄ battery at 85 °C. FT-IR spectroscopic investigations of lithium electrodes suggest the presence of alkoxide species in the solid electrolyte interphase (SEI), implying a ring-opening reaction of C₄mmor with lithium metal. In contrast, the SEI derived from N-methyl-N-propylpiperidinium FSI lacks the alkoxide signature but shows signs of alkyl unsaturation, and the activation energy for Li+ transport through this SEI is slightly lower than that for the C₄mmor-derived SEI. Our detailed findings give insight into the capabilities and limitations of rechargeable lithium metal batteries utilizing a C₄mmor FSI electrolyte.

Li-Metal symmetrical cell studies using ionic organic plastic crystal electrolyte

A low current density preconditioning process, which produces an improved lithium transport mechanism is created by the action of charge flow through a plastic crystal electrolyte (figure). A reduction in cell polarisation at high applied current density is demonstrated which approaches the rates required for these electrolytes to be used in practical devices.

Functionalization of bamboo pulp fabrics with noble metal nanoparticles

Noble metal (gold and silver) nanoparticles (NPs) were synthesized in-situ on bamboo pulp fabrics. The gold NPs were reduced by bamboo pulp fabrics and bonded to fibers under heating, and an alkaline condition was needed to synthesize silver NPs in the presence of bamboo pulp fabrics. The synthesized gold and silver NPs endowed bamboo pulp fabrics with different colors because of their localized surface plasmon resonance (LSPR) property. The colors of the fabrics treated with metal NPs were extended through complex synthesis of gold and silver NPs in different proportions. The bamboo pulp fabrics treated with noble metal NPs showed good fastness to light and rubbing. In addition, the gold and silver NPs imparted bamboo pulp fabrics excellent UV protection property and remarkable antibacterial activity.

Silver nanoparticles prepared by gamma irradiation across metal-organic framework templates

In this study, we demonstrate for the first time the successful fabrication of well-dispersed ultrafine silver nanoparticles inside metal-organic frameworks through a single step gamma irradiation at room temperature. HKUST-1 crystals are soaked in silver nitrate aqueous solution and irradiated with a Cobalt 60 source across a range of irradiation doses to synthesize highly uniformly distributed silver nano-particles. The average size of the silver nanoparticles across the Ag@HKUST-1 materials is found to vary between 1.4 and 3 nm for dose exposures between 1 and 200 kGy, respectively. The Ag@HKUST-1 hybrid crystals exhibit strong surface plasmon resonance and are highly durable and efficient catalytic materials for the reduction of 4-nitrophenol to 4-aminophenol (up to 14.46 × 10-3 s-1 for 1 kGy Ag@HKUST-1). The crystals can be easily recycled for at least five successive cycles of reaction with a conversion efficiency higher than 99.9%. The gamma irradiation is demonstrated to be an effective and environmental friendly process for the synthesis of nano-particles across confined metal-organic frameworks at room temperature with potential applications in environmental science.

Ti-SrO metal matrix composites for bone implant materials

Titanium-strontia (Ti-SrO) metal matrix composites (MMCs) with 0, 1, 3 and 5% (weight ratio) of SrO have been fabricated through the powder metallurgy method. Increasing the weight ratio of SrO from 0 to 5%, the compressive strength of Ti-SrO MMCs increased from 982 MPa to 1753 MPa, while the ultimate strain decreased from 0.28 to 0.05. The elastic moduli of Ti-3SrO and Ti-5SrO MMCs were higher than those of Ti and Ti-1SrO MMC samples. Additionally, the micro hardness of Ti-SrO MMCs was enhanced from 59% to 190% with the addition of SrO. The enhanced compression strength and micro hardness of Ti-SrO MMCs were attributed to the Hall-Petch effect and the SrO dispersion strengthening in the Ti matrix. MTS assay results demonstrated that Ti-SrO MMCs with 3% SrO exhibited enhanced proliferation of osteoblast-like cells. Alkaline phosphatase activity of cells was not influenced significantly on the surface of Ti-SrO MMCs compared with pure Ti in a term longer than 10 days. The cell morphology on the Ti-SrO MMCs was observed using confocal microscopy and scanning electron microscopy, which confirmed that the Ti-3%SrO MMCs showed optimal in vitro biocompatibility. This journal is © the Partner Organisations 2014.