CADDS: an automated die design system for sheet-metal blanking

This article reports on the design and implementation of a Computer-Aided Die Design System (CADDS) for sheet-metal blanks. The system is designed by considering several factors, such as the complexity of blank geometry, reduction in scrap material, production requirements, availability of press equipment and standard parts, punch profile complexity, and tool elements manufacturing method. The interaction among these parameters and how they affect designers' decision patterns is described. The system is implemented by interfacing AutoCAD with the higher level languages FORTRAN 77 and AutoLISP. A database of standard die elements is created by parametric programming, which is an enhanced feature of AutoCAD. The greatest advantage achieved by the system is the rapid generation of the most efficient strip and die layouts, including information about the tool configuration.

Die design and construction; lanking, piercing, compound, progressive, trimming, flanging, forming, and cam dies.

Mode of access: Internet.

Lubrication efficiency and die design in wire drawing

With the competitive challenge facing business today, the need to keep cost down and quality up is a matter of survival. One way in which wire manufacturers can meet this challenge is to possess a thorough understanding of deformation, friction and lubrication during the wire drawing process, and therefore to make good decisions regarding the selection and application of lubricants as well as the die design. Friction, lubrication and die design during wire drawing thus become the subject of this study. Although theoretical and experimental investigations have been being carried out ever since the establishment of wire drawing technology, many problems remain unsolved. It is therefore necessary to conduct further research on traditional and fundamental subjects such as the mechanics of deformation, friction, lubrication and die design in wire drawing. Drawing experiments were carried out on an existing bull-block under different cross-sectional area reductions, different speeds and different lubricants. The instrumentation to measure drawing load and drawing speed was set up and connected to the wire drawing machine, together with a data acquisition system. A die box connected to the existing die holder for using dry soap lubricant was designed and tested. The experimental results in terms of drawing stress vs percentage area reduction curves under different drawing conditions were analysed and compared. The effects on drawing stress of friction, lubrication, drawing speed and pressure die nozzle are discussed. In order to determine the flow stress of the material during deformation, tensile tests were performed on an Instron universal test machine, using the wires drawn under different area reductions. A polynomial function is used to correlate the flow stress of the material with the plastic strain, on which a general computer program has been written to find out the coefficients of the stress-strain function. The residual lubricant film on the steel wire after drawing was examined both radially and longitudinally using an SEM and optical microscope. The lubricant film on the drawn wire was clearly observed. Therefore, the micro-analysis by SEM provides a way of friction and lubrication assessment in wire drawing.

Expert system for hot forging design

Planning hot forging processes is a time-consuming activity with high costs involved because of the trial-and-error iterative methods used to design dies and to choose equipment and process conditions. Some processes demand many months to produce forged parts with controlled shapes, dimensions and microstructure. This paper shows how expert systems can help engineers to reduce the time needed to design precision forged parts and dies from machined parts. The software ADHFD interfacing MS Visual Basic v.5.0 and SolidEdge v.3.0 was used to design flashless hot forged gears, chosen from families of gears. © 1998 Elsevier Science S.A. All rights reserved.

Manufacture of high pressure die-cast radio frequency filter bodies

The manufacture of a radio frequency filter box using high pressure die casting (HPDC) is compared to the traditional high speed machining route. This paper describes an industrial exercise that concluded HPDC to be an economical and appropriate method to produce larger volumes of thin-walled telecommunications components. Modifications to the component design were made to make the component suitable for the HPDC process. Development of the die design through simulation modelling is described. The wrought alloy was replaced by near-eutectic Al-Si die casting alloy that was found to give better temperature stability performance. Apart from the economic benefits, HPDC was found to give lower filter efficiency losses through better surface finish. The effects of HPDC process variables, such as intensification pressure and injection piston velocity, on component quality, particularly porosity levels, were investigated. The pressure was analysed in terms of HPDC machine set pressure and the pressure measured in the die cavity by pressure sensors. Porosity was found to decrease with increased pressure and slightly increase with higher casting velocities.

Flow of metal in constrained plane-strain extrusion forging- Part II

With many innovations in process technology, forging is establishing itself as a precision manufacturing process: as forging is used to produce complex shapes in difficult materials, it requires dies of complex configuration of high strength and of wear-resistant materials. Extensive research and development work is being undertaken, internationally, to analyse the stresses in forging dies and the flow of material in forged components. Identification of the location, size and shape of dead-metal zones is required for component design. Further, knowledge of the strain distribution in the flowing metal indicates the degree to which the component is being work hardened. Such information is helpful in the selection of process parameters such as dimensional allowances and interface lubrication, as well as in the determination of post-forging operations such as heat treatment and machining. In the presently reported work the effect of aperture width and initial specimen height on the strain distribution in the plane-strain extrusion forging of machined lead billets is observed: the distortion of grids inscribed on the face of the specimen gives the strain distribution. The stress-equilibrium approach is used to optimise a model of flow in extrusion forging, which model is found to be effective in estimating the size of the dead-metal zone. The work carried out so far indicates that the methodology of using the stress-equilibrium approach to develop models of flow in closed-die forging can be a useful tool in component, process and die design.

Estudio de la embutición de una aleta para automoción.

[ES]se desea el diseño de un troquel para una buena embutición de la pieza, ahorrando en costes de fabricación. Para ello se procederá al estudio de la estampación mediante el MEF, para lo que se emplea el software Autoform. El resultado del estudio ha de ser una pieza embutida sin formación de arrugas ni grietas y debe cumplir la norma de adelgazamiento máximo del 20%, todo tratando de ahorrar lo máximo posible en costes.

Complex tracer mobilities in polymer networks revealed by fluorescence correlation spectroscopy

Gels are elastic porous polymer networks that are accompanied by pronounced mechanical properties. Due to their biocompatibility, ‘responsive hydrogels’ (HG) have many biomedical applications ranging from biosensors and drug delivery to tissue engineering. They respond to external stimuli such as temperature and salt by changing their dimensions. Of paramount importance is the ability to engineer penetrability and diffusion of interacting molecules in the crowded HG environment, as this would enable one to optimize a specific functionality. Even though the conditions under which biomedical devices operate are rather complex, a bottom-up approach could reduce the complexity of mutually coupled parameters influencing tracer mobility. The present thesis focuses on the interaction-induced tracer diffusion in polymer solutions and their homologous gels, probed by means of Fluorescence Correlation Spectroscopy (FCS). This is a single-molecule-sensitive technique having the advantage of optimal performance under ultralow tracer concentrations, typically employed in biosensors. Two different types of hydrogels have been investigated, a conventional one with broad polydispersity in the distance between crosslink points and a so-called ‘ideal’, with uniform mesh size distribution. The former is based on a thermoresponsive polymer, exhibiting phase separation in water at temperatures close to the human body temperature. The latter represents an optimal platform to study tracer diffusion. Mobilities of different tracers have been investigated in each network, varying in size, geometry and in terms of tracer-polymer attractive strength, as perturbed by different stimuli. The thesis constitutes a systematic effort towards elucidating the role of the strength and nature of different tracer-polymer interactions, on tracer mobilities; it outlines that interactions can still be very important even in the simplified case of dilute polymer solutions; it also demonstrates that the presence of permanent crosslinks exerts distinct tracer slowdown, depending on the tracer type and the nature of the tracer-polymer interactions, expressed differently by each tracer with regard to the selected stimulus. In aqueous polymer solutions, the tracer slowdown is found to be system-dependent and no universal trend seems to hold, in contrast to predictions from scaling theory for non-interacting nanoparticle mobility and empirical relations concerning the mesh size in polymer solutions. Complex tracer dynamics in polymer networks may be distinctly expressed by FCS, depending on the specific synergy among-at least some of - the following parameters: nature of interactions, external stimuli employed, tracer size and type, crosslink density and swelling ratio.

Direkte generative Fertigung von Schmiedegesenken eröffnet neue Möglichkeiten

Umformwerkzeuge sind eine neue und bislang nicht erforschte Anwendung generativ gefertigter Werkzeuge. Der Vortrag präsentiert ein Fallbeispiel, bei dem ein typisches Schmiedeteil mit recht komplexer Geometrie erfolgreich unter Verwendung eines generativ gefertigten Schmiedegesenks hergestellt werden konnte. Die Marktanforderungen zur frühestmöglichen Verfügbarkeit echter Schmiedeteile werden dargestellt. Die gesamte Prozesskette von der 3D-CAD-Werkzeugkonstruktion über die Schmiedeprozesssimulation, das Laserstrahlschmelzen der Gesenkeinsätze und die Gesenkmontage bis hin zu den eigentlichen Schmiedeversuchen unter produktionsähnlichen Bedingungen wird dargestellt und mit konventioneller Schmiedegesenkkonstruktion und ‑fertigung verglichen. Die Vorteile und Besonderheiten der generativen Prozesskette werden herausgestellt. Die gefertigten Schmiedeteile werden hinsichtlich Formfüllung, Maßhaltigkeit und Gefüge mit konventionell geschmiedeten Teilen verglichen. Die Lieferzeit der generativ gefertigten Schmiedegesenke wird der von konventionell hergestellten gegenübergestellt, ebenso die Kosten, um die Vorteile des Einsatzes generativer Fertigung herauszustellen. Es werden Randbedingungen beschrieben, unter denen die generative Fertigung von Schmiedegesenken technisch und wirtschaftlich sinnvoll ist.

The Mechanics of the drawing of polygonal sections from round at elevated temperature

Economic factors such as the rise in cost of raw materials, labour and power, are compelling manufacturers of cold-drawn polygonal sections, to seek new production routes which will enable the expansion in the varieties of metals used and the inclusion of difficult-to-draw materials. One such method generating considerable industrial interest is the drawing of polygonal sections from round at elevated temperature. The technique of drawing mild steel, medium carbon steel and boron steel wire into octagonal, hexagonal and square sections from round at up to 850 deg C and 50% reduction of area in one pass has been established. The main objective was to provide a basic understanding of the process, with particular emphasis being placed on modelling using both experimental and theoretical considerations. Elevated temperature stress-strain data was obtained using a modified torsion testing machine. Data were used in the upper bound solution derived and solved numerically to predict drawing stress strain, strain-rate, temperature and flow stress distribution in the deforming zone for a range of variables. The success of this warm working process will, of course, depend on the use of a satisfactory elevated temperature lubricant, an efficient cooling system, a suitable tool material having good wear and thermal shock resistance and an efficient die profile design which incorporates the principle of least work. The merits and demerits of die materials such as tungsten carbide, chromium carbide, Syalon and Stellite are discussed, principally from the standpoint of minimising drawing force and die wear. Generally, the experimental and theoretical results were in good agreement, the drawing stress could be predicted within close limits and the process proved to be technically feasible. Finite element analysis has been carried out on the various die geometries and die materials, to gain a greater understanding of the behaviour of these dies under the process of elevated temperature drawing, and to establish the temperature distribution and thermal distortion in the deforming zone, thus establishing the optimum die design and die material for the process. It is now possible to predict, for the materials already tested, (i) the optimum drawing temperature range, (ii) the maximum possible reduction of area per pass, (iii) the optimum drawing die profiles and die materials, (iv) the most efficient lubricant in terms of reducing the drawing force and die wear.

A simulation-based design method to transfer surface mount RF system to flip-chip die implementation

The flip-chip technology is a high chip density solution to meet the demand for very large scale integration design. For wireless sensor node or some similar RF applications, due to the growing requirements for the wearable and implantable implementations, flip-chip appears to be a leading technology to realize the integration and miniaturization. In this paper, flip-chip is considered as part of the whole system to affect the RF performance. A simulation based design is presented to transfer the surface mount PCB board to the flip-chip die package for the RF applications. Models are built by Q3D Extractor to extract the equivalent circuit based on the parasitic parameters of the interconnections, for both bare die and wire-bonding technologies. All the parameters and the PCB layout and stack-up are then modeled in the essential parts' design of the flip-chip RF circuit. By implementing simulation and optimization, a flip-chip package is re-designed by the parameters given by simulation sweep. Experimental results fit the simulation well for the comparison between pre-optimization and post-optimization of the bare die package's return loss performance. This design method could generally be used to transfer any surface mount PCB to flip-chip package for the RF systems or to predict the RF specifications of a RF system using the flip-chip technology.

Einflüsse von Folienqualität und Blister-Design auf die Funktionalität von Blisterverpackungen

Ziel dieser Arbeit ist die Untersuchung der Einflüsse von Blister-Design und Folienqualität auf die Funktionalität von Blisterverpackungen. Hierzu werden analytische Methoden mittels Interferometrie, IR-Spektroskopie, Betarückstreuverfahren, Wirbelstromverfahren und Impedanzspektroskopie entwickelt, die zur quantitativen Bestimmung von Heißsiegellacken und Laminatbeschichtungen von Aluminium-Blisterfolien geeignet sind. Ein Vergleich der Methoden zeigt, dass sich das Betarückstreuverfahren, die Interferometrie und IR-Messungen für die Heißsiegellackbestimmung, die Interferometrie und das Wirbelstromverfahren für die Bestimmung von Kunststofflaminaten eignen.rnIm zweiten Abschnitt der Arbeit werden Einflüsse des Heißsiegellack-Flächengewichtes von Deckfolien auf die Qualität von Blisterverpackungen untersucht. Mit Zunahme des Flächengewichtes zeigt sich eine Erhöhung der Siegelnahtfestigkeit aber auch der Wasserdampfdurchlässigkeit von Blistern. Die untersuchten Heißsiegellacke zeigen Permeationskoeffizienten vergleichbar mit Polyvinylchlorid. In Untersuchungen zur Siegelprozessvalidität zeigt das Heißsiegellack-Flächengewicht nur geringfügige Auswirkungen auf diese. rnIm dritten Abschnitt der Arbeit werden Einflüsse des Blister-Designs auf die Benutzerfreundlichkeit von Blisterverpackungen durch eine Handlingstudie untersucht. Variationen der Öffnungskräfte von Durchdrück-Blistern wirken sich deutlich auf die Bewertungen der Blister durch die Probanden aus. Während die meisten Probanden alle getesteten Durchdrück-Blister innerhalb der Testdauer von 4 Minuten öffnen können (>84%), treten beim Peel-Blister und Peel-off-push-through-Blister deutlich mehr Handlingprobleme auf. Die Handlingprobleme korrelieren mit dem Alter, der Lebenssituation, der gesundheitlichen Verfassung und der Sehfähigkeit der Probanden. rn

Die Gestaltung der Globalität. Schlüsselwörter der sozialen Ordnung (II) = The design of the global order: the keywords of social order. ZEI Discussion Paper C215, 2013

No abstract.

Within-Die Gate Delay Variability Measurement using Re-configurable Ring Oscillator

We report a circuit technique to measure the on-chip delay of an individual logic gate (both inverting and non-inverting) in its unmodified form using digitally reconfigurable ring oscillator (RO). Solving a system of linear equations with different configuration setting of the RO gives delay of an individual gate. Experimental results from a test chip in 65nm process node show the feasibility of measuring the delay of an individual inverter to within 1pS accuracy. Delay measurements of different nominally identical inverters in close physical proximity show variations of up to 26% indicating the large impact of local or within-die variations.