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65. Single Point Incremental Forming: analysis of sustainability of the process through an experimental approach

Author

Ambrogio, G, Filice, L, Gagliardi, F, DI LORENZO, Rosa, INGARAO, Giuseppe, Ambrogio, G, Di Lorenzo, R, Filice, L, Gagliardi, F, and Ingarao, G

Subjects
SPIF, process parameters, energy consumption, environmental burdens, Settore ING-IND/16 - Tecnologie E Sistemi Di Lavorazione
Abstract

In literature, manufacturing processes have been studied with different approaches, but a lack of knowledge on the analysis of the energy required is still present. The aim of this paper is to carry out energy analysis on Single Point Incremental Forming process. Accordingly, a wide experimental investigation was executed by taking into account different process parameters (i.e. tool depth step, punch velocity and product shape). The total energy consumption was monitored during all the experiments and properly weighted with respect to the deformation energy, required to execute the process. A sensitivity analysis was also carried out to highlight the conditions which allow to save energy reducing neither the process nor the product quality.

Published
2013

66. A Comparison of Mechanical Properties and Microstructure in Friction Stir Welded and MIG Welded Light Alloys

Author

BUFFA, Gianluca, CANNIZZARO, Luigi, FRATINI, Livan, MICARI, Fabrizio, Filice, L, Buffa, G, Cannizzaro, L, Filice, L, Fratini,L, and Micari, F.

Subjects
Settore ING-IND/16 - Tecnologie E Sistemi Di Lavorazione, FSW, MIG, microstructure, aluminum alloys
Abstract

Joining technologies are in a very interesting phase today due to some relevant innovations concerning new techniques. Friction Stir Welding (FSW) is a relatively new process, patented by TWI in 1991, able to weld through a solid state bonding materials considered difficult to be welded or unweldable by more traditional fusion welding techniques. By using this process welded joints are obtained with no external heat supplier, generating the required temperature increase by means of a revolving pin that follows a proper trajectory partially sunk in the workpiece surface. As for today, although first examples of industrial application can be found in the aeronautical and aerospace fields, the process is hardly applied for other sectors of the transportation industry, as the naval and the automotive ones, in which traditional fusion processes as MIG or TIG are still used. In the paper a comparison between the mechanical and metallurgical properties of FSWed and MIG welded sheets is carried out. In particular, two different thicknesses of AA5083 H321 aluminum alloy sheets, usually utilized for naval and marine applications, were utilized for the welds utilizing both the processes. The obtained results clearly highlight the supremacy of FSW in both mechanical resistance and joint integrity.

Published
2012

67. Energy efficiency analysis in Incremental Sheet Forming operations

Author

Ambrogio, G, Anghinelli, O, Gagliardi, F, Filice,L, DI LORENZO, Rosa, Ambrogio, G, Anghinelli, O, Di Lorenzo, R, Gagliardi, F, and Filice,L

Subjects
Incremental Sheet Forming, Energy Efficiency, Sensitivity Analysis, Settore ING-IND/16 - Tecnologie E Sistemi Di Lavorazione
Abstract

In literature, manufacturing processes have been studied with different approaches, but a lack in terms of their environmental impact and energy required is still present. The aim of this paper is to compute some energy efficiency analysis on a specific manufacturing process. More in detail, the attention will be focused on the Incremental Sheet Forming process in order to evaluate the required energy and how it changes for changing process conditions. Accordingly, a wide experimental investigation has been executed taking into account different process parameters (i.e. tool depth step, punch diameter, wall inclination angle and sheet thickness). The total energy consumption has been monitored during all the experiments and properly weighted with respect to the deformation energy, required to execute the process. At the end, a sensitivity analysis has been carried out in order to highlight which conditions allow to reduce the energy consumption without reducing both the process suitability and the product quality.

Published
2012

72. Formatura della lamiera: il processo incrementale

Author

Ambrogio, G, Filice, L, MICARI, Fabrizio, Ambrogio, G, Filice, L, and Micari, F.

Subjects
formatura incrementale, Lamiere, Settore ING-IND/16 - Tecnologie E Sistemi Di Lavorazione
Published
2007

75. Prediction of Tool Wear in Machining

Author

Micari, F., Filice, L., Umbrello, D., Attanasio, Aldo, MICARI F, FILICE L, UMBRELLO D, and ATTANASIO A

Subjects
FEM analysis, Tool Wear, Machining operations
Published
2007

76. La formatura superplastica di leghe di Titanio per l'impiego aeronautico

Author

Gagliardi, F, Filice, L, Lazzaro, S, Cinquegrana, D, Mazzeo, S, MICARI, Fabrizio, Gagliardi, F, Filice, L, Lazzaro, S, Cinquegrana, D, Mazzeo, S, and Micari, F.

Subjects
Titanio, Formatura superplastica, Settore ING-IND/16 - Tecnologie E Sistemi Di Lavorazione
Published
2007

85. A stabilized formulation with maximum entropy meshfree approximants for viscoplastic flow simulation in metal forming

Author

Universitat Politècnica de Catalunya. Departament d'Enginyeria Civil i Ambiental, Universitat Politècnica de Catalunya. LACÀN - Mètodes Numèrics en Ciències Aplicades i Enginyeria, Greco, F., Filice, L., Peco, Christian, Arroyo Balaguer, Marino, Universitat Politècnica de Catalunya. Departament d'Enginyeria Civil i Ambiental, Universitat Politècnica de Catalunya. LACÀN - Mètodes Numèrics en Ciències Aplicades i Enginyeria, Greco, F., Filice, L., Peco, Christian, and Arroyo Balaguer, Marino

Abstract

The finite element method is the reference technique in the simulation of metal forming and provides excellent results with both Eulerian and Lagrangian implementations. The latter approach is more natural and direct but the large deformations involved in such processes require remeshing-rezoning algorithms that increase the computational times and reduce the quality of the results. Meshfree methods can better handle large deformations and have shown encouraging results. However, viscoplastic flows are nearly incompressible, which poses a challenge to meshfree methods. In this paper we propose a simple model of viscoplasticity, where both the pressure and velocity fields are discretized with maximum entropy approximants. The inf-sup condition is circumvented with a numerically consistent stabilized formulation that involves the gradient of the pressure. The performance of the method is studied in some benchmark problems including metal forming and orthogonal cutting., Peer Reviewed, Postprint (author's final draft)

Published
2015

89. Influence of tool coating on the process performance of AISI 304 Incremental Sheet Forming

Author

Giuseppina Ambrogio, Filice, L., Gautier, G., and Rizzuti, S.

Subjects
Friction, Coatings, Incremental Sheet Forming
Abstract

Incremental Sheet Forming (ISF) is a process in which a tool, following an imposed CNC trajectory, progressively deforms a clamped sheet avoiding the use of dedicated tools. Up to now, although many works were carried out on this process, some aspects are not well assessed and further investigations are required. In particular, the role played by friction is not fully understood and requires more detailed investigations. In this paper the role played by the tool coating is investigated in order to evaluate the friction effect, the tool wear and the process load. In detail, an investigation on the surface quality, the process loads and the economical issue is earned out comparing a set of coated and uncoated tools. © 2011 IBF (RWTH Aachen) & IUL (TU Dortmund).

Published
2011

91. Simulation des procédés d'extrusion de profils creux par la méthode des éléments naturels

Author

Alfaro, I., Cueto, Elías, Olivera, J., Filice, L., Gagliardi, F., Chinesta, Francisco, Laboratoire Kastler Brossel (LKB (Lhomond)), Université Pierre et Marie Curie - Paris 6 (UPMC)-Fédération de recherche du Département de physique de l'Ecole Normale Supérieure - ENS Paris (FRDPENS), École normale supérieure - Paris (ENS Paris), Université Paris sciences et lettres (PSL)-Université Paris sciences et lettres (PSL)-Centre National de la Recherche Scientifique (CNRS)-École normale supérieure - Paris (ENS Paris), Université Paris sciences et lettres (PSL)-Université Paris sciences et lettres (PSL)-Centre National de la Recherche Scientifique (CNRS)-Centre National de la Recherche Scientifique (CNRS), Institut de Recherche en Génie Civil et Mécanique (GeM), Université de Nantes - UFR des Sciences et des Techniques (UN UFR ST), Université de Nantes (UN)-Université de Nantes (UN)-École Centrale de Nantes (ECN)-Centre National de la Recherche Scientifique (CNRS), Fédération de recherche du Département de physique de l'Ecole Normale Supérieure - ENS Paris (FRDPENS), École normale supérieure - Paris (ENS-PSL), Université Paris sciences et lettres (PSL)-Université Paris sciences et lettres (PSL)-Centre National de la Recherche Scientifique (CNRS)-École normale supérieure - Paris (ENS-PSL), and Université Paris sciences et lettres (PSL)-Université Paris sciences et lettres (PSL)-Centre National de la Recherche Scientifique (CNRS)-Université Pierre et Marie Curie - Paris 6 (UPMC)-Centre National de la Recherche Scientifique (CNRS)

Subjects
[SPI.MECA]Engineering Sciences [physics]/Mechanics [physics.med-ph], [SPI.MAT]Engineering Sciences [physics]/Materials
Published
2009

93. An Inverse Approach to Asses Material Models by Means of Machining Tests

Author

Chinesta, Francisco, Filice, L., Micari, F., Rizzuti, S., Umbrello, D., Institut de Recherche en Génie Civil et Mécanique (GeM), Université de Nantes - UFR des Sciences et des Techniques (UN UFR ST), and Université de Nantes (UN)-Université de Nantes (UN)-École Centrale de Nantes (ECN)-Centre National de la Recherche Scientifique (CNRS)

Subjects
[SPI.MECA]Engineering Sciences [physics]/Mechanics [physics.med-ph], [SPI.MAT]Engineering Sciences [physics]/Materials
Abstract

Numerical simulation is a very useful tool that allows to obtain significant information in machining, but, untilnow,many difficulties has to be overcome in this field. In fact the reliability of results obtained from finiteelement analysis is strictly related to the accuracy of input data. Among these, the constitutive equation of theworkpiece material and the friction along the tool-chip interface are probably the most important aspects.In this paper an inverse approach based on Arbitrarian Lagrangian Eulerian (ALE) simulations is proposed. Theprocedure permitted to determine a simplified material law for the workpiece material by using only machiningtests. The results will be presented in the paper. [NO PDF]

Published
2008

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