A finite element simulation of micro-mechanical frictional behaviour in metal forming

Friction is a critical factor for sheet metal forming (SMF). The Coulomb friction model is usually used in most finite element (FE) simulation for SMF. However, friction is a function of the local contact deformation conditions, such as local pressure, roughness and relative velocity. Frictional behaviour between contact surfaces can be based on three cases: boundary, hydrodynamic and mixed lubrication. In our microscopic friction model based on the finite element method (FEM), the case of dry contact between sheet and tool has been considered. In the view of microscopic geometry, roughness depends upon amplitude and wavelength of surface asperities of sheet and tool. The mean pressure applied on the surface differs from the pressure over the actual contact area. The effect of roughness (microscopic geometric condition) and relative speed of contact surfaces on friction coefficient was examined in the FE model for the microscopic friction behaviour. The analysis was performed using an explicit FE formulation. In this study, it was found that the roughness of deformable sheet decreases during sliding and the coefficient of friction increases with increasing roughness of contact surfaces. Also, the coefficient of friction increases with the increase of relative velocity and adhesive friction coefficient between contact surfaces.

Structure-property relationships in nylon 6 nanocomposites based on octaphenyl-, dodecaphenyl-POSS, montmorillonite, and their combinations

Binary and ternary nanocomposites were produced by incorporating, via melt compounding, two types of octa-and dodecaphenyl substituted polyhedral oligomeric silsesquioxanes (POSS), montmorillonite (MMT), and combinations of POSS with MMT into nylon 6. The tensile, flexural, and dynamic thermo-mechanical properties of these materials were characterized and their structure-property relationships discussed. The results show that the losses in ductility and toughness experienced after inclusion of MMT into nylon 6 can be balanced out by co-mixing MMT with the dodecaphenyl- POSS to produce a ternary nanocomposite. This trend however was less pronounced in the ternary MMT/octaphenyl-POSS system. Analysis of the microstructure organization in these materials using XRD and SEM sheds some light on understanding the differences in behavior. Both types of POSS particles mixed alone in nylon 6 were found to be polydisperse (500 nm to a few microns in size) and locally aggregated, yielding materials with similar mechanical performance. The co-mixing of MMT with the octaphenyl- POSS served to break down the POSS crystal aggregates, enhancing their micro-mechanical reinforcing action. On the other hand, the POSS crystals were not affected in the MMT/dodecaphenyl-POSS system, which led to improving their toughening ability.

Mechanical properties of micro-porous metals produced by space-holding sintering

Micro-porous nickel foams with an open cell structure were fabricated by the space-holding sintering. The average pore size of the micro-porous nickel specimens ranged from 30 μm to 150 μm, and the porosity ranged from 60 % to 80 %. The porous characteristics of the nickel specimens were observed using scanning electron microscopy (SEM). The mechanical properties were studied using compressive tests. For comparison, macro-porous nickel foams prepared by the chemical vapour deposition method with pore sizes of 800 μm and 1300 μm and porosity of 95 % were also presented. Results indicated that the ratio value of 6 and higher for the specimen length to cell size (L/d) is satisfying for obtaining stable compressive properties. The micro-porous nickel specimens exhibited different deformation behaviour and dramatically increased mechanical properties, compared to those of the macro-porous nickel specimens.

Mechanical behavior of nano-micro composite core spun yarns

Effects of micro-structural parameters on mechanical properties of carbon nanotube polymer nanocomposites

A comparison between the elastic modulus of carbon nanotube (CNT) polymer nano composites predicted by classical micromechanics theories, based on continuum mechanics and experimental data, was made and the results revealed a great difference. To improve the accuracy of these models, a new two-step semi-analytical method was developed, which allowed consideration of the effect of the interphase, in addition to CNT and matrix, in the modeling of nanocomposites. Based on this developed method, the inuence of microstructural parameters, such as CNT volume fraction, CNT aspect ratio, partial and complete agglomerations of CNTs, and overlap and exfoliation of CNTs, on the overall elastic modulus of nanocomposites was investigated. ©2014 Sharif University of Technology. All rights reserved.

Micro-porous nickel produced by powder metallurgy

Micro-porous nickel (Ni) with an open cell structure was fabricated by a special powder metallurgical process, which includes the adding of a space-holding material. The average pore size of the micro-porous Ni samples approximated 30 μm and 150 μm, and the porosity ranged from 60 % to 80 %. The porous characteristics of the Ni samples were observed using scanning electron microscopy (SEM) and the mechanical properties were evaluated using compressive tests. For comparison, porous Ni samples with a macro-porous structure prepared by both powder metallurgy
(pore size 800 μm) and the traditional chemical vapour deposition (CVD) method (pore size 1300 μm) were also presented. Results indicated that the porous Ni samples with a micro-porous structure exhibited different deformation behaviour and dramatically increased mechanical properties,
compared to those of the macro-porous Ni samples.

Mechanical properties of titanium foam for biomedical applications

Understanding the mechanical behaviour of pure titanium (Ti) foam is crucial for the design and development of Ti foam-based load-bearing implants. In this work, pure titanium foam is fabricated by a powder metallurgical process using the space-holder technique with a spacer size of 500 to 800 µm. Experimental data from static compression testing on the Ti foam are presented. The application of theoretical formulae to predict Young's modulus and yield strength of titanium foams is also discussed. A foam with 63% porosity, 87 ± 5 MPa yield strength, and 6.5 ± 1.3 GPa Young's modulus is found to be appropriate for a number of dental and orthopaedic applications.

Mechanical properties of porous Ti-26NB alloy for regenerative medicine

Porous titanium-26at.%niobium (hereafter, Ti-26Nb) alloys with different porosities were prepared by space-holder sintering. The porous structure of the alloys was characterized by scanning electron microscopy (SEM). Mechanical properties of the porous alloys were investigated using compression test. Results indicate that the porous alloys with 60, 70 and 80% porosities exhibit interconnected porous structure with pore sizes of 100-300 µm. The porous structure has the potential to provide new bone tissue ingrowth ability. The mechanical properties of these porous alloys decrease with the increase of porosity. The mechanical properties of the porous Ti-26Nb alloys can be tailored to match those of human bone.

Synthesis, characterization and analytical modelling of mechanical behavior of a conducting polymer actuator

Electrochemical synthesis of a tri-layer polypyrrole based actuator optimized for performance was reported. The 0.05 M pyrrole and 0.05 M tetrabutylammonium hexaflurophosphate in propylene carbonate (PC) yielded the optimum performance and stability. The force produced ranged from 0.2 to 0.4mN. Cyclic deflection tests on PC based actuators for 3 hours indicated that the displacement decreased by 60%. PC based actuator had a longer operating time, exceeding 3 hours, compared to acetonitrile based actuators. A triple-layer model of the polymer actuator was developed based on the classic bending beam theory by considering strain electrode material. A tri-layer actuator was fabricated [4, 6], by initially sputter coating a PVDF film with approximately 100nm of gold layer, resulting in a conductive film with a surface resistance of 8-10Ω. The PVDF film was about ~145µm thick had an approximate pore size of 45μm. A solution containing 0.05M distilled pyrrole monomer, 0.05M (TBAPF6) and 1% (w/w) distilled water in PC (propylene carbonate) solution was purged with nitrogen for 15 minutes. The continuity between PPy and PVDF. Results predicted by the model were in good agreement with the experimental data.

Microstructure and mechanical properties of nitrided and chromized short steel fiber reinforced aluminum based P/M composites

The present investigation is on the microstructure evolution and hardness of powder metallurgically processed Al- 0.5 wt.%Mg base 10 wt.% short steel fiber reinforced composites. The 0.38 wt.% C short steel fibers of average diameter 50µm and 500-800µm length were nitrided and chromized in a fluid bed furnace. Nitriding was carried out at 525°C for 90, 30 and 5 min durations. Chromizing was performed at 950°C for 53 and 7 min durations, using thermal reactive deposition (TRD) and diffusion technique. The treated fibers and resulting reaction interfaces were characterized using metallographic, microhardness and XRD techniques.

Effects of multiple laser shock processing (LSP) impacts on mechanical properties and wear behaviors of AISI 8620 steel

The aim of this paper was to address the effects of multiple laser shock processing (LSP) impacts with different pulse energy on mechanical properties and wear behaviors of AISI 8620 steel. Wear analyses were conducted by means of calculation of volume loss and scanning electron microscope (SEM) of the wear surface. Surface profiles, roughness and micro-hardness were measured. The micro-structures in the surface layer of the untreated and LSPed samples (treated by multiple LSP impacts) were investigated by using transmission electron microscopy (TEM) observations. Experimental results and analyses indicated that multiple LSP impacts can remarkably improve the wear resistance of AISI 8620 steel, and the wear mechanism of multiple LSP impacts on AISI 8620 steel was also entirely revealed. The wear process of the unpolished sample subjected to multiple LSP impacts can be described as follows: the wear rate was big at the beginning of sliding dry wear, but then decreased after the micro-indention in the sample surface was polished to the disappear. This phenomenon can be attributed to the fact that multiple LSP impacts generate many micro-indents in the sample surface.

Effects of Si on microstructural evolution and mechanical properties of hot-rolled ferrite and bainite dual-phase steels

Based on the thermo-mechanical controlled process, the effects of Si on microstructural evolution, tensile properties, impact toughness, and stretch-flangeability of ferrite and bainite dual-phase (FBDP) steels were systematically investigated. The addition of Si from 0 to 0.95% promoted the formation of fine and equiaxed ferrite grains, and high Si (0.95%) also resulted in the formation of blocky martensite islands and retained austenite. Yield and tensile strengths, and uniform and total elongations all increased with increasing Si content. Therefore, the tensile strength and ductility balance was improved by Si addition due to the increasing strain-hardening rate. The fractured morphologies after hole-expansion showed that the excellent stretch-flangeability of FBDP steels was associated with the micro-cracks propagating through in ferrite phase as well as the elongated ferrite grains along the direction perpendicular to the crack. 0.95% Si steel had a similar high combination of tensile strength and impact toughness to 0.55% Si steel, and especially 0.95% Si steel exhibited an excellent combination of tensile strength and stretch-flangeability.

Utilizing polypropylene fibers to improve physical and mechanical properties of concrete

The influence of polypropylene fibers has been studied in different proportioning and fiber aspect ratios to improve physical and mechanical properties of fiber-reinforced concretes. Fibers are used in two different lengths (12 mm and 19 mm) and proportions (0.1% and 0.3%) in concrete mixture design. Hardened concrete properties, such as 7- and 28-day compressive strength, splitting tensile strength, flexural strength, water and air absorption, and restrained shrinkage cracking were evaluated.

No statistically significant effects were observed for polypropylene fibers on the compressive strength of concrete, while toughness indexes, splitting tensile and flexural strength and durability parameters showed an increase in the presence of polypropylene fibers. Increased fiber availability (fiber aspect ratio) in the concrete matrix, in addition to the ability of longer polypropylene fibers to bridge on the micro cracks, are suggested as the reasons for the enhancement in mechanical properties. Finally, crack width in fiber-reinforced concrete is calculated analytically with fiber property variables (fiber type, length, diameter and proportion). Results are compared with experimental values and concluded that with an increase in fiber length and/or decrease in fiber diameter crack width, decrease significantly.

Shrinkage induced stretchable micro-wrinkled reduced graphene oxide composite with recoverable conductivity

A novel thermo-mechanical shrinking method is reported to fabricate a three dimensional (3D) stretchable and highly conductive micro-wrinkled reduced graphene oxide (MWrGO) supported on an elastic polydimethylsiloxane (PDMS) substrates. This 3D rGO architecture not only increases the specific area for more electrons to pass through but also bestows stretchability to the conductive pathway. The structural change of micro-wrinkles has been monitored by an in situ straining microscopy. The electrical conductivity of the samples remained fairly constant and stayed above 25 S/m under low deformation (no more than 30% strain) for up to 500 mechanical stretching-release cycles. Additionally, the MWrGO/PDMS composite can be stretched bi-axially because the shrinking process itself is isotropic. This MWrGO based stretchable composite with stable electrical properties and long life span could form a new platform of stretchable electronics.