Contact pressure and wear in sheet metal forming - an FEM analysis

Wear is the principal cause of tool failure in most sheet metal forming processes. It is well known that the contact pressure between the blank and the tool has a large influence on the wear of the tool, and hence the tool life. This investigation utilises the finite element method to analyse the contact pressure distribution over the die radius for a particular deep drawing process. Furthermore, the evolution of the predicted contact pressure distribution throughout the entire stroke of the punch is also examined. It was found that the majority of the process shows a steady state pressure distribution, with two characteristic peaks over the die radius, at the beginning and end of the sheet contact area. Interestingly, the initial transient contact pressure response showed extremely high localised peak pressures; more than twice that of the steady state peaks. Results are compared to wear reported in the literature, during similar experimental deep drawing processes. Finally, the significance and effect of the results on wear and wear-testing techniques are discussed.

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.

Extracting fingerprint features using textures

Personal identification of individuals is becoming increasingly adopted in society today. Due to the large number of electronic systems that require human identification, faster and more secure identification systems are pursued. Biometrics is based upon the physical characteristics of individuals; of these the fingerprint is the most common as used within law enforcement. Fingerprint-based systems have been introduced into the society but have not been well received due to relatively high rejection rates and false acceptance rates. This limited acceptance of fingerprint identification systems requires new techniques to be investigated to improve this identification method and the acceptance of the technology within society. Electronic fingerprint identification provides a method of identifying an individual within seconds quickly and easily. The fingerprint must be captured instantly to allow the system to identify the individual without any technical user interaction to simplify system operation. The performance of the entire system relies heavily on the quality of the original fingerprint image that is captured digitally. A single fingerprint scan for verification makes it easier for users accessing the system as it replaces the need to remember passwords or authorisation codes. The identification system comprises of several components to perform this function, which includes a fingerprint sensor, processor, feature extraction and verification algorithms. A compact texture feature extraction method will be implemented within an embedded microprocessor-based system for security, performance and cost effective production over currently available commercial fingerprint identification systems. To perform these functions various software packages are available for developing programs for windows-based operating systems but must not constrain to a graphical user interface alone. MATLAB was the software package chosen for this thesis due to its strong mathematical library, data analysis and image analysis libraries and capability. MATLAB enables the complete fingerprint identification system to be developed and implemented within a PC environment and also to be exported at a later date directly to an embedded processing environment. The nucleus of the fingerprint identification system is the feature extraction approach presented in this thesis that uses global texture information unlike traditional local information in minutiae-based identification methods. Commercial solid-state sensors such as the type selected for use in this thesis have a limited contact area with the fingertip and therefore only sample a limited portion of the fingerprint. This limits the number of minutiae that can be extracted from the fingerprint and as such limits the number of common singular points between two impressions of the same fingerprint. The application of texture feature extraction will be tested using variety of fingerprint images to determine the most appropriate format for use within the embedded system. This thesis has focused on designing a fingerprint-based identification system that is highly expandable using the MATLAB environment. The main components that are defined within this thesis are the hardware design, image capture, image processing and feature extraction methods. Selection of the final system components for this electronic fingerprint identification system was determined by using specific criteria to yield the highest performance from an embedded processing environment. These platforms are very cost effective and will allow fingerprint-based identification technology to be implemented in more commercial products that can benefit from the security and simplicity of a fingerprint identification system.

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.

Nanofretting behaviors of NiTi shape memory alloy

Nanofretting refers to cyclic movements of contact interfaces with the relative displacement amplitude at the nanometer scale, where the contact area and normal load are usually much smaller than those in fretting. Nanofretting widely exists in microelctromechanical systems (MEMS) and may become a key tribological concern besides microwear and adhesion. With a triboindenter, the nanofretting behaviors of a nickel titanium (NiTi) shape memory alloy are studied under various normal loads (1–10 mN) and tangential displacement amplitudes (2–500 nm) by using a spherical diamond tip. Similar to fretting, the nanofretting of NiTi/diamond pair can also be divided into different regimes upon various shapes of tangential force–displacement curves. The dependence of nanofretting regime on the normal load and the displacement amplitude can be summarized in a running condition nanofretting map. However, due to the surface and size effects, nanofretting operates at some different conditions, such as improved mechanical properties of materials at the nanometer scale, small apparent contact area and single-asperity contact behavior. Consequently, different from fretting, nanofretting was found to exhibit several unique behaviors: (i) the maximum tangential force in one cycle is almost unchanged during a nanofretting test, which is different from a fretting test where the maximum tangential force increases rapidly in the first dozens of cycles; (ii) the tangential stiffness in nanofretting is three orders magnitude smaller than that in fretting; (iii) the friction coefficient in nanofretting is much lower than that in fretting in slip regime; (iv) no obvious damage was observed after 50 cycles of nanofretting under a normal load of 10 mN.

Design and simulation of an interdigital-chaotic advection micromixer for lab-on-a-chip applications

This paper presents the design and simulation of a novel passive micromixer. The micromixer consists of two inlet tanks, one mixing channel and two outlet channels. In order to maximise the mixing efficiency, the following considerations are made: (i) The inlet tanks are followed by a series of microchannels, in which the flow is split. The microchannels are arranged in an interdigital manner to maximise the contact area between the two flows. (ii) The microchannels attached to the lower inlet tank have an upward slope while those attached to the upper tank have a downward slope. The higher-density flow is fed to the lower inlet tank and gets an upward velocity before entering the mixing channel. (iii) Two triangular barriers are placed within the mixing channel to impose chaotic advection and perturb the less-mixed flow along the top and bottom surfaces of the channel. (iv) Finally, two outlet channels are incorporated to discard the less-mixed flow. Three-dimensional simulations are carried out to evaluate the performance of the micromixer. Simulations are performed in the absence and presence of the gravitational force to analyse the influence of gravity on the micromixer. Mixing efficiencies of greater than 92% are achieved using water and a 1011'density biological solvent as the mixing fluids.

Design and simulation of an interdigital-chaotic advection micromixer for lab-on-a-chip applications

The paper presents the design and simulation of a novel passive micromixer. The micromixer consists of two inlet tanks, one mixing channel and two outlet channels. In order to maximise the mixing efficiency, the following considerations are made : (i) The inlet tanks are followed by a series of microchannels, in which the flow is split. The microchannels are arranged in an interdigital manner to  maximise the contact area between the two flows. (ii) The microchannels attached to the lower inlet tank have an upward slope while those attached to the upper tank have a downward slope. The higher-density flow is fed to the lower inlet tank and gets an upward velocity before entering the mixing channel. (iii) Two triangular barriers are placed within the mixing channel to impose chaotic advection and perturb the less-mixed flow along the top and bottom surfaces of the channel. (iv) Finally, two outlet channels are incorporated to discard the less-mixed flow. Three-dimensional simulations are carried out to evaluate the performance of the micromixer. Simulations are performed in the absence and presence of the gravitational force to analyse the influence of gravity on the micromixer. Mixing efficiencies of greater than 92 % are achieved using water and a low-density biological solvent as the mixing fluids.

Adhesion performance of polymer nanofibres under shear loading

Geckos have extraordinary wall-climbing ability because of the millions of hairs with micro/nano fibrillar structures on their feet. Mimicking gecko's feet is of scientific and engineering importance for development of physical adhesion materials and devices. The design of gecko-inspired physical adhesives seems to be geometry dominated. In this study, Finite Element Method (FEM) has been used to analyse the vertical peel-off force of polyporpylene (PP) nanofibres having different fibre dimensions, inclining angels and contact areas on a flat glass substrate. It has been found that the main parameters affecting the frictional adhesion are fibre diameter and fibre aspect ratio, the inclining angle between the fibre and the substrate surface, and the intimate contact areas. Our analysis has shown that PP nanofibres with a diameter of less than 200nm can generate less peel-off force than fibres of larger diameters, indicating more stable adhesion with the glass substrate for thinner fibres. A bent fibre with more intimate contact area can bear more shear force than a straight fibre with less contact area. Also, under the same shear loading, fibres with an inclining angle of less than 30° provide a low peel off force.

Novel ultrathin nanoflake assembled porous MnO2/carbon strip microspheres for superior pseudocapacitors

A novel hierarchical MnO2/carbon strip (MnO2/C) microsphere is synthesized via galvanostatic charge-discharge of a MnO@C matrix precursor where the carbon is from a low-cost citric acid. This hierarchical structure is composed of manganese oxides nanoflakes and inlaid carbon strips. The ultrathin nanoflakes assemble to form porous microspheres with a rippled surface superstructure. Due to its improved conductivity and remarkable increased phase contact area, this novel structure exhibits an excellent electrochemical performance with a specific capacitance of 485.6 F g -1 at a current density of 0.5 A g-1 and an area capacitance as high as 4.23 F cm-2 at a mass loading of 8.7 mg cm-2. It also shows an excellent cycling stability with 88.9% capacity retention after 1000 cycles. It is speculated that the present low-cost novel hierarchical porous microspheres can serve as a promising electrode material for pseudocapacitors. © 2014 American Chemical Society.

Self-assembled V2O5 interconnected microspheres produced in a fish-water electrolyte medium as a high-performance lithium-ion-battery cathode

Interconnected microspheres of V2O5 composed of ultra-long nanobelts are synthesized in an environmental friendly way by adopting a conventional anodization process combined with annealing. The synthesis process is simple and low-cost because it does not require any additional chemicals or reagents. Commercial fish-water is used as an electrolyte medium to anodize vanadium foil for the first time. Electron microscopy investigation reveals that each belt consists of numerous nanofibers with free space between them. Therefore, this novel nanostructure demonstrates many outstanding features during electrochemical operation. This structure prevents self-aggregation of active materials and fully utilizes the advantage of active materials by maintaining a large effective contact area between active materials, conductive additives, and electrolyte, which is a key challenge for most nanomaterials. The electrodes exhibit promising electrochemical performance with a stable discharge capacity of 227 mAh·g–1 at 1C after 200 cycles. The rate capability of the electrode is outstanding, and the obtained capacity is as high as 278 at 0.5C, 259 at 1C, 240 at 2C, 206 at 5C, and 166 mAh·g–1 at 10C. Overall, this novel structure could be one of the most favorable nanostructures of vanadium oxide-based cathodes for Li-ion batteries. [Figure not available: see fulltext.]

Production of Ti-6Al-4V billet through compaction of blended elemental powders by equal-channel angular pressing

In this work, compaction by warm equal-channel angular pressing (ECAP) with back pressure was used to produce Ti-6Al-4V billets from both commercially pure (CP) titanium and titanium hydride (TiH 2) powders, which were mixed with pulverised binary Al-V master alloys of two distinct Al/V ratios and with elemental aluminium powder to arrive at the nominal alloy composition. It was demonstrated that the right combination of temperature, high hydrostatic pressure and plastic shear deformation permits consolidation of the powder mixture to maximum green densities of 99.26%. Moreover, after direct compaction of blended elemental powders by equal-channel angular pressing (ECAP) with back pressure, the sintering temperature required for chemical and microstructural homogenisation of the compacts could be reduced by 150-250°C. This was possible due to high green density, increased contact area between powder particles and the formation of fast diffusion paths associated with grain refinement by severe plastic deformation. The sintered Ti-6Al-4V billets exhibited a maximum density of 99.88%, Vickers hardness of 409-445 HV1 and ultimate tensile strength in the range of 1000-1080MPa. In contrast to findings of other authors, the use of TiH 2 powders in conjunction with ECAP processing did not bring any benefits with regard to the production of the Ti-6Al-4V alloy.

Theoretical investigation of wear-resistance mechanism of superelastic shape memory alloy NiTi

Recent experimental research indicates that superelastic shape memory alloy nickel–titanium (NiTi) is superior to stainless steel against wear and could be applied in tribological engineering. It is believed that the super wear resistance of shape memory alloys is mainly due to the recovery of the superelastic deformation. Our recent wear study indicates that wear rate is very sensitive to the maximum contact pressure. In the present investigation, which involves applying Hertz contact theory and the finite element method, the wear behaviour of shape memory alloys is examined against that of stainless steels through analyzing the maximum contact pressure and the plastic deformation. Our investigation indicates that the contribution of superelasticity to the high wear resistance of NiTi is directly linked to the low transformation stress and the large recoverable transformation strain. Furthermore, the low Young's modulus of this alloy also plays an important role to reduce the maximum contact pressure and therefore reduce the wear rate. Additionally, the high plastic yield strength of transformed martensite NiTi enhances its wear resistance further.

Healthy parks, healthy people : the health benefits of contact with nature in a park context : a review of current literature

This review identifies significant research that has not previously been compiled. It will provide key information for decision making by park managers, forming the basis of a program of future research to overcome the limited knowledge in this area. It is part of stage two of this project, funded by the International Park Strategic Partners Group. It builds on an earlier review (completed early in 2002 with funding provided by Parks Victoria) by addressing the health and wellbeing benefits of contact with nature in a parks context, at an individual and community level.

Predicting the resistance of fired clay bricks to salt attack

The salt attack of Fired Clay Bricks (FCBs) causes surface damage that is aesthetically displeasing and eventually leads to structural damage. Methods for determining the resistances of FCBs to salt weathering have mainly tried to simulate the process by using accelerating aging tests. Most research in this area has concentrated on the types of salt that can cause damage and the damage that occurs during accelerated aging tests. This approach has lead to the use of accelerated aging tests as standard methods for determining resistance. Recently, it has been acknowledged that are not the most reliable way to determine salt attack resistance for all FCBs in all environments. Few researchers have examined FCBs with the aim of determining which material and mechanical properties make a FCB resistant to salt attack. The aim of this study was to identify the properties that were significant to the resistance of FCBs to salt attack. In doing so, this study aids in the development of a better test method to assess the resistance of FCBs to salt attack. The current Australian Standard accelerated aging test was used to measure the resistance of eight FCBs to salt attack using sodium sulfate and sodium chloride. The results of these tests were compared to the water absorption properties and the total porosity of FCBs. An empirical relationship was developed between the twenty-four-hour water absorption value and the number of cycles to failure from sodium sulfate tests. The volume of sodium chloride solution was found to be proportional to the total porosity of FCBs in this study. A phenomenological discussion of results led to a new mechanism being presented to explain the derivation of stress during salt crystallisation of anhydrous and hydratable salts. The mechanical properties of FCBs were measured using compression tests. FCBs were analysed as cellular materials to find that the elastic modules of FCBs was equivalent for extruded FCBs that had been fired a similar temperatures and time. Two samples were found to have significantly different elastic moduli of the solid microstructure. One of these samples was a pressed brick that was stiffer due to the extra bond that is obtained during sintering a closely packed structure. The other sample was an extruded brick that had more firing temperature and time compared with the other samples in this study. A non-destructive method was used to measure the indentation hardness and indentation stress-strain properties of FCBs. The indentation hardness of FCBs was found to be proportional to the uniaxial compression strength. In addition, the indentation hardness had a better linear correlation to the total porosity of FCBs except for those samples that had different elastic moduli of the solid microstructure. Fractography of exfoliated particles during salt cycle tests and compression tests showed there was a similar pattern of fracture during each failure. The results indicate there were inherent properties of a FCB that determines the size and shape of fractured particles during salt attack. The microstructural variables that determined the fracture properties of FCBs were shown to be important variables to include in future models that attempt to estimate the resistance of FCBs to salt attack.

A potential novel rapid screening NMR approach to boundary film formation at solid interfaces in contact with ionic liquids

The boundary films generated on a series of inorganic compounds, typical of native films on metal and ceramic surfaces, when exposed to various ionic liquids (ILs) based on the trihexyl(tetradecyl)phosphonium cation have been characterized using multinuclear solid-state NMR. The NMR results indicate that SiO₂ and Mg(OH)₂ interact strongly with the anion and cation of each IL through a mechanism of adsorption of the anion and subsequent close proximity of the cation in a surface double layer (as observed through ¹H−²⁹Si cross polarization experiments). In contrast, Al₂O₃, MgO, ZnO, and ZrO₂ appear less active, strongly suggesting the necessity of hydroxylated surface groups in order to enhance the generation of these interfacial films. Using solid-state NMR to characterize such interfaces not only has the potential to elucidate mechanisms of wear resistance and corrosion protection via ILs, but is also likely to allow their rapid screening for such durability applications.