Prediction of the Interface Behavior of a Steel/CFRP Hybrid Part Manufactured by Stamping.

Carbon fiber-reinforced plastic (CFRP) is a lightweight material. The automotive industry has focused on producing a steel/CFRP hybrid part to reduce overall weight. After manufacturing, delamination can occur at the interface between the CFRP and steel owing to the hybrid part constituting dissimilar materials.

Multi-Load Topology Optimization Design for the Structural Safety Maintenance of Low- and Intermediate-Level Radioactive Waste Packaging Containers in the Case of a Collision.

This paper presents an optimized design approach using nonlinear dynamic analysis and finite element methods to ensure the structural integrity of square-shaped containers made from ductile cast iron for intermediate- and low-level radioactive waste packaging. Ductile cast iron, with its spherical graphite structure, effectively distributes stress throughout the material, leading to a storage capacity increase of approximately 18%. Considering the critical need for containers that maintain integrity under extreme conditions like earthquakes, the design focuses on mitigating stress concentrations at the corners of square structures.

A Methodological Approach for Motor Selection in Dental Impression Material Dispensers Using Experimental and Image Analysis Techniques.

This study presents a methodology to prevent the overdesign of electric dispensers for dental impression materials by analyzing the necessary load and determining the appropriate pressurization speed and drive motor capacity. We derived an equation to calculate the required torque and rotational speed of the motor based on the extrusion load and the speed of the impression material. A specialized load measurement system was developed to measure the load necessary to extrude the impression material.

Spring-In Prediction of CFRP Part Using Coupled Analysis of Forming and Cooling Processes in Stamping.

The spring-in phenomenon of the composite parts can affect the assembly process. This study aims to predict the spring-in phenomenon of a carbon fiber reinforced plastic (CFRP) part. Here, we predict the spring-in of the CFRP part using a coupled analysis of the forming and cooling processes during the stamping process.

The Effect of Boron (B) and Copper (Cu) on the Microstructure and Graphite Morphology of Spheroidal Graphite Cast Iron.

This study examines the impacts of copper and boron in parts per million (ppm) on the microstructure and mechanical properties of spheroidal graphite cast iron (SCI). Boron's inclusion increases the ferrite content whereas copper augments the stability of pearlite. The interaction between the two significantly influences the ferrite content.

Prediction of Extrusion Machine Stem Fatigue Life Using Structural and Fatigue Analysis.

In this study, the characteristics of the SKD61 material used for the stem of an extruder were analyzed through structural analysis, tensile testing, and fatigue testing. The extruder works by pushing a cylindrical billet into a die with a stem to reduce its cross-sectional area and increase its length, and it is currently used to extrude complex and diverse shapes of products in the field of plastic deformation processes. Finite element analysis was used to determine the maximum stress on the stem, which was found to be 1152 MPa, lower than the yield strength of 1325 MPa obtained from tensile testing.

Influence of the surface flaws in oil-tempered wires on the fatigue life of automotive engine valve springs.

The purpose of this study is to evaluate the fatigue life of an automotive engine valve spring when the micro defect is applied to a 2300 MPa-class oil-tempered wire (OT wire) with 2.5 mm of diameter as the critical flaw depth. First, the deformation of the surface flaws in the OT wire during the valve spring manufacturing processes was derived via FE analysis using the sub-modeling technique, and the residual stress of the final spring was measured and applied to the spring stress analysis model.

Approximation Model Development and Dynamic Characteristic Analysis Based on Spindle Position of Machining Center.

To evaluate the dynamic characteristics at all positions of the main spindle of a machine tool, an experimental point was selected using a full factorial design, and a vibration test was conducted. Based on the measurement position, the resonant frequency was distributed from approximately 236 to 242 Hz. The approximation model was evaluated based on its resonant frequencies and dynamic stiffness using regression and interpolation methods.

Design of an Intermediate Die for the Multi-Pass Shape Drawing Process.

The multi-pass shape drawing process is mainly used in metal forming processes to manufacture long components with constant arbitrary cross-sectional shapes along their lengths. The cross-roller guide is a typical component that is manufactured by a multi-pass shape drawing process. The cross-roller guide is mostly used in optical measurement equipment where high-precision movement is required.

Novel Approach toward the Forming Process of CFRP Reinforcement with a Hot Stamped Part by Prepreg Compression Molding.

The use of carbon fiber-reinforced plastics (CFRP) is markedly increasing, particularly for the manufacturing of automotive parts, to achieve better mechanical properties and a light weight. However, it is difficult to manufacture multi-material products because of the problems due to the adhesive between CFRP and steel. The prepreg compression molding (PCM) of laminated CFRP can reduce the production time and increase the flexibility of the manufacturing process.

A Study on the Mechanical Properties of an Automobile Part Additively Printed through Periodic Layer Rotation Strategies.

In metal product manufacturing, additive manufacturing (AM) is a method that has the advantage of fabricating complex shapes and customized production, unlike existing machining methods. However, owing to the characteristics of the AM process, anisotropy of macrostructure occurs because of various causes such as the scan direction, melting, fusion, and cooling of the powdered material. The macrostructure anisotropy is realized from the scan direction, and when a single layer is stacked in one direction, it is expressed as orthogonal anisotropy.

Prediction of the Delamination at the Steel and CFRP Interface of Hybrid Composite Part.

The purpose of this study was to predict the adhesive behavior of steel and carbon-fiber-reinforced plastic (CFRP) hybrid parts based on the cohesive zone model (CZM). In this study, the steel sheet and CFRP were joined by epoxy resin in the CFRP prepreg during the curing process, which could generate delamination at their interface because of the springback of steel or the thermal contraction of the CFRP. First, double cantilever beam (DCB) and end-notched flexure (ENF) tests were performed to obtain various adhesion properties such as the critical energy release rate of mode I, mode II (, ), and critical stress ().

Design of Center Pillar with Composite Reinforcements Using Hybrid Molding Method.

Recently, with the increase in awareness about a clean environment worldwide, fuel efficiency standards are being strengthened in accordance with exhaust gas regulations. In the automotive industry, various studies are ongoing on vehicle body weight reduction to improve fuel efficiency. This study aims to reduce vehicle weight by replacing the existing steel reinforcements in an automobile center pillar with a composite reinforcement.

A State-of-the-Art Review on Advanced Joining Processes for Metal-Composite and Metal-Polymer Hybrid Structures.

Multi-materials of metal-polymer and metal-composite hybrid structures (MMHSs) are highly demanded in several fields including land, air and sea transportation, infrastructure construction, and healthcare. The adoption of MMHSs in transportation industries represents a pivotal opportunity to reduce the product's weight without compromising structural performance. This enables a dramatic reduction in fuel consumption for vehicles driven by internal combustion engines as well as an increase in fuel efficiency for electric vehicles.

Design of Multi-Stage Roll Die Forming Process for Drum Clutch with Artificial Neural Network.

The multi-stage roll die forming (RDF) process is a plastic forming process that can manufacture a transmission part with a complex shape, such as a drum clutch, by using a die set with rotational rolls. However, it is difficult to satisfy dimensional accuracy because of spring-back and unfilling. The purpose of this study is to design a multi-stage RDF process for the manufacturing of a drum clutch to improve dimensional accuracy using an artificial neural network (ANN).

Feasibility of Reduced Ingot Hot-Top Height for the Cost-Effective Forging of Heavy Steel Ingots.

Feasibility studies have been performed on ingots with reduced hot-top heights for the cost-effective hot forging of heavy ingots. The quality of the heavy ingots is generally affected by internal voids, which have been known to be accompanied by inclusions and segregation. To guarantee the expected mechanical performance of the forged products, these voids should be closed and eliminated during the hot open die forging process.

Design of Lightweight CFRP Automotive Part as an Alternative for Steel Part by Thickness and Lay-Up Optimization.

Mechanical properties, such as strength and stiffness, of laminated carbon fiber reinforced plastic (CFRP) are generally affected by the lay-up method. However, no precise design rules to replace steel products with CFRP have been established that satisfy these properties. Therefore, this study proposes a set of rules to design automotive parts with equivalent bending stiffness through structural analysis and genetic algorithms (GAs).

Effect from cyclic fatigue of nickel-titanium rotary files on torsional resistance.

Introduction: The aim of this study was to evaluate the effect of cyclic fatigue on the torsional resistance of nickel-titanium (NiTi) rotary instruments.

Methods: ProFile (#25/0.06; Dentsply Maillefer, Ballaigues, Switzerland) and ProTaper (F1, Dentsply Maillefer), both of which have the same external diameter at D5, were tested using a fatigue testing machine for the mean number of cycles of failure (mNCF).