SELECTED ABSTRACTS OF METALWORKING LITERATURE SEPTEMBER 1984-MARCH 1985 Reprinted with Permission From Metals Abstracts Published by METALS INFORMATION a joint service of The American Society for Metals and The Institute of Metals Metals Park, Ohio, USA and London, England
September 1984
52
Working (Forming)
52-1470
Backward Extrusion of internally Shaped Tubes From Round
B i l l e t s . An analytical method is proposed for estimating the steady-state punch pressure for three-dimensional backward extrusion (or piercing) of complicated internally shaped tubes from circular billets. A kinematically admissible velocity field is derived to formulate an upper-bound solution using velocity transformation and mapping function. The configuration of deforming boundary surfaces are determined by minimizing the extrusion power with respect to some chosen parameters. Experiments are carried out with commercially pure AI billets for internally shaped tubes at various reductions of area by using different sizes of shaped punches, such as square and regular hexagons. It is shown that the theoretical predictions for extrusion load are in good agreement with the experimental values. 11 ref. --AA D.Y. Yang, and C.H. Han. J. Eng. Ind. (Trans. ASME), May 1984, 106, (2), 143-149, [in English]. ISSN 0022-0817.
52-1471 The Study of Distorted Grid Patterns for Flow-Through Conical Converging Dies by the Multitriangular Velocity Field. A variety of velocity fields may be used to analyze the intermediate and final distorted grids for the so-called "flow-through" metalforming processes such as wire drawing, rolling, extrusion, etc. The triangular velocity field describes the flow of homogeneous, perfectly plastic Mises' material through a conical converging die. The traditional triangular velocity field was treated and the solution extended. The shape of the distorted grids was uniquely determined by the minimization of the power (drawing or extrusion stresses) required to cause its distortion for a given set of independent process parameters, i.e. process geometry-reduction in area and semitone angle, and friction. Actual power (forming stress requirements) was estimated by the upper-bound technique. For the unitriangular velocity field, the power was minimized with respect to the shape of the workpiece (the shape of the triangle). For the multitriangular velocity field, the power was minimized with respect to the shape and the number of triangles. Further, the number of triangles was treated as a real number. Thus, the accurate lower upper-bound was found and the reasonable solution in predicting real distortion grid patterns was then obtained. The analysis determines the severity of the distortion as a function of process geometry and friction. 11 r e f . - - A A J. Pan, W. Pachla, S. Rosenberry, and B. Avitzur. J. Eng. Ind. (Trans. ASME), May 1984, 106, (2), 150-160, [in English]. ISSN 0022-0817. 52-1472 L u b r i c a t i o n in the Rolling o f L i g h t M e t a l s . Technical considerations involved in the rolling lubrication of light metals, primarily AI and Mg, are examined. Topics discussed include lubrication for hot and cold rolling, roll coating, foil rolling and lubricant composition. The use of an appropriate lubricant can reduce metal transfer to the roll surface. Straining of rolled stock is a function of lubricant viscosity. 58 ref.--G.P.K. J.A. Schey. Light Met. Age, Apr. 1984, 42, (3-4), 16, 18-20, [in English]. ISSN 0024-3345. 52-1473 Extruder Designs, Fabricates and Erects Skyscraper C u r t a i n W a l l s . Cupples Products, St. Louis, Mo., not only designs and extrudes AI components for the curtain walls of high-rise buildings, but also assembles and erects the walls. Cupples is currently providing over 8 billion Ib of AI extrusions, sheet and die castings for the 45 story Hong Kong headquarters of the Hong Kong & Shanghai Banking Corp. The large volume of required extrusions led Cupples to install a computer-controlled Sutton 3000 ton press.--G.P.K. Light Met. Age, Apr. 1984, 42, (3-4), 33-34, [in English]. ISSN 0024-3345.
Coreless Induction Furnaces Are Key to Success of Arizona Extruder. Pimalco, a Phoenix manufacturer of extruded AI components for aero-
shown. The influence of normal and of planar anisotropy on the geometrical properties of deep-drawn cups is described. The possibilities offered by the forming limit diagram, the forming limit curve and the strain analysis to detect critical strain combinations in the drawn component, to control the process reliability and to optimize the process parameters in drawing of irregularly shaped components are discussed. The effect of the deformation process on the forming limit diagram is depicted. Factors such as tool wear, part dimensions and hold-down load are considered. Forming limit curves cited in the literature for steel 1403, AIMgO.4Sil.2 and TiCu2 are compared. 18 ref.--B.L. E. Dannenmann. Blech Rohre Profile, Mar. 1984, 31, (3), 96-101, [in German]. ISSN 0006-4688. 52-1476 Important Basics of Deep D r a w i n g , - - I I . Failures in rotationally symmetrical drawn parts occur as tears. Tears occurring before the bottom is completely formed are premature tears whereas those resulting after the bottom is shaped in the region of the die corner rounding are true tears; when the latter occur at the junction of the bottom rounding and the sidewall, optimal tearing, requiring the highest force, occurs. The max. bearable load FBR = 7r x part dia. x sheet thickness x die radius x r r where ~'r is the tearing factor. When the calculated drawing force is equal to or greater than FBR tearing failure occurs. The limiting drawing ratio is a function of punch d i a . / s h e e t thickness; 58% of deep drawing failures in right-angled drawn parts are due to folds and tears, 19% to folds alone, 15% to tears alone, 6% to flow figures, 2% to orange peeling. The effect of blank shape on sheet thickness increase in the flange at corners is depicted. Three deformation zones are identified: in the corner, radial tensile and tangential compression stresses occur; in the straight portions, tensile stresses predominate; in the transition zone, the tangential stresses decrease to straight portion levels. The tearing factor decreases with increasing part size and is larger for steel 1403 than for steel 1203 and AIMg5 because of the poorer work hardening and anisotropy factors of the latter.--B.L. E. Doege, and N. Sommer. Blech Rohre Profile, Mar. 1984, 31, (3), 102-105, [in German]. ISSN 0006-4688. 52-1479 F u n d a m e n t a l s o f Deep Drawing. The basic principles of deep drawing sheet metal into a wide range of useful components are discussed. A variety of steel, stainless steel and Cu, AI alloys can be deep drawn to parts ranging india, from 1 / 2 t o 4 1/2 in. and lengths up t o 6 1 / 2 in. Advantages include highspeed production, max. use of material and the ability to economically produce complex parts.--G.P.K. T.G. Boileau. Precis. Met., May 1984, 42, (5), 47-48, 51, [in English]. ISSN 0032714X.
Strain Measurement Over Large Areas of an Industrial Stamping. Circle grid strain analysis has greatly improved the understanding of 52-1480
failure in press forming and recent developments in automatic image analysis have increased the speed and repeatability of measurement. The method, however, is generally applied only to a critical point or along a line in a stamping and is less effective for measuring strain over large areas of a part. A method of strain determination from the nodal point measures of a deformed grid, coupled with computeraided analysis and plotting, permits the rapid investigation of strain over most or all of the area of a stamping. The theory of such a technique and results obtained from measurements made on an automotive stamping is presented. Various methods of illustrating the results are given and the information which can be obtained from such an investigation is d i s c u s s e d . - - A A E. Chu, R. Sowerby, R. Soldaat, and J.L. Duncan. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Proc. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A, 8409-72-0579) 9-22, [in English].
52-1474
space applications, is successfully using two coreless induction furnaces to provide aircraft-quality ingots. The Brown Boveri induction furnaces offer high alloy recovery rates, good bath control and production flexibility. The ability to make quick alloy changes in the induction furnaces enables Pimalco to melt > 30 different alloys with typically short casting runs.--G.P.K. Light Met. Age, Apr. 1984, 42, (3-4), 40-41, [in English]. ISSN 0 0 2 4 - 3 3 4 5 52-1475 I n f l u e n c e o f Plastic Properties and Surface Microstructure o f T h i n Sheet on Drawing and Bending Processes.--I. In sheet metal forming the parameters strain-hardening coefficient n (defined by the flow curve kf = c ~ where kf is the flow stress, ~1 is strain in the tensile direction, c is constant) and perpendicular plastic anisotropy ratio r (defined by r = ~b/~s = q~1/--(~1 + ~s) where ~u and '~s are strains in width and thickness directions, respectively) are of particular importance when describing materials behavior. The effect of these parameters on the process limitations in deep drawing, stretching and bending is
50
VOL. 4, NO. 1, JULY 1985
52-1481 Case Studies Using Grid Square Strain Analysis. The results of grid square strain analysis applied to a number of automobile body panels of lowcarbon steel are presented. The use of the method in solving practical press shop problems, especially those involving poor shape fixability, is demonstrated. 10 ret. --AA T.J. Nihill, and W.R. Thorpe. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Proc. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 8409-720579) 23-33, [in English]. S u b s t i t u t i o n o f a L o w - C a r b o n S t e e l With a Rephosphorized Variety for an Automotive Panel: the Application of Grid Square Strain Analysis. The forming process for an experimental trunk-lid outer-panel fabri52-1482
cated from low-carbon and rephosphorized steels has been analyzed by the SIROSTRAIN grid square strain analysis system. Two main stages in the deformation have been identified: initial punch contact, in which the strain is concentrated
J. APPLIED METALWORKING
around the point of impingement of the punch on the blank, and stretching over the punch radius, in which the straining occurs preferentially in the low curvature region at the front of the panel. In increasing the yield strength of the sheet steel from ~ 200 to ~ 300 MPa, the second stage of deformation was suppressed and more material flowed through the draw bead system. This behavior may be offset by increasing the blank holder pressure, although wear problems are likely to occur if this path is taken. In this particular panel, therefore, down-gaging to a higher strength steel should be accompanied by a tooling modification to raise the strain level across the punch face. With the present design, the most likely modifications would be to the draw bead system or to the punch radius. 13 r e f . - - A A W.R. Thorpe, and T.J. Nihill. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 8409-720579) 34-45, [in Engllsh].
52-1483 Study of Surface Deflection in Door Outer Panel. Larger surface deflection than permissible is sometimes caused around the handle portion of the automotive door outer panel. This phenomenon is prominent when using highstrength steel sheet for this part. If the forming technique to restrain this surface deflection significantly is developed, it will be easier to use high-strength steel sheet for the door o u t e r p a n e l There are some reports regarding the occurrence of surface deflection in forming the process of growth and decline, restraint and reduction of surface deflection. After forming an automotive door outer panel to make an experimental model with the handle portion, the deformation of the material at forming is observed and elastic recovery at unloading of the panel and the mechanism of the surface deflection occurrence and what tension should be given to restrain the surface deflection at the process of growth and decline are considered.--AA T. Shimomura, and M. Yoshida. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 840972-0579) 46-53, [in English].
52-1484 A Study of the Growth Mechanism and Removal Techniques of Surface Deflection Observed in Autobody Outer Panels. Geometrical surface defects, such as wrinkles, minute surface deflection and springback, are most serious problems in the press forming of high-strength steel sheets into autobody outer panels. The origin of surface deflections in typical autobody panels is investigated by a method of successive cutting of the panel using a sensitive spherometer. Surface deflection is classified into two types, plastic and elastic. The former includes traces of initial buckle and wrinkle and buckles which take place at unloading. The latter are caused by the differential in springback of nonuniformly deformed surface or shape. Stretching is effective for the removal of the former type of deflection, while partial heavy stamping or partial heating of sheet can be expected to control the elastic deflection. The effects of the mechanical properties of the sheet on the growing and reducing of both types of deflection are examined.--AA T. Satoh, T. Amaike, Y. Tokunaga, H. Takizawa, and S. Ujihara. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A, 8409-72-0579) 54-61, [in English].
52-1485 New Forming Method for Avoiding Geometrical Detects o f O u t e r Autobody Panels. The geometrical surface defects of outer body panels is one of the serious problems in press forming of steel sheets, particularly highstrength stee~ sheets. A study is carried out on a new forming method which introduces the technique of local warming of material to press forming for preventing the defect around the handle of a door outer panel from appearing. This new method, the "locally warm forming" process, has been shown to be effective for improving the geometrical face quality of outer panels. 8 r e f . - - A A Y. Hayashi, and M. Takatani. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. ConL], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A, 8409-720579) 62-72, [in English].
52-1486 Analysis and Control of Buckling Behavior Due to Elastic Recovery in Press Forming. To answer the increasing requirements for better surface formation accuracy of automobile outer panels, it is important to clarify the factors governing geometrical and surface defects on the pressed panels and to find the method for improvement. As a basic step for that purpose, the geometrical surface defects due to elastic recovery were investigated by phenomenon simulation, model forming and actual pressing to analyze their initiation process, constituent elements and governing factors. The geometrical surface defects can be c|assified into three types of surface deflections--c~, (] and "~, deflection. They are initiated by buckling or springback due to elastic recovery and the most important of the initiation factors of the two is the nonuniform distribution of stress during forming. The factors which control surface deflections include yield strength, sheet thickness, n' value and r value on the material side and application of pressure, tension and partial heating on or around the deflection portion from the press forming technical s i d e . - - A A K. Yoshida et al. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. ConL], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group. Melbourne, Australia, 1984, (Met.A., 8409-72-0579) 73-84, [in English].
52-1487
E f f e c t of Sheet Metal Thickness on Forming Limits. It has been observed that the forming limits change considerably with the thickness of sheet, exhibiting an increase in the limits with increasing thickness. However, even the most commonly used M.K. model does not contain any term dependent on thickness, and hence its predictions of the forming limits are invariably lower than actual values at higher thicknesses. An explanation for this increase in forming limit can be sought by way of the presence of triaxial stress in the neck, which becomes more pronounced in the case of sheets with larger thickness. Using this concept, a modification is incorporated in the M.K. model to predict forming limits, which match the experimental results much better than the other models. 11 ref. --AA
J. APPLIED METALWORKING
U.S. Rag, and R.C. Chaturvedi. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A, 840972-0579) 85-94, [in English].
S2-1488
Fluid Forming of S h e e t Metal in Production. Fluid forming is a sheet metal forming process employing the flexible die technique. Only one rigid tool half is necessary and a rubber diaphragm backed by oil pressure serves both as a blank holder and a flexible die member. The pressure is evenly distributed on the blank and is accurately controlled during the stroke when punch pressing. Local stress concentrations are thus minimized, which reduces thinning and crack initiation. This means that very high draw ratios, up to 3:1, may be achieved in one operation and that thinner blanks can be used. Often simplified tooling and fewer drawing steps are employed in fluid forming as compared with conventional deep drawing. The fluid forming process is intended for low and medium series production, especially within the aircraft and automotive industries and job shops. Optimization of parameters is discussed, production examples fabricated from stainless and heat resistant steels, Ti- and AI-base alloys and brasses are presented and a description is given of the fluid forming process and of the ASEA QUINTUS fluid forming equipment for high-pressure, flexible die forming with pressures up to 200 M P a . - - A A F. Rydell, T. Johannisson, and P.-E. Nilsson-Jatko. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. ConL], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met,A, 8409-72-0579) 95-105, [in English]. 52-1489
Assessment of Behavior of S h e e t Metal During Hydroforming.
The behavior of Cu sheet during the bulge test is discussed in the light of formability which may adequately be described in terms of deformation and shape. The local shape of the deformed shell is interpreted through the concept of prelateness, which is derived from the principal curvatures and which describes their deviation from a reference sphere. The effects of two important process parameters on the bulge test, the magnitude of the die shoulder radius and the amount of drawin present during forming, are discussed. Experimental results show that the deformed bulge is never a spherical surface or one of constant shape. Furthermore, evolution of the over-all shape depends on the severity of d e f o r m a t i o n Reducing the die shoulder radius and permitting draw-in appear to make the shell less prolate and also improve the formability of the material in the hydroforming process. These parameters also have similar effects on stretch formability. 11 r e f . - - A A H.M. Shang, F.S. Chau, C.J. Tay, and S.L. Toh. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A, 8409-72-0579) 106-117, [in English].
52-1490 C A D / C A M / C A E for Roll Forming. The benefits of computer-aided design of sheet metal forming and the associated toolage have become obvious in the roll forming area. An interactive package, CADROF, recently developed by John Lysaght (Australia) is described showing the package versatility and the way in which the user may employ the computer creatively to examine alternative design approaches. The package, by offering a direct path from CAD to CAM, reduces the risk of numerical design errors creating unsuitable toolage. Options available within the package enable a wide range of sections to be designed without recourse to special techniques or tedious data entry. More importantly, the package includes options which present quantitative and qualitative information to the designer so that the stresses induced in the sheet metal during forming can be critically assessed. Residual stresses which induce springback, flair, bending and twist of a section are important; current developments of this work are described. 25 r e f . - - A A W.Y.D. Yuen. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 8409-72-0579) 118-132, [in English}. 52-1491
Predicting the Effect of Die Gap on Flange Springback. An an-
alytical method of calculating springback in a simple flanging operation is prese n t e d The die parameters incorporated include the distance between the die wall and flanging steel, or the die gap, which is assumed to be no less than the sheet thickness. By assuming that the flange is formed in plane strain bending under negligible stretching (or compression) loads, the moment distribution in the flange is calculated as a function of the sheet material's strain-hardening and anisotropic properties and the die parameters. Using the ordinary elastic plate bending theory, springback of the flange after removal from the die is subsequently determined, Ca(culated results for several mild (dual phase, CRLC and AKDQ) and highstrength steels (SAE950X, SAE980X, HS110) are in general agreement with existing experimental data. These calculations also indicate that the effect of die gap on flange springback is greatest when the ratio of the die gap to sheet thickness is slightly greater than one. Some potential applications of the method are discussed. 11 r e f . - - A A N.-M. Wang. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A, 8409-72-0579) 133-147, [in English]. 52-1492 Springback of C o m p l e x Bent Parts. The springback associated with the removal of forming loads during the manufacture of automotive body components is controlled by the elastic parameters but it also depends on the plastic behavior which governs the stress distribution before springback. The anisotropic behavior of the material has a great influence on the final shape and both the plastic and the elastic anisotropy have to be considered. Furthermore, the evolution of the elastic parameters with the plastic strain has to be considered'. The different anisotropic parameters are e x p e r i m e n t a l l y determined for a h i g h - s t r e n g t h (DPUS80) and a mild (MS-XES) steel. A model is then developed to predict the springback of a complex bent part including the wall curling. Comparison with experiments and further predictions of the model are also examined. 7 r e f . - - A A M.L. Chakhari, and J.M. Jalinier. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. Conf.], Melbourne, Australia, 20-24 Feb. 1984, Interna-
VOL. 4, NO. 1, JULY 1985
51
tional Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 840972-0579) 148-159, [in English]. 52-1493 M o d e l i n g o f Sheet Metal Flow Through a Drawbead. A computer model has been written to simulate the deformation of a metal strip being pulled through a drawbead. The model calculates the following values for a constant clearance drawbead: drawing force, bead opening force, intertacial pressures between the strip and the bead surfaces, the stress and strain distribution across the strip at any stage during the process and the final elongation and thickness of the strip. The input parameters to the model are the drawbead geometry, the material stress--strain relationship and the coefficient of friction between the strip and the bead surfaces. The model shows good agreement with experimental and published results provided the shape of the strip through the drawbead conforms to the geometry of the drawbead radii. When the strip shape does not conform to the bead geometry, which can occur with low beads or large bead clearances, the model gives better results when the actual strip radii are used as input data rather than the bead radii. The model may be used to predict alterations to the drawbead geometry to maintain the same level of strain in the panel if the thickness or strength of the sheet is changed. 10 r e f . - - A A J.M. Yellup. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Proc. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 8409-72-0579) 166-177, [in English].
52-1494 Development of High-Purity Ferritic Stainless S t e e l With Excellent S t r e t c h a b i l i t y . The effect of alloying elements on the strain hardening exponent, n-value, of ferritic stainless steel sheets have been investigated to improve stretchability. Results have shown that the chemical composition may determine the n-value almost uniquely. The major requirements to improve the n-value are: lowering Cr content, reducing carbon and nitrogen contents and adding Ti, the content of which is about ten times that of (C + N), and reducing substitutional minor elements, such as phosphorus, Si and AI. Consequently, 13% Cr steel which has the appropriate chemical composition has a high n-value of ~ 0.27. The effect of substitutional elements on the n-value may be closely related to the increase in lattice distortions or internal stresses induced by the dissolution of substitutional elements into the matrix. The combined addition of Ti and P may form a precipitate of (Ti, Fe, Cr)P, which causes a harmful effect on the n-value. On the basis of experimental findings, low C, N - - 1 3 C r - - T i steel has been produced. The steel has excellent stretchability and high deep drawability and can be used for kitchen s i n k s . - - A A K. Miyakusu, Y. Uematsu, and K. Hoshino. Efficiency in Sheet Metal Forming, IDDRG t3th Biennial Congress [Proc. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 8409-72-0579) 178-189, [in English].
52-1495 Characteristics of Continuous-Annealed Steel Sheets for Automotive U s e , The characteristics and metallurgical features of some unusual cold rolled steel sheets, produced by the newly developed continuous annealing line, are discussed. Controlled rapid cooling at 10 to 1 0 0 ~ after intercritical annealing with alloyed low-carbon steels provides dual-phase high-strength steel sheets with markedly stable mechanical properties. The steel sheets exhibit good stretchability and high bake hardenability. Low-C mild steel sheets with good drawability and resistance to aging are obtained by control of cooling rate before overaging. Nonaging ultra-deep-drawing mild steel sheets are produced by continuous annealing without overaging with an extra-low-C steel and a smaller amount of Nb than that of a conventional interstitial-free steel. Phosphorus and Nb-added extra-low-C high-strength steel sheets manufactured by continuous annealing with rapid cooling are characterized by an extremely high r-value and a low yield strength. High-temp. annealing, > 830~ and rapid cooling of the P and Nbadded, extra-low-C steel produce ultra-deep-drawing and bake-hardening highstrength steel sheets. Bake hardenability results from dissolution of niobium carbides after recrystallization. 12 r e f . - - A A S. Satoh et al. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Proc. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 8409-72-0579) 190-201, [in English].
52-1496 High-Strength Steel Sheet for Automotive Applications-Manufacturing Properties and Functional Performance. High-strength steel sheet in hot (FeE355HF) and cold rolled gages (P275, FeE420HF, FeE275HF and FeE420HF) has been produced by German steel companies for more than ten years. However, while high-strength hot rolled strip found increasing application in the truck industry (mainly for frames), the demand for cold rolled sheet remained at a low level. However, during the last five years a growing interest by the car industry in high-strength cold rolled steel sheet has been noticed. To support this trend five German steel companies, represented by the Verein Deutsoher EisenhLittenleute (VDEh), took the initiative for an extensive research program. Selected aspects of the steels investigated are summarized, including formability, corrosion resistance, strength, crash performance, noise emission, stiffness, repairability, suitability for mass production and e c o n o m i c s . - - A A E.-J. Drewes et al. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Proc. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 8409-72-0579) 202-212, [in English].
5 2 - 1 4 9 7 Formability of High-Strength Hot Rolled Steels for Automobile Suspension and Reinforcement Parts. The application of high-strength steels to structural components is an effective method of reducing a vehicle weight. Production forming trials were conducted to evaluate the formability of hot rolled steel sheets with a tensile strength of 550 MPa grade, containing an ordinary carbon, Si, Mn and an ultra-low sulfur content with the shape controlled sulfide, produced at a low coiling temp. Forty parts (68 kg/unit) were tested in actual trial, while > 132 parts (107 kg/unit) were examined on film. A s a r e s u l t , ~ 70% (the number of components) were formed successfully, while press troubles occurred with the parts of stretch or deep-drawn type with a complicated profile. The material properties necessary for successful forming of the press troubled parts have been
52
VOL. 4, NO. 1, JULY 1985
obtained by multiple regression analysis; it is reasoned that those severe parts can be formed by correcting the deformation p a t h . - - A A T. Takano, K. Abe, and M. Usuda. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Proc. ConL], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 840972-0579) 213-224, [in English].
52-1498 Shape Accuracy and Denting Behavior--Criteria for the Selection of High-Strength Steel Sheet. It is concluded that among various high-strength steel sheets, dual-phase steels are most promising candidates for application in outer body panels. Their excellent performance is closely associated with the low initial yield strength, the high work-hardening rate and the additional benefit through bake hardening. These combined properties contribute to the favorable stretch formability, higher shape accuracy and increased dent resistance.--AA W. Milschenborn, O. Maid, K. BliJmel, G. Hartmann, and W. Bleck. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Proc. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A, 8409-72-0579) 225-235, [in English].
52-1499
Control o f E a r i n g in A I - - M g Alloys. The texture of A I - - M g alloy of Type 5052 has been studied as a function of process variables such as annealing position, hot roll condition and temper rolling. The systematical variations in the strength of the cube and retained-rolling texture components could be incorporated into a model for calculation of the earing for a large variety of processing routes. Compared to a series of earing measurements, reasonable agreement is found. 7 r e f . - - A A B. Andersson, and S.E. Naeaa. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Proc. Conf.], Melbourne, Australia, 20-24 Feb. 1984, international Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 840972-0579) 244-253, [in English]. 52-15OO The Deformation and Fracture Mechanism of Dual-Phase Steel Sheets Under Biaxial Stress Combinations. Using the method of the formability limit diagrams (FLD) the deformation capacity and the deformation and fracture mechanism of the dual-phase steel sheets have been studied under various biaxial stress-state combinations. The results proved the influence of the stress state on the steel sileet deformation and fracture mechanism. The theoretical assertion that during balanced biaxial strain deformation no local necking occurs was experimentally confirmed. 8 r e f . - - A A G. Pirvu. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Proc. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 8409-72-0579) 254-262, [in English]. 52-1501 D e e p - D r a w a b i l i t y o f a D u a l - P h a s e Steel. An attempt has been made to obtain an understanding of the relationships between texture, microstructure and plastic anisotropy of an intercritically annealed dual-phase steel. Detailed texture analysis, using the measurement of orientation distribution functions (ODF) of crystallites, has been carried out on the starting material, materials after different amount of cold deformation and cold deformed and subsequently annealed materials. The Lankford parameter, r, has been calculated on the basis of the ODF's for each sample. It has been observed that although reasonably strong { 111}, {3371 fiber textures can be developed easily in this steel, the values of r have been found to be rather low. For any particular treatment, the value of r has been found to vary as function of the angle to the rolling direction. An attempt has been made to rationalize these findings and possible ways and means of improving the r value are discussed. 12 r e f . - - A A R.K. Ray. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Proc. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 8409-72-0579) 263-274, [in English]. 52-1502 B e h a v i o r o f Galvanized Coatings During Forming. The crack formation, flaking, galling and related surface phenomena of various Zn and ZnAI hot dip coatings are investigated using simulative forming tests such as hydraulic bulging, bending and bending under tension. The crack formation is studied by optical and scanning electron microscopy and the mechanism of cracking is explained on the basis of these observations. The friction coefficients and galling tendencies of various coatings are determined under dry sliding conditions. The Z n - - 5 5 % A I - - 1 % Si and the Z n - - 5 % AI alloy coatings have better ductility when compared to the conventional near 100% Zn coating. The earlier observed existence of a distinct galling limit pressure for a galvanized coating is also verified.--AA S. M~kimattila, and A. Ranta-Eskola. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Proc. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 8409-72-0579) 293-304, [in English].
52-1503 A New Method for Evaluating the Powdering Phenomenon of Precoated Sheet Metals. One problem in using precoated metals is that a powdering phenomenon which occurs in the stamping process lowers the rate of production. Evaluation methods commonly used in powdering tests include a visual assessment and a comparison of transparency following cellophane taping. Such methods, however, are not scientific and do not yield accurate results. A new method is presented for evaluating the powdering phenomenon whereby the powdering test specimen is precisely weighed before and after a cylindrical cup test or a hat channel drawing test is conducted. The main points discussed are tool conditions and dimensions, lubrication and degreaaing. The method has made it possible to standardize the evaluation procedure for powdering and to forecast accurately the amount of powdering that will occur in the stamping l i n e s . - - A A M. Shiokawa, H. Takizawa, S. Ujihara, and Y. Hayashi. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Proc. Conf.], Melbourne, Australia, 20-24 Feb. 1954, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 8409-72-0579) 305-316, [in English].
J. APPLIED METALWORKING
52-1504 Analysis of Formability and Some Problems in Stamping o f Coated Steel Sheets. An evaluation method for the formability of various coated steel sheets has been established. The most suitable coated steel sheets should be selected for each automobile part from the viewpoint of corrosion resistance, powdering and flaking, frictional resistance, stability during successive stamping operations, etc. Judging from the aptitude for formability and stamping operations, steel sheets of electroplated alloy series are the best, Although many efforts to improve the steel grades of lower formability have been made by steelmakers, it still seems necessary to take great care with such steels in press forming because the recent improvement of coated steel sheets has been almost entirely centered on corrosion resistance rather than press formability.--AA M. Ejima, Y. Tokunaga, and T. Honda. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 8409-72-0579) 317-328, [in English].
52-1505
Formability of Aluminum-Coated Steel S h e e t . Peeling of coated metal due to severe press forming in hot dip AI (AI--Si) coated steel sheet has been experimentally investigated from the viewpoints of coating weight and of A I - - S i - - F e intermetallic alloy layer thickness. Experimental materials are of 1.0 mm thick AI-coated steels with various coating weights ranging from 38 to 84 g / m 2 on one side, Coated metal peeling occurred by a three-station direct redrawing as the coating weight exceeded 50 g / m 2. The increase of the intermetallic alloy layer thickness was far more detrimental to the coating adhesion than that of coating weight. 7 r e f . - - A A T. Yamada, and H. Kawase. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 8409-720579) 329-338, [in English]. 5 2 - 1 5 0 6 Ltiders Band Patterns and Their Effect on the Properties and Performance o f M e t a l l i c C o a t e d S t e e l S t r i p . Hot dipped Zn and A I - - Z n coated steel strip can be subjected to a variety of post-coating mechanical working processes to develop the required forming characteristics, flatten the strip and smooth the coated surface for subsequent coil painting. Each of these processes develops a characteristic deformation pattern on the surface of the base which is generally observed as a transverse LiJders bands. Strain aging occurs within these bands and the resulting deterioration of ductility can be both large and variable depending on, among other factors, the particular Li.iders band pattern generated. It is possible, and for some forming applications eminently desirable, to control the development of the Liiders bands and, by limiting the proportion of the deformed bands, minimize the change in the product ductility after storage. Such a product may be used for processes other than simple roll forming and bending and has been used successfully for both Zn and A I - - Z n coated steels in drawing and stretching operations and severe bending applications such as Pittsburgh Iockseaming.--AA F.A. Rose. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. ConL], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 8409-72-0579) 339-349, [in English].
52-1507 The Influence of Grain Size on the Instantaneous Anisotropy Parameter in a L o w - C a r b o n S t e e l . The plastic anisotropy of textured polycrystalline materials has often been described by the r v a l u e - - t h e ratio of width and thickness strains. The r values of low-carbon steels agreed reasonably well with values calculated on the basis of the Taylor theory for large grain sizes. In steels with smaller grain size increasing variation is found in the absolute level of the r values but the variation with testing direction (planar anisotropy) is still well predicted. Calculation of the instantaneous anisotropy parameter, p, as a function of strain showed that the value of p extrapolated to zero strain in all cases agreed with the prediction from the measured texture. With small grain sizes a sudden drop was observed with increasing strain, this being complete within 2-3% strain. The influence of grain size on the plastic anisotropy can be understood if it is assumed that the grain boundary resistance parameter K in the Hall--Perch relation depends on the contraction ratio, q, a different way to the Taylor factor M(q). 26 ref.--AA P.I. Welch, and H.J. Bunge. Efficiency in Sheet Metal Forming, IDDRG 13fh Biennial Congress [Proc. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A, 8409-72-0579) 358-359, [in English].
52-1508
Stress--Strain Relationship in Simple Shear of In-Plane
Deformation for Various Steel Sheets. In sheet metal forming of asymmetrical geometry, planar shear deformation is caused by the presence of differential metal flow and may be an important factor governing the deforming behavior, including such a surface deflection as seen around a door handle emboss in a door outer panel. It has not been, however, possible to develop a shear deformation test suitable for stable measurement of stress--strain relationship over a wide range of strain. First the characteristics of a newly-designed test device for simple shear deformation in plane are described. Second, according to this test, the stress--strain curves for carbon, rephosphorized high-strength and dual-phase sheet steels are obtained and discussed in connection with the planar anisotropy of material behavior in the in-plane simple shear and uniaxial tensile characteristics. This device can also work well in the measurement of Bauschinger effect in simple shear d e f o r m a t i o n . - - A A K. Miyauchi. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. ConL], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 8409-72-0579) 360-371, [in English]. 5 2 - 1 5 0 9 Parameters Affecting the Strain Rate Sensitivity of Aluminum Alloys. The origins of strain rate sensitivity in AI and its alloys (1145, 1100, 3003, 3004, 5005 and 5082) are discussed in terms of the various mechanisms of plastic deformation. The important mechanisms under various conditions are indicated and the ways in which they are influenced by chemical composition, processing to sheet and conditions during forming are described. 17 r e f . - - A A
J. APPLIED METALWORKING
R.G. O'Donnell, and B,A. Parker. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A, 840972-0579) 372-382, [in English].
52-1510 Thermal Gradients, Strain Rate and Ductility in Sheet S t e e l Tensile Specimens. The effect on ductility of strain rate and thermal gradients arising from deformation is examined in tensile specimens of 1008 AI-killed steel, The total elongation eto t is taken as the measure of ductility, since it reflects changes in the strain hardening n and strain-rate sensitivity m. Tensile specimens are pulled to failure in 2 2 ~ air, at initial strain rates from 10 - 3 to 10 - ; s - t , with thermocouples recording thermal gradients in the 50.8 mm gage section. The max. temp. is ~ 110~ just prior to failure at the highest rate. The etot, however, remains fairly constant with rate at ~ 40%. When thermal gradients are prevented by immersing the specimens in circulating water at 22~ elm increases with rate to a max. of ~ 54% at 10 - ~ s - ~ . Direct measurements of isothermal values of m at 22, 60 and 9 0 ~ show that m increases with rate. The eto t, therefore, would be expected to increase with rate. Since under nonisothermal conditions ere t does not change, it appears that m and thermal gradients are competing influences on ductility at higher rates. Enhanced ductility in stampings should be possible by suppressing gradients, either by controlling die temp. or by heat transfer properties of a lubricant. 15 r e f . - - A A R.A, Ayres. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met, A., 8409-72-0579) 383-393, [in English]. 52-151 1 A S t u d y o f the Dynamic Dent Resistance. The effects of sheet thickness and panel yield strength on the dynamic dent resistance of 300 mm 'z' shallow shells with various curvature were studied. The dynamic dent resistance was improved by substituting high-strength steel sheet (H1) for mild steel sheet (T50, T60, T70 and T80), as is the static dent resistance. On the other hand, the effect of sheet thickness on the dynamic dent resistance differed according to the panel curvature and the applied energy. The dynamic dent depth of a flat panel increased linearly with the increase in applied energy and d e c r e a s e d with increase in sheet thickness. In the case of panels with radii of curvature of 3 0 0 to 1500 mm, the effect of sheet thickness was complicated. In the range of very small and very large applied energy, the dynamic dent depth decreased with the increase in sheet thickness. In the range of intermediate amount of applied energy, however, it was reversed. This denting behavior was explained by using a model of panel deflection under impact I o a d i n g . - - A A S. Nomura, Y. Yutori, J. Iwaya, M. Miyahara, and I. Kokubo. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 8409-72-0579) 394-402, [in English].
52-1512 A Shear Test for Sheet Metal Rendability. Test methods for determination of the feasibility of sheet metals for bending are mostly based on optical inspection of the outside of the bend, which method may be too inaccurate for some applications. It is proposed that more useful bendability tests with a higher degree of resolution could be developed by measuring mechanical properties of the material in the bending zone. One such mechanical testing method is suggested. A special sample geometry and an experimental tool are d e s c r i b e d which enable shearing of the sheet in the direction of the prior bending axis. The max. force and the total amount of work required to shear a bent specimen in this way are proposed to be important indicators of the severity of the bending operation to the sheet, The test is purely mechanical and can be performed on standard materials testing machines. Results are presented for shearing air-bent and undeformed high-strength dual-phase steels. 10 r e f . - - A A S.N. Rasmussen. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 8409-72-0579) 415-426, [in English]. 52-1513 The Differential Work Hardening Coefficient and Classical Work Hardening Laws. The calculation of sheet metal forming operations needs insight into the plastic properties of metals, especially the work hardening behavior under given conditions of stress and strain. For many years this was described by fitting empirical "laws" to the measured stress--strain curves and calculating from them a so-called strain hardening exponent, the n-value. For different classes of materials, AI alloys, Cu alloys, C r - - N i steels, different empirical relationships have been developed and found to be "significant" or sufficient. In contrast to the empirical laws, which are integral relationships between stress and strain, a differential definition of an equation of plastic state and measurements of the differential work hardening coefficient are presented compared to the predictions of some classical work hardening laws. 18 r e f . - - A A L. Ratke, and P.I. Welch. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 8 4 0 9 - 7 2 - 0 5 7 9 ) 427-435, [in English].
52-1514 The D e f i n i t i o n o f Acceptable Anisotropy Parameters for Formability Testing. The definition and usefulness of various strain ratio parameters in AI alloy sheet metal forming operations are investigated both theoretically and experimentally. The strain ratio, r, defined as the ratio of the true width strain and true thickness strain, is shown to be both theoretically and practically incorrect, both as a measure of average anisotropy and as a measure of integral anisotropy. As a measure of instantaneous anisotropy the parameter p, defined as the ratio of the instantaneous (differential) width and thickness extensi6ns, is shown to be meaningful and procedures are described for the determination of this parameter. As an integral measure of anisotropy the integral of p, P, is best suited, the integration being carried out between those strain limits which are of interest. The R value originally described by Lankford, et al., the slope of the linear fit to the true width s t r a i n - - t r u e thickness strain curve, is shown to be equivalent to this integral if the fit is carried out between the same strain limits. 24 r e f . - - A A
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53
P.I. Welch, L. Ratke, and H.J. Bunge. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Proc. Conf], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Corp, Melbourne, Australia, 1984, (Met.A,, 840972-0579) 436-443, [in English].
52-151S Anisotropic Behavior of Sheet Metals in Proportional and Nonproportional S t r a i n i n g . Stamping of complex parts involves large plastic deformation of sheet metals. The success of the forming operation strongly depends on the loading history imposed on the sheet to obtain a given shape and on the plastic behavior of the material. Experimental results show a great influence of the nonlinearity of loading and of the plastic anisotropy of the sheet on the occurrence of plastic instabilities leading to the forming limit. This work analyzes the occurrence of plastic instabilities in the general case of an anisotropic orthotropic material under nonproportional loading, Numerical simulations are based on the existence of inhomogeneities due to the distribution of cavities nucleated around particles and modeled as an equivalent geometrical defect. Forming limit diagrams (FLD's) have been determined in proportional loading for a sequence of two proportional Ioadings and in nonproportional loading (curved strain paths). The results show the influence of the shape of the strain path on the forming limit and the effect of the theological parameters: strain-hardening, plastic anisotropy, etc. A good correlation between simulations and experiments is observed and the model developed helps in the understanding of the plastic behavior of anisotropic sheets under complex loading. 41 r e f . - - A A A. Barata da Rocha, F. Barlat, and J.M. Jalinier. Efficiency in Sheet Metal Forming, IDDRG t3th Biennial Congress [Proc. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A, 8409-72-0579) 444-455, [in English].
52-1516 Tribology During Deep D r a w i n g - - F r i c t i o n , Lubrication, Testing of Lubricants. The influence of friction on the formation of wrinkles during the deep drawing of St14 steel under the blank holder has been investigated based on the finite difference method and the Rayleigh min. principle. A calculation based on fluid mechanics principles has been used to quantify the influence of various parameters on the level of the pressure of the lubricating agent for the zones which were unprotected. The location of the crack, which determines the magnitude of the limiting drawability, has been decided in accordance with a new failure criterion for materials, combined with the differential shell calculations. Finally, strip-drawing equipment has been introduced, through which the frictional effects in individual zones could be simulated and the value of/~ as a function of the important friction parameters could be calculated, 9 r e f . - - A A J. Reissner. Efficiency in Sheet Metal Forming, IDDRG f3th Biennial Congress [Proc. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A, 8409-72-0579) 456-466, {in English].
52-1517
The Influence of S u r f a c e T o p o g r a p h y on the Forming
Performance of Aluminum. Series of commercially pure AI and AIMn(Mg) alloys were cold rolled with rolls with different finishes in the final stages to produce different sheet surfaces. Stretchability was evaluated using a hemispherical punch test using heavy mineral oil and grease. With increasing roughness the fracture position moves away from the pole and, generally, the max. strain becomes lower and the distribution broader on the pole side of the fracture. The resulting dome height as function of roughness showed a max. at intermediate values when lubricated with grease and min. with oil. The drawability was measured by comparing the drawing load and fracture load. The first correlated weakly with the sliding friction. The friction around the punch profile radius, which determines the fracture load, appears to be governed by the same factors as for stretching. Strip cast materials have linear defects in rolling direction and seem to benefit from high friction. Strip draw test showed that there was min. friction depending on coarseness and orientation of streaks and the hardness of the material. 9 r e f . - - A A B. Andersson. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Proc. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A, 8409-72-0579) 467-475, [in English]. 52-1518 Factors Influencing Friction and Galling Behavior of Sheet Metals. Lubricant or contaminant films between the sliding surfaces of sheet metal and tools may break. Then metallic contact often takes place. This leads to damage of the metal surfaces such as galling or metal pick-up. The occurrence of galling during industrial production is also, from the economical point of view, a difficult problem since it often interrupts the forming process for die or punch repair and may necessitate hand finishing or rejection of the product. The influences of the sheet and tool materials, lubricant, surface pressure, sliding length, surface roughness of the tool, sliding velocity and surface temp. on the friction and galling b e h a v i o r in press working of AI-base alloys, brasses, stainless steels, highstrength, low-alloy steels and AI-killed steels are investigated using a bending under tension type strip drawing tester. 24 r e f . - - A A J.O. Kumpulainen. Efficiency in Sheet Metal Foming, IDDRG 13th Biennial Congress [Prec. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A,, 8409-72-0579) 476-490, [in English].
S2-1519 The E f f e c t o f Surface Roughness on the Formability of Cold Reduced Sheet S t e e l . The effects of surface roughness of AI-killed and rephosphorized steel sheet on formability and the related phenomenon of scoring (galling) are reviewed. Scoring (galling) is a phenomenon in deep-drawing that may lead to fractured parts and disturbs a smooth running process. Caused by the damaged surface the products are of a low quality and must be repaired or rejected. Scoring arises as a consequence of material build-up at those spots where material particles from the sheet surface adhere to the tool surface (cold welding). 23 r e f . - - A A W.C. Emmens, and L. Hartman. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 840972-0579) 491-503, [in English].
54
VOL. 4, NO. 1, JULY 1985
52-1520 The Choice of Meaningful Parameters Obtained From Profile Analysis in Order to Characterize the Deep Drawing Capacity of a Metal S h e e t . Surface profilometry is commonly practiced on metal sheets before deep drawing as part of a routine, over-all mechanical and metallurgical characterization. Strip drawing is a wide-spread technique for chocking the mechanical response of a metal sheet under simplified conditions. By tracking the surface profile during strip drawing, it is possible to obtain a bettor understanding of the parameters physically relevant with respect to deep drawing. It is shown that the max. slope of the Abbott bearing curve is essentially equal to the inverse of the arithmetic C.L.A. roughness Ra. The mean peak density Np and the average summit length L s of a virgin sheet are obtained during the strip drawing under varying normal load F N. Finally, as an asymmetry parameter, the ratio of the full to the empty parts of the surface profile is studied. 7 r e f . - - A A J. von Stebut, and B. Moul~ne. Efficiency in Sheet Metal Forming, IDDRG t3th Biennial Congress [Prec. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A, 840972-0579) 504-514, [in English].
52-1521 Application of the Toyota Diffusion (TD) Process to Tooling for Sheet Metal Forming. The Toyota Diffusion (TD) Process produces an extremely hard, dense layer of carbide on the surface of carbon steels by diffusion of C from the substrate, which reacts with a strong carbide-forming element in a molten salt bath. The unique combination of properties of the carbide layer has led to the widespread application of the TD Process to sheet metal working tooling where its role in improving tool life is now well e s t a b l i s h e d . - - A A G.J. Cocks, and P. Fisher. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. ConL], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 8409-72-0579) 515-520, [in English].
52-1522
Buckling and Its Growth in Biaxial Diagonal Stretch on Square
Plates of Steel Sheet. A diagonal biaxial tensile test was developed and used to simulate the process in which surface defects are induced in the forming of large panels such as automotive outer panels fabricated from carbon and highstrength steels. The initiation and growth of buckles were investigated and the effects of material properties and biaxial loading conditions were studied. In the case of uniaxial stretching, the material properties had little influence on the buckling heights. However, in the case of biaxial stretching, the materials with smaller yield strength Cry showed smaller buckling heights. The average max. elongation and the rain. side stretching force for preventing buckling formation have good correlations with Cry. A smaller ay was proved to be desirable for preventing buckle formation. Specific biaxial loading conditions were found to exist to prevent buckling. 7 ref.--AA M. Matsui, and N. lwata. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. ConL], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A, 8409-72-0579) 521-531, [in English]. 52-1523 The Effect of Mechanical Properties on the Wrinkling Behavior of Sheet Materials in the Yoshida Test and in a Cone Forming Test. The Yoshida buckling test and a cone forming test were performed on a range of metals to investigate the effect of material properties on wrinkling behavior of different materials under different degrees of confinement. The growth of wrinkles was delayed by larger values of work hardening exponent, yield elongation (Liiders strain) and of the ratio r"/YS, but was promoted by increasing yield strength in both tests. The coefficient of normal plastic anisotropy and the coefficient of strain rate sensitivity were investigated but were found not to be significant in determining wrinkling resistance. The Yoshida test and the cone forming test gave similar results for the effect of material properties on wrinkling behavior, but the Yoshida test was more restricted in its application; AI and its alloys tore before wrinkling occurred. The materials studied included carbon and austenitic stainless steels, Ti, 7 0 / 3 0 brasses, Cu- and AI-base alloys 1100, 3004 and 5005. 11 r e f . - - A A A.M. Szacinski, and P.F. Thomson. Efficiency in Sheet Metal Forming, IDDRG 131h Bienniel Congress [Proc. ConL], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A, 840972-0579) 532-537, [in English].
52-1524
Analysis of Strain Propagation Behavior in "Yoshida Buckling
T e s t " . The stretching of a square specimen in the diagonal direction, "Yoshida Buckling Test" (YBT), was proposed to simulate the surface distortion behavior in press forming of steel sheets into autobody panels. The relation among mechanical properties, strain propagation and buckling behavior in YBT specimen are examined by FEM analysis and experiments. It is verified that the buckling occurs not only by compressive stress under loading but also by residual compressive stress after unloading. The compressive stress, ~2, induced at the center of the specimen, increases as the elongation becomes large under the condition of unrestricted lateral boundary displacement. The compressive stress reduces as the yield strength and r0, at 0 ~ to the lateral direction, decrease, and r45 and rgO increase. The effect of work-hardening properties, n-value and d~/d~p on compressive stress is discussed. The equivalent relations concerning the effects of mechanical properties on strain propagation ability and compressive stress in YBT under and after loading are o b t a i n e d . - - A A T. Hira, S. Azuma, T. Abe, T. Sasaki, and K. Yoshida. Efficiency in Sheet Metal Forming, IDDRG 131h Biennial Congress [Prec. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 8409-72-0579) 543-553, [in English].
5 2 - 1 5 2 5 The Yoshida T e s t - - a Critical Evaluation and Correlation With Low-Strain Tensile Parameters. The optimization of strain distribution in shallow panels is dependent on the ability of the metal to work harden rapidly during the early stages of pressing. The Yoshida test has been proposed as a suitable method for establishing the relative ability of a metal to distribute strain in a pressing and hence to resist buckling during forming. After analyzing Yoshida test data, it is proposed that a modified test parameter be used, independent of the gage
J. APPLIED METALWORKING
length extension. The effect of thickness differences has been established so that compensation can be made for thickness differences which often occur between samples. A study of uniaxial tensile test data demonstrated the high accuracy with which a simply measured property can predict the Yoshida test result and, by inference, the tendency of a material to satisfactorily distribute strain during pressing. The most appropriate parameter is the yield to tensile ratio and this simple property should be as useful as the Yoshida test. 12 r e f . - - A A J.S.H. Lake. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A, 8409-72-0579) 554-564, [in English].
52-1526 Analysis of Surface Defects and Side Wall Curl in Press Forming. The major problem of press forming in stamping shops has changed gradually, first from fracture to wrinkle, and at present is shape and dimension such as surface deflection and side wall curl. There are two reasons why the problem in shape and dimension is picked up as a current important theme. First, a slight defect in shape and dimension is a rather delicate problem which is, in a sense, difficult to remove and has remained unsolved. Second, the application of high-strength steel sheet has intensified the significance of this problem concerning springback, and has encouraged research on it. In Japan, much research has been carried out focusing on the improvement of shape and dimension of formed panels for five years, particularly for the last two years, on the surface deflection around the handle part o1 door outer panels. 26 r e f . - - A A Y. Hayashi. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A, 8409-72-0579) 565-580, [in English].
52-1527
Developments in Sheet Materials for Forming Applications.
The past five to ten years have witnessed significant changes and improvements to many grades of sheet, especially in the area of coated and uncoated steels and AI alloys. Some of the changes have arisen from improvements to metallurgical understanding, but the main changes have been achieved by the introduction of new processing techniques such as ladle refining, vacuum degassing, continuous slab casting, continuous rapid annealing, temp.-controlled rolling, shape-controlled rolling, electrodischarge conditioning of rolls and electrolytic coating. The main changes to metallurgy and processing, with regard to their effects on formability, are reviewed. The new grades resulting from these changes are then outlined. 10 ref.--AA R.M. Hobbs. Efficiency in Sheet Metal Forming, IDDRG 13th Bienniel Congress [Prec. ConL], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A., 8409-72-0579) 581-591, [in English]. 52-1528 T h e P o s s i b i l i t y o f a Unique Test for Sheet M e t a l F o r m a b i l i t y . Sheet metal forming, like most other manufacturing operations, is a system and must be analyzed as such. The system elements include the sheet metal being formed, characteristics of the press, die design, part shape, die material and surface preparation and lubrication, in characterizing formsbility of sheet metal, the approach of Marciniak is used to differentiate between intrinsic properties (characteristics of sheet metal), derivative properties (characteristics of both sheet metal and strain path) and simulative properties (characteristics of idealized formability systems). Intrinsic and derivative properties and selected simulative tests are described. The conceptual possibility of developing a unique test for sheet metal formability is discussed. 48 r e f , - - A A B.S. Levy. Efficiency in Sheet Metal Forming, IDDRG 13th Biennial Congress [Prec. Conf.], Melbourne, Australia, 20-24 Feb. 1984, International Deep Drawing Research Group, Melbourne, Australia, 1984, (Met.A. 8409-72-0579) 592-605, [in English].
52-1533
The State of the Art of High-Energy Rate Bulk Forming. The
field of high*energy rate bulk forming as applied to steels, AI-base alloys, Ti-base and Ni-base alloys is reviewed considering the machine and process advantages in relation to conventional machines; the different types of HERF machines and their respective industrial roles; the economics of HERF hammers; and HERF processes. The latter topic is explored in depth and covers: hot f o r m i n g - - p r o c e s s advantages, die life, dwell time, tooling design, component accuracy, die materials; cold f o r m i n g - - p r o c e s s advantages, production experience, tooling design, upsetting and heading, tool life, tool materials; warm forming--process advantages, forging temp., process experience; powder compaction--process advantages, types of powder; powder f o r g i n g - - p o w d e r preforms, process advantages, component density, process experience; cropping--process advantages, long billets, short billets, blade life, economic potential; blanking and piercing--process advantages, tool design, economic potential. Both the machines and the processes discussed are illustrated by numerous figures and there is extensive reference to relevant published literature. 45 r e f . - - A A S.A. Tobias. J. Mech. Work. Technol., May 1984, 9, (3), 237-277, [in English]. ISSN 0378-3804. 52-1534 An Analysis of the Ring Upsetting of Sintered Material, On the basis of plasticity theory for porous metal, an analysis of ring compression has been carried out employing the upper-bound approach. The plastic flowability and the neutral radius of the porous metal ring have been calculated and the deformation characteristics of the power forging then obtained from the results. Ringcompression experiments have been carried out on sintered-Fe porous metal of various relative densities under various friction conditions: good agreement is observed between the calculated curves and the experimental results from the tests. It is demonstrated that the friction factor for powder-metal forming can be determined not only from the relationship between reduction in height and reduction in internal dia., but also independently from the relationship between reduction in height and relative density, if the initial relative density is known. 8 r e f . - - A A H.K. Oh, and J.H. Mun. J. Mech. Work. TechnoL, May 1984, 9, (3), 279-290, [in English]. ISSN 0378-3804.
J. APPLIED METALWORKING
52-1535 Frictional Effects on Flow Stress Determination at High Temperatures and Strain Rates. It has been reported recently that the average die pressure as measured during the initial compression of nonlubricated cylinders was < 5% greater than that for lubricated samples, when the final dia.-toheight ratio is less than two. These tests were carried out at room temp. and l o w strain rates, To determine whether these results occur at high temp. and high strain rates, cylinders of hot rolled low-carbon steel were upset under lubricated and nonlubricated conditions. The steel samples were deformed by a cam plastometer at constant true strain rates of 2,0, 20.0 and 140.0 s - 1 , The results clearly show that the average die pressure for lubricated and nonlubricated samples are, within experimental accuracy, equal. Further testing demonstrated that the average die pressure does not depend on sample geometry for cylinders with initial aspect ratios of 0.5, 0.65 and 0.85, deformed to a true strain of 0.7. For the range of aspect ratios examined, it can be concluded that a correction for friction in the calculation of flow stress is unnecessary. 11 r e f . - - A A D.L. Baragar, and A.F. Crawley. J. Mech. Work. Technol., May 1984, 9, (3), 291299, [in English]. ISSN 0378-3804,
52-1536
Mechanical Properties o f a Composite Wax Model M a t e r i a l S i m u l a t i n g P l a s t i c F l o w o f M e t a l s . Although the use of nonmetallic, model materials for the simulation of plastic deformations of engineering alloys is well established in research laboratories, the search for the " p e r f e c t " material still continues. It is highly unlikely that a successful conclusion will be reached in the foreseeable future, but the exploration of the properties of the existing materials reveals that they often possess considerable versatility. If this is utilized in smallscale laboratory experiments, the patterns of flow and the response of the prototype to the changing manufacturing conditions can be studied at a relatively low cost since no production plant need be involved. The investigation provides numerical data which indicate the ability of a ceresin, Carnauba, paraffin and b e e s w a x mixture to represent satisfactorily a variety of metalforming conditions. 23 ref. --AA R.S. Lee, and T.Z. Blazynski. J. Mech. Work. Technol., May 1984, 9, (3), 301-302, [in English]. ISSN 0378-3804. 52-1537 Pass Design and Redundant Strains in Forward T u b e Extrusion. The reduction or, ideally, elimination of redundant shears in metalforming operations leads, in general terms, to an improvement in the quality of the product combined with an increased rate of yield and, in more extreme cases, to the possibility of using less expensive materials than those necessarily employed in conventional forming passes. Since the geometry of the pass determines the incidence, pattern and level of redundant deformation, the problem of rational die design becomes all important. This investigation is concerned with establishing t h e relationship between the profile of the extrusion die and the development of the redundant shears and points the way towards rationalization of tooling in the process of tube extrusion. 21 r e f . - - A A T.Z. Blazynski, and R,S. Lee. J. Mech. Work. TechnoL, May 1984, 9, (3), 313-324, [in English]. ISSN 0378-3804.
52-1539
Aluminum Forgings: Some Design Considerations. It is necessary to consider certain design criteria for AI forgings to optimize costs of production including parting line, mismatch, die closure, draft, corner and fillet radii, part configuration and recovery. As AI forgers develop new alloys and educate themselves about automotive engineering needs, and automotive designers b e c o m e more familiar with AI forgings, the benefits of using AI forgings can be easily expanded.--J.H.B. M.A. Holtz, J. Davis, and D. Crawford. Automot. Eng., May 1984, 92, (5), 44-49, [in English]. ISSN 0098-2571. 52-1543 Some Structural Elements and Information for a Technological Data Bank on Hot Forming Processes. The systematized knowledge on formability of various materials, as the basic elements for a technological data bank, are not complete or they are unreliable. This appears to be the main obstacle in automation of hot forming operations. Results on hot forming of various alloyed steels (specific forces and plasticity) in a broad range of working conditions are r e v i e w e d . - - A A R. Kova(3evi6, and S. Ble~i6. International Symposium on the Plasticity and Resistance to Metal Deformation, Fourth [Prec. Conf.], Herceg-Novi, Yugoslavia, 26-28 Apr. 1984, Titograd Ironworks of "Boris Kidri~:" Nikr and Aluminum Combine, Titograd, Yugoslavia, 1984, (Met.A., 8409-72-0588) 141-152, [in English]. 52-1545 Warm Forming of Aluminum Alloy Sheet. Factors involved in the warm forming of AI alloy sheets are discussed, the aim being to define conditions which give good stretch formability and also a strong formed product. Results are described for a nonheat treatable alloy, 5083, in which the warm forming temp. is limited by the requirement to retain a contribution to strength by strain hardening. For heat treatable alloys 2014 and 7075, the possibilities of combining the forming operation with solution treatment are explored. An upper limit to the forming temp. is imposed by the development of cavitation. S t r e s s - - s t r a i n relationships obtained from uniaxial tests at elevated temp. can be used to assist in the understanding of biaxial stetching behavior. 10 r e f . - - A A W.T. Roberts, and D.V. Wilson. International Symposium on the Plasticity and Resistance to Metal Deformation, Fourth [Prec. Conf.], Herceg-Novi, Yugoslavia, 2628 Apr. 1984, Tifograd Ironworks of "Boris Kidri(~" Nik~i6 and Aluminum Combine, Titograd, Yugoslavia, 1984, (Met.A, 8409-72-0588) 163-176, [in English]. 52-1548 Formable Aluminum Alloys With High Strength. A good combination of formability and strength is a requirement for an increasing amount of AI sheet alloys. The possibilities of achieving this are reviewed and discussed in terms of the metallurgical aspects of alloy development, processing and sheet forming. Reference is made to current applications and areas for potential development in formable alloys with high strength. The following alloys are cited: 7075, 7475, 7029, 3004, 5182 and Anticorodal 1 2 0 . - - A A
VOL. 4, NO. 1, JULY 1985
55
P. Furrer, and P.M.B. Rodrigues. International Symposium on the Plasticity and Resistance to Metal Deformation, Fourth [Proc. Conf.], Herceg-Novi, Yugoslavia, 2628 Apr. 1984, Titograd Ironworks of "Boris KidriC" Nik~i6 and Aluminum Combine, Titograd, Yugoslavia, 1984, (Met.A., 8409-72-0588) 357-372, [in English].
52-1609 Structure and Properties of Rod and Wire for Steel Ropes After Controlled Cooling. (Translation: BISI 22613). See Met. A., 8406-52-
52-1553
52-1610 Surface Defects in Rolled Products of Austenitic Steel. (Translation: BISI 22697). See Met. A., 8405-52-0959.
Cold Roll Shaping of Bar and Wire. IBM Corp; buys typewriter filter shafts manufactured by cold rolling AISI 1018 steel bar into their shape. This precision component meets a flatness requirement which mandates a no-twist tolerance of 0.05 mm m a x . / 3 . 6 5 m. General Electric and Allis-Chalmers and other companies purchase miniature l-beams which are cold rolled to serve as spacers. Made from 1008 and stainless steel wire, they allow coolants to circulate between laminations and large electric motors and generators. Another firm purchases selfpiercing nut stock for the automotive industry, produced from 1015 steel bar which is cold rolled to a restricted hardness of Rockwell B 90-95. These examples indicate a definite trend toward increased cold roll shaping of steel bar and wire for two key r e a s o n s . - - A A Eng. Dig. (Canada), June 1984, 30, (6), 44-45, [in English]. ISSN 0013-7901. 52-1554
Semihot Extrusion of Constant Velocity Joints for Vehicles.
Semihot extrusion is employed by a car manufacturer for the production of constant velocity joints for front wheel drive vehicles. The advantages include the fact that workpieces free from scale and to close manufacturing tolerances can be produced. Saving in energy, reduction in material costs and economies in floor space are further a d v a n t a g e s . - - A A E. Reichelmann. IPE Int. Ind. Prod. Eng., 1984, 8, (1), 67-68, [in English]. ISSN 0343-334X.
52-1555 Interactions Between Rolling Oil Emulsions and Aluminum Alloy Surfaces. In o i l / w a t e r / s o l i d contact angle experiments, AI alloy (5052) surfaces with a high percentage of MgO in the oxide layer were wetted by naphthenic oil and naphthenic oil containing 1% oleic acid. The opposite behavior, poor wetting, was observed on alloy surfaces of almost pure aluminum oxide. On the latter surfaces, however, oil wetting was increased by decreasing the pH and by adding Mg ions to the water being displaced. The same trends in wetting were observed in interactions between pure oxide powders and a commercial rolling emulsion containing naphthenic oil and oleic acid. The implications of this behavior to process lubrication and surface quality in AI rolling are discussed. 9 r e f . - - A A F.E. Lockwood, K. Bridger, and M.E. Tadros. ASLE Trans., July 1984, 27, (3), 203206, [in English]. ISSN 0569-8197.
52-1589 Equipment for the Plastic Working of Metals in a Pulsating Magnetic F i e l d . The dynamic working effects are produced in an induction-coil/ workpiece system, by a high-energy magnetic field generated from pulsed a.c. impressed in the coil and eddy current induced in the workpiece. The inductor is a built-in component in the form of a bulging, compressing, or pancake coil suitable, for instance, in joining Cu pipes with column plates or perforated bottoms and Cu and AI pipes with steel rings, die-forming pipe bells, making reduction connections between conductors and power cables, and forming flat Cu and AI products. Working pressures of up to 101~ Pa are attainable for fractions of 1 ms, and the systems are conductive to automation and, particularly in the case of high-conductivity metals, replacing conventional labour-intensive techniques.--J.R. J. B e d n a r c z y k PoL Tech. Rev., 1983, 150, (4), 7-8, [in English]. ISSN 0032-3012.
52-1597 New Design and Operational Solutions in the Manufacture of Semi-Finished Tube Products by the Erhardt Method. (Translation: BISI 22681). See Met. A., 8405-52-0943. A. Trzaska. Hutnik (Katowice), May 1983, 50, (5), 183-188, [in English]. ISSN O019-5669.
52-1598 Deformation in Conditions of Non-Uniform Reduction Over Width. (Translation: BISI 22482). See Met. A., 8406 52-1076. V,V, Chigirinskii, and V.I. Derevyanko. Izv. V.U.Z. Chernaya Metal/., 1983, (9), 5255, [in English]. ISSN 0383-0797.
52-1599 Resistance of Metal to Deformation During Hot Rolling on Continuous Sheet Mills. (Translation: BISI 22483). See Met. A., 840(5-521078, V.I. Tareovskii, and A.G. Zhigalin. tzv. V.U.Z. Chernaya Metal/., 1983, (9), 59-61, [in English). ISSN 0363-0797.
52-1601 The Method of Local Shaping of the Regular Polygonal CrossSection on the Tube. (Translation: BISI 22684). See Met. A., 8312-52-1532. M. Cywinski, and Zb. Musio~ek. RudyMet. Niezelaz., May 1983, 28, (5), 164-166, [in English], ISSN 0035-9696.
52-1602 Process Computer System for Programme Control and Data Collection at a 16 MN Open-Die Forging Plant. (Translation: BISI 20117). See Met. A., 8305-52-0719. E. Neuschutz et al. Stahl Eisen, 18 May 1981, 101, (10), 641-644, [in English]. ISSN 0340-4803.
52-1604 The Piercing Process During Tube Rolling in a Three-Roll Rotary Piercing Mill. (Translation: BlSl 20149). See Met. A., 8302-52-0266. W. Kubinski, and Z. Polek. StahlEisen, 10 Aug. 1981, 101, (16) Suppl., 18-28, [in English]. ISSN 0340-4803.
52-1606 Production of Drawn Hexagon Bars. (Translation: BISI 21972). See Met. A., 8 3 0 7 - 5 2 - 0 9 6 9 E.F. Popov et al. Stal', Jan. 1983, (1), 38-39, [in English]. ISSN 0038-920X.
52-1607 Production of Hot-Sized Section Steel in Four-Stand Sizing Blocks. (Translation: BlSl 22608). See Met. A., 8406-52-1085. F.E. Dolzhenkov et al. Stal', Nov. 1983, (11), 37-38, [in English]. ISSN 0038-920X.
56
VOL. 4, NO. l, JULY 1985
1090. I.G. Uzlov et aL Stal', Nov. 1983, ( t 1), 66-69, [in English]. ISSN 0038-920X.
G.A. Buryakovskii et al. Stal', Dec. 1983, (12), 64-66, [in English]. ISSN 0038920X.
5 2 - 1 6 1 2 Defects of Tube Blanks Manufactured From Ingots in Piercing Presses. (Translation: BISI 22775). See Met. A., 8405 52-0716. W. Kubinski eta/. Wiad. Hutn., May 1983, 39, (5), 137-142, ]in English]. ISSN 00435139.
52-1614
Cold Working Continuous Lengths of Metal. A method of cold working continuous lengths of rod by twisting includes the steps of clamping the rod etc., at spaced apart clamps and then rotating a central part of the clamped length by means of a twisting head incorporating a chuck for clamping to the rod. Between successive clamping and twisting operations the rod is advanced through the apparatus by feed rollers Various twisting and untwisting patterns are possible. The chuck may be rotated in one direction and then in the opposite direction while a single length of rod remains clamped. Alternatively the chuck may be rotated in a first direction only. This twists section of rod in one direction. This section of rod is then advanced to position and subsequent rotation of chuck in the same direction untwists the section whilst applying initial twist to the new section. K.T. Jones, P.G. Davies, and Allied Steel and Wire Ltd. 23 May 1984, Patent no. GB2129720A (UK), 9 Nov, 1983. 52-1615
P i p e - R o l l i n g Mills. A pipe rolling mill includes a plurality of fixed bases each supporting a mill housing which in turn carries a pair of rolls. Each pair of rolls is mounted on a roll replacement carriage respectively, which is movable on a first set of fixed rails on the respective housing in a direction perpendicular to the rolling path. Associated with each set of rolls are two shift carriages having rails on their upper surfaces. Supported on the rails of one of the shift carriages is a retraction carriage. Situated on the other shift carriage is a further carriage carrying fresh rolls. To change the working rolls, the retraction carriage pulls the operative carriage up the rails onto the rails on the shift carriage and itself moves onto fixed rails. After disconnecting the carriages the shift carriages are moved parallel to the rolling path by a hydraulic piston and cylinder unit thereby aligning the second roll replacement carriage on the second shift carriage with the rails. The carriage then lowers the replacement carriage into the working position. H. Kato, and I s h i k a w a j i m a - H a r i m a J u k o g y o KK. 23 May 1984, Patent no. GB2129722A (UK), 15 Oct. 1982.
52-1617 Extrusion and Stamping of Material. Apparatus for plasticforming a material in the cold or hot states, particularly by direct extrusion, backflow extrusion, or stamping comprises a container for the material, a male die part, a female die part, a moulding aperture formed in one of the die parts through which the material is forced upon relative movement of the die parts towards each other, and a plurality of die elements making-up the female die part and having end faces which form collectively the die surface of the female die part. The female die part is mounted in a housing which comprises a housing body which is closed at one end by a cover and at its other end with an apertured support plate which is fixedly mounted on the housing body, the housing body defining a space for a liquid pressure medium which communicates with a reservoir containing a gaseous pressure medium. One of the die elements of the female die part is immovably supported by the support plate, and the remaining die elements are moveable relative to the one die element and 1o each other, by means of movable supports which are taken through apertures in the support plate and each engage a respective concentric cylindrical supporting element which faces the space containing the liquid pressure medium. B.I. Paunov, B.S. Ivanov, T.A. Balevski, and Institute po Metaloznie i Technologia na Metalite. 23 May 1984, Patent no. GB2129724A (UK), 11 Nov. 1982. 52-1618
Skeining Apparatus. Apparatus for forming skeins in fine Ca wire during coil winding operations comprises a pair of guides passing wire to a coil winder. A chain driven around two sprockets carries a looping finger to pick up the wire and form loops around a pair of needles. One needle carried on a spinner so that when a sufficient number of loops have been formed rotation of the spinner twists the loops into a skein. Shortening of the twisting loops is accommodated by one needle swinging back towards the other. Wire tension is controlled by disc tensioners. A tensioner may be automatically controlled. One needle may be mounted on a power driven biassing and ejection assembly to control skein tension and so that the skein may be released from the needles. G.E. Whellams. 31 May 1984, Patent no. GB2130259A (UK), 7 Aug. 1982. 5 2 - 1 6 2 0 Light Metal Alloys. A method is disclosed of superplastically form ing an article from a light metal base alloy of a kind capable of having its crystal structure modified by cold working in such a way that subsequent dynamic recrystallisation by hot working is facilitated. It comprises cold working a first blank of the alloy to form a second blank having the modified crystal structure and forming the second blank into the article by hot working so that dynamic recrystallisation is induced therein and superplastic deformation occurs, the degree of modification of the crystal structure during cold working being such that as the dynamic recrystallisation continues the grain size is progressively refined. ( 1] Li 1.5-4.0 wt.%, Mg 0-5 wt.%, Zr 0-0.4 wt.%, Cu 0-6.0 wt.%, Zn 0-5 wt.%, balance AI, (2) Li 10-15 wt.%. balance Mg; (3) Mg 6-12 wt.%, balance AI. R. Grimms, and Alcan International Ltd. 4 Apr. 1984, Paten1 no. GB2126936A (UK), 26 Aug. 1983. 52-1621
High Modulus Shafts Produced by Directionally Working
Nickel-Base Alloys. High modulus turbine shafts are described as are the pro cess parameters for producing these shafts. The shafts have a high modulus as a
J. APPLIED METALWORKING
result of having high ( 111 ) texture in the axial direction and are produced from a Ni base material having a strengthening phase and a moderate to high stacking fault energy. A combination of hot axisymmetric deformation followed by cold axisymmetric deformation produces an intense singular ( 1 t 1~ texture and results in shaft material whose modulus is on the order of 25% greater than that of the steel materials used in the prior art. Preferably the alloy contains, in wt.% Mo 6-18, Cr 0-10, AI 3-10, W 0-10, Ta 0-6, Nb 0-6 the balance being Ni. J.P. Winfree, H.A.J. Chin, T.E. O'Connell, and United Technologies Corp. 16 May 1984, Patent no. GB2129014A (UK), 5 Sept. 1983.
52-1622
A Method of Forming a S h e e t . A method of forming a sheet of e.g. metal includes the step of providing a plurality of elongate slots longitudinally of fold lines so that, when portions are bent out of the plane of the lamina stamped from the sheet, the force necessary to bend bridge portions separating adjacent slots is less than would be required to bend the material of the lamina if the slots were not present. The apertures may be stamped out simultaneously with stamping the sheet from stock. K. Carter, and G.P. Carter. 16 May 1984, Patent no. GB2129339A (UK), 29 Oct. 1982. 52-1623
Equipment for Stamping or Embossing a Metallic Workpiece.
Equipment for metal working, e.g. embossed marking of profiled bars, has a frame, a toolholder, an interchangeable indexable tool with tool members at its periphery, and a countertool. The tool can be moved towards the countertool by a cylinderand-piston unit, so that a work-piece disposed between the tool and the countertool is worked. The working frame, is adjustably mounted on a machine housing. The cylinder-and-piston unit, operates on the tool disc through its working piston, either directly or through an interposed pressure pad, and the tool disc entrains the toolholder when it is thus moved through its working stroke. The tool disc is rotated about its axis by a motor and a transmission. R. Peddinghaus. 23 May 1984, Patent no. GB2129725A (UK), 3 Nov. 1983.
52-1624 Process for Forming Oxalate Coating on Metal Surfaces [ f o r Fastener Manufacture]. A fastener is made from a high tensile steel blank by cold forming a lubricated blank that has been provided with an adherent base coating by contacting the blank with a solution of oxalic acid and an accelerator comprising a chlorate and an organic nitro-compound. D.B. Freeman, and Pyrene Chemical Services Ltd. 23 May 1984, Patent no. GB2129837A (UK), 23 Sept. 1983.
52-1625 Press Formability of Commercially Pure Titanium Sheet for Plate Heat Exchangers. ( T r a n s l a t i o n ) . See Met. A., 8212-52-1739. T. Nishimura, A. Hasegawa, Y. Moriguchi, and M. Taniguchi. Kobelco Tech. Bull., 1983, (1058), Pp 6, [in English].
52-1626 Nonuniformity of the Mechanical Properties of Sheet Rolled on a Continuous 1700 Mill. ( T r a n s l a t i o n ) . See Met. A., 8405-52-0929. V.L. Kostrykin et al. Metallurgist (USSR), Sept. 1983, (9), 311-313, [in English]. ISSN 0026-0894.
52-1636 S t a b i l i t y o f GP Zones in Plastically Deformed A I - - 4 C u A l l o y , It is shown by differential scanning calorimetry and transmission electron micro ;copy that extensive plastic deformation of A I - - 4 C u (wt.%) alloy following quenc,1ing causes fragmentation of GP zones to an extent which depends on stratn. Subsequent continuous heating of samples causes two concurrent processes: dissolution of small and growth of large GP zones. The fragmentation after 33% strain is so extensive that no growth process was observed. The activation energy for dissolution of GP zones in unstrained and strained material is 126 _+ 6 k J/tool and about 100 k J / m o l respectively. 1 4 r e f . - - A A A. Klee, and M.W. Grabski. Met. Sci., Mar. 1984, 18, (3), 158-160, [in English]. ISSN 0306-3453. 52-1637 Structural Characteristics and Extrusion Behaviour of P b - Sn A l l o y s in S e m i s o l i d S t a t e . The extrusion behaviour of semisolid P b - - 1 9 S n
kW capacity, with wheels of 500 mm dia., capable of handling AI feed bars up to 40 mm dia. and of producing heavy architectural sections, have been supplied. 19 ref.--J.R. C. Etherington. Chart. Mech. Eng., Feb. 1964, 31, (2), 28-32, [in English]. ISSN 0306-9532.
52-1660
Modified Wire Microstructure Improves Rope Wire Properties.
The hydrodynamic drawing process creates better conditions for the deformation and dislocation of cementite laminae and for the formation and development of the ferrite texture compared to the conventional method. Improved mechanical properties (tensile strength, yield strength) result. As the cementite laminae can be aligned prallel with the wire axis more easily and to a greater extent with the hydrodynamic drawing methods, the ideal resistance of hydrodynamically drawn wires over the full range of the total reductions is lower than that of conventionally drawn wires. 35 r e f . - - A A J.W. Pilarczyk. Wire World Int., Jan.-Feb. 1984, 26, (1), 12-16, [in English]. ISSN 0043-6046.
52-1661
Profitability Improved by Phosphating Before Forming.
Profitability in the cold forming of steel can be appreciably improved by phosphating the metal surface. Phosphating forms conversion coatings which largely prevent the risk of the cold welding of workpieces and tool. The c o a t i n g s also facilitate the forming process. From the various phosphating procedures it is always possible to select methods which are particularly suitable for certain materials and for specific types of forming. Phosphating processes with which little or no sludge is precipitated are particularly useful and certain nitrate-accelerated processes take account of this factor; the temperature of the bath is also important from the standpoint of c o s t s . - - A A G. Siemund. Wire World Int., Jam-Feb. 1984, 26, (1), 17-19, [in English]. ISSN 0043-6046.
5 2 - 1 6 7 1 E l e c t r o f o r m i n g o f Complicated Structures for the Nucleakand Aerospace Industry. Electroforming is a modern production technique for complicated structures. Applications of this technique are discussed in the following fields: fabrication of concentrators for 100 kW solar energy plants; production of water-cooled screens, boxes and targets for nuclear fusion experiments (Joint European Torus, JET); large scale fabrication of erosion protection shapes for aeroplanes; fabrication of compact wind tunnel models. Composition of electroforming electrolytes (nickel, copper), bath parameters and process technology are discussed in detail. Additionally a short review on former applications is g i v e n . - - A A R. Suchentrunk, and F. Gammel. Z. Werkst., Sept. 1983, 14, (9), 298-305, [in English]. ISSN 0049-6688.
52-1674 Method of Making Hollow Bodies Under Pressure From Aluminum A l l o y s . A method of manufacturing a hollow body under pressure from an AI alloy comprises: preparing an alloy of a composition consisting of (by wt.) 5.6 < Zn < 6.1, 2.0 <_ Mg _< 2.4, 1.3 _< Cu _< 1.7, 0 . 1 5 < Cr < 0.25, Fe < 0.10, Fe + Si _< 0.25, Mn < 0.04, Zr < 0.03, Ti _< 0.04, b a l a n c e A I and impurities; casting the alloy in the form of a billet; hot extruding a billet at a temp. between 350-450~ by the indirect process into the form of a case; drawing out the resultant case hot then cold; hot necking the drawn case between 350-450~ solution annealing the hot necked case between 450-490~ and quenching with water a t a t e m p . < 40~ and two step tempering (Type T73) the quenched case. R. Develay, M. Anagnostidis, and Soci~td Metallurgique Gerzat. Off. Gaz., 27 Mar. 1984, Patent no. US4439246 (USA), 22 July 1981. ISSN 0360-5132.
52-1682
The Drawing of Copper Tubes on a F l o a t i n g P l u g , Investigations on the process of drawing Cu tubes strain hardened by a preliminary reduction of 15-97% have been carried out to determine by experiment the practical values of the safety margin factor "Yij and the unit elongation in the draw hi. The mathematical relationships of the magnitude of drawing stresses a c of Cu tubes as a function of assumed deformation in the draw ,~ and strain-hardening state of the material are derived based on experimental investigations. The values of safety margin factors ~ij dependent upon the reduction zj and hi and the values ~c as a function of ,~j and zj calculated from derived equations are listed. Knowledge of the relationships presented and the magnitudes of the parameters 3"ii, ~c and ,~i permits the design of an optimum schedule for drawing Cu tubes, which means lowering the number of drafts and labor content in producing the finished p r o d u c t . - - A A W. Krochmal, and R. Rutkowski. Tube Int., June 1984, 3, (2), 93-95, [in English]. ISSN 0263-6794.
alloys has been studied on materials with conventionally solidified dendritic structures and with non-dendritic structures obtained through mechanical stirring during solidification. This stirring performed at a constant temperature above the solidus produces a semisolid slurry with approximately spherical primary particles. The volume fraction, particle size, and interparticle spacing of the primary phase decrease as the stirring temperature increases. Whereas the alloy with the nondendritic structure (rheocast) can be extruded in the semisolid state under low extrusion forces giving a perfectly continuous rod, the alloy with the dendritic structure requires l a r g e r f o r c e s and p r o d u c e s a f r a g m e n t e d product. T h e s e experiments suggest that extrusion can be performed advantageously in the semisolid state with alloys obtained by mechanical stirring during solidification. 11 ref. --AA M.A. Taha, and M. Suery. Met. Techno/., June 1984, 11, (6), 226-230, [in English]. ISSN 0307-1693.
52-1683
52-1645 Update on C o n f o r m - - t h e Continuous Extrusion Forming o f Metals. The Conform technique basically comprises an open-sided container in
5 2 - 1 6 8 4 The Impact of C.H.Q. Wire Rod and Bar Developed by CSC on Downstream Industry. The technology of cold heading as developed in Taiwan
the form of a rotating wheel grooved around its periphery to accommodate continuous-rod feedstock, a stationary "shoe" providing a closing side over part of the wheel circumference and carrying the extrusion die and tooling, and a metal abutment fitted into the groove and constituting a closed end of an extrusion chamber. On rotation of the wheel the feedstock is carried round by friction, and in front of the abutment deforms plastically to fill a short length of the groove. In this region the bulk compressive stress in the stock rapidly reaches the flow stress required to extrude it through the die to give extrusions of practically any desired length. The extrusion temp. and pressure can be as high as 500~ and tO kbar, and particulate as well as rod feedstock is acceptable. The process development at the Springfield works of the United Kingdom Atomic Energy Authority, which so far has concentrated on extruding non-ferorus metals with emphasis on high-tonnage AI and Cu products, is reviewed and illustrations given of the equipment and some typical tubular AI extrusions from 9.5 mm dia. feedstock. Machines of up to 350-
J. APPLIED METALWORKING
A New Mill for Specialty Steel Precision Bar Products.
Installation of a new type, three-roll finishing section in an existing specialty steel bar mill has provided significant improvements in mill availability and product quality and close*tolerance products. In addition to a review of the principles of threeroll forming, the facilities and performance data are described. 16 r e f . - - A A W. Kaiser, and H. Brauer. Iron SteelEng., June 1984, 61, (6), 72-79, [in English]. ISSN 0021-1559.
has become one of the major production processes of downstream steel industry. The screw nut industry has developed a high-speed forming technology with capacity of 1000 pieces / min. This achievement has constituted part of the industrial growth in Taiwan. To match the rapid growth of downstream steel industry in Taiwan, CSC has developed a suitable C,H,Q. steel. The following topics are included in this paper: cold heading wire rod and bar used in the former ROC downstream steel industry; the present situation of cold heading wire rod and bar developed by CSC; influence of the development of cold heading wire rod and bar by'CSC downstream industry; and prediction of future developments of cold heading wire rod and bar in ROC steel industry.--AA T.S. Liao. Impact of Iron and Steel Industry on Downstream Industry [Proc. Conf.], Yogyakarta, Indonesia. 25-29 Apr. 1983, South East Asia Iron and Steel Institute, P.O. Box 7759, Airmail Distribution Center, Manila International Airport, Pasay City, Philippines, 1983, (Met.A., 8410-72-0631) Pp 12, [in English].
VOL. 4, NO. 1, JULY 1985
57
52-1685
The Rod Mill Finishing Block Cooling System Improvement in C S C . The cooling system in the finishing block of Morgan Mill has similar cooling patterns. Because the pass width is 23.85 mm on stand No. 16 and 5.62 mm on stand No. 25 for 5.5 mm rod, the cooling condition will be poor in stand No. 25 pass compared with stand No. 16 R-pass. The cooling system will need to be modified for the use of smaller size carbide rolls dnd high cooling water temp, Over the past few months, the carbide rolls (near scrap size) pass tonnage had decreased > 30% compared with the new tonnage in CSC rod mill. Several changes had been made to regain the original roll performance. Details concerning the calculation of the configuration angles, spraying conditions and judgement of pass wear pattern are i n c l u d e d . - - A A M.Y. Hong, and Y.C. Liu. Impact of Iron and Steel Industry on Downstream Industry [Prec. Conf.], Yogyakarta, Indonesia, 25-29 Apr. 1983, South East Asia Iron and Steel Institute, P.O. Box 7759, Airmail Distribution Center, Manila International Airport, Pasay City, Philippines, 1983, (Met.A., 8410-72-0631) Pp 13, [in English]. 5 2 - 1 6 8 6 SMS Section Mills--Optimized for Economical Rolling of Wire Rods, Bars and Profiles. Rolling mill design features have an important influence on economical rolling, finished product properties and on economical further processing in downstream industries. It was demonstrated with SMS wire-rod-, merchant bar- and medium section mills that SMS design features result in substantial improvements in economics and handling of the rolled products during rolling and further processing in downstream industries.--AA K.H. Willems, W.J. Ammerling, and P.V. Campenhausen. Impact of Iron and Steel Industry on Downstream Industry [Prec. Conf.], Yogyakarta, Indonesia, 25-29 Apr. 1983, South East Asia Iron and Steel Institute, P.O. Box 7759, Airmail Distribution Center, Manila International Airport, Pasay City, Philippines, 1983, (Met.A, 841072-0631) Pp 22, [in English].
52-1687 The Feasibility Study o f R o l l i n g Large Round B i l l e t in CSC (China Steel Co.) Billet-Mill. For increasing the availability of mill, a study has been made of the feasibility of rolling large round billet to develop rolling technique. The first trials on rolling large round billet were conducted in early 1980. However, the mill equipment and technique at that time were not sufficient enough to insure high-quality products. After years of experience, a technology was developed for rolling large round b i l l e t s . - - A A J.-W. Lee. Impact of Iron and Steel Industry on Downstream Industry [Prec. Conf.], Yogyakarta, Indonesia, 25-29 Apr. 1983, South East Asia Iron and Steel Institute, P.O. Box 7759, Airmail Distribution Center, Manila International Airport, Pasay City, Philippines, 1983, (Met.A., 8410-72-0631) Pp 7, [in English].
52-1690
Quality and Manufacturing Improvements of Low-Carbon
Aluminum-Killed Steel for Cold Heading Application. Through the modification of the equipment and new technology developed recently, China Steel has made it possible to produce low-carbon AI-killed steel for bar and rod by the use of continuously casting blooms. In the past two years, China Steel has made considerable efforts in the technology of steelmaking, continuous casting, billet conditioning and rolling control, and has made impressive progress in manufacturing technology and quality of products. Numerous improvements were made in 1981. For example, the surface defects of bloom and billet, such as corner crack, scum, pinhole and seam, have been reduced; the internal quality had been improved greatly and the sliver rejection rate of rod had also been reduced greatly. Details of these improvements are g i v e n . - - A A C.A. Lin, B.L. Chen, S.J. Chen, C.Y. Wu, and L J , Hu. Impact of Iron and Steel Industry on Downstream Industry [Prec. Conf.], Yogyakarta, Indonesia, 25-29 Apr. 1983, South East Asia Iron and Steel Institute, P.O. Box 7759, Airmail Distribution Center, Manila International Airport, Pasay City, Philippines, 1983, (Met.A. 8410-72-0631) Pp 18, [in English]. Continuously Cast Round Billets as Raw Material for the Production of Seamless Tubes and the Processing of the Billets on the Mannesmann High-Performance Piercing Mill. In the production of seamless 52-1691
tubes the first stage, piercing, is particularly important because the quality of the hollow bloom greatly influences the quality of the finished tube. The various piercing methods are discussed, with particular emphasis on max. possible elongation, productivity, size tolerances and billet dimensions. The advantages of a highperformance piercing mill can be deduced from this comparison. The development of the modern two-roll piercing mill with vertically arranged rolls, d.c. drive. Diescher disks and a bar changing system has reached a stage where all requirements regarding quality, productivity, wear and maintenance have been met. This type of mill can be used for all possible plant configurations. This modern piercing mill technology in conjunction with new developments in continuous casting technology guarantees a hollow bloom characterized by close size tolerances and particularly smooth, crack-free bore and outer s u r f a c e . - - A A F. HiJls, and K. Oberem. Impact of Iron and Steel Industry on Downstream Industry [Prec. Conf.], Yogyakarta, Indonesia, 25-29 Apr. 1983, South East Asia Iron and Steel Institute, P.O. Box 7759, Airmail Distribution Center, Manila International Airport, Pasay City, Philippines, 1983, (Met.A., 8410-72-0631) Pp 13, [in English].
Energy Saving o f a Reheating Furnace by Increasing Preheated Air Temperature and Preheating Fuel Gas. In the six-zone 52-1692
pusher-type reheating furnace at the hot strip mill of Mizushima Works, Kawasaki Steel Corp., recovery of waste gas heat was intensified by enhancing preheating efficiency of combustion air and by preheating combustion gas. The object of this modification was to obtain thermal efficiency equal to or better than that obtained by the energy-saving-type reheating furnace, which employed the walking beam and increased the furnace length, resulting in reduction of the unit consumption of fuel. Through this modification, preheated air temp. reached 6 5 0 ~ and fuel gas temp. 2 8 0 ~ Y. Shinohara, Y. Miyake, S. Takizawa, M. Obashi, and K. Takagi. Impact of Iron and Steel Industry on Downstream Industry [Prec. ConL], Yogyakarta, Indonesia, 25-29 Apr, 1983, South East Asia Iron and Steel Institute, P.O. Box 7759, Airmail Distribution Center, Manila International Airport, Pasay City, Philippines, 1983, (Met.A, 8410-72-0631) Pp 17, [in English].
58
VOL. 4, NO. 1, JULY 1985
Roll Forming: Poised for a Quantum Jump. The advances in roll forming technology, which include widespread incorporation of computerization and the use of CAD/CAM technology to develop the forming roll sequences, are discussed. In many roll forming applications, various lengths and hold patterns are the rule rather than the exception. Computerized die changes are providing relief to some such operations as indicated by the examples shown. It is believed that roll forming will be the method of choice in the future for a range of parts that could not have been considered only a few years ago.--S.K.B. D. Daniels. Met. Stamp., June 1984, 18, (6), 4-6, 8, [in English]. ISSN 0026-069X. 52-1695
52-1700
Forged Straight Bevel G e a r s - - a n Overview. (Pamphlet). Over the past 20 years a number of companies have developed proprietary processes for forging net shape straight bevel gears. The inherent complexity of bevel gear geometry requires tight process control to forge gears which require no further machining on the teeth. Electrode design, die manufacture, scale control and finish machining are critical areas which require special attention to obtain functional gears with integrally forged teeth. Gears with integrally forged teeth have inherent advantages over conventionally manufactured gears. These advantages include improved strength, less raw material, design flexibility and cost savings. Examples of these benefits are discussed. 12 r e f . - - A A D.K. Benedict. International Off-Highway Meeting [Prec. Cool.}, Milwaukee, Wis., U.S,A., 12-15 Sept. 1983, SAE, 400 Commonwealth Dr., Warrendale, Pa. 15096, U.S,A., 1983, SAE Tech. Paper Series No. 831264, Pp 6, [in English]. 52-1701 F a b r i c a t e d I n t a k e and Exhaust Manifolds--the S t e e l S t o r y . (Pamphlet). The merits of manufacturing passenger car intake and exhaust manifolds from stainless and carbon steel stampings or fabrication are described. Information on manufacturing methods, projected costs and prototype work is presented. Successful current applications and potential future applications of fabricated manifolds are r e v i e w e d . - - A A M.M. Cleeton. Passenger Car Meeting [Prec. ConL], Dearborn, Mich., U.S.A., 6-9 June 1983, SAE, 400 Commonwealth Dr., Warrendale, Pa. 15096, U.S.A., 1983, SAE Tech. Paper Series No. 831006, Pp 8, [in English].
52-1702 Computer-Assisted Implementation of Powder Forging Processes. (Pamphlet). Computerized methods have been developed for powder preform forging processes to reduce the trial-and-error development required for preform design and to improve dimensional control in the finished parts. The part volume and volume distribution are calculated from digitized input of the drawings. Die dimensions are calculated including thermal and elastic effects. Shrink ring dimensions and interferences are also calculated if required. Preform design is accomplished using an interactive computer program that includes consideration of densification, cracking limits and die chilling. At the present stage of development, some user decisions are necessary and previous experience is helpful for application of the system to complexly-shaped parts. Currently, the completely integrated system is ideally applicable to a family of similar parts, such as bearings, cam rings or gears. The method is illustrated for a part forged from 4640 lowalloy steel p o w d e r . - - A A H.A. Kuhn. Passenger Car Meeting [Prec. Conf.}, Dearborn, Mich., U.S.A., 6-9 June 1983, SAE, 400 Commonwealth Dr., Warrendale, Pa. 15096, U.S.A., 1983, SAE Tech. Paper Series No. 831041, Pp 5, [in English]. 52-1708 T h e E f f e c t o f Mechanical Properties on .,,e W r i n k l i n g Behavior of Sheet Materials in the Yoshida T e s t . The effect of material properties on the initiation of wrinkling and on wrinkle height at 2% mean axial extension of a range of sheet metals (mild steel, austenitic stainless steels 409D and 404, Ti, Cu, 7 0 / 3 0 brass and AI alloys 1100, 3004, 5005) was investigated using the Yoshida or 'handkerchief' test. The onset of wrinkling was accelerated by strain rate, normal plastic anisotropy and by yield strength but was delayed by increase in Li.iders strain (yield elongalion) when present, by work hardening and by positive strain-rate sensitivity. The growth of wrinkles was retarded by Li.iders strain, work hardening, by high values of the ratio r ' / Y S and of the coefficient of strain-rate sensitivity, but was promoted by increasing yield strength. Initiation of wrinkling occurred later when the upper yield point had not been removed but growth was more rapid. Growth was slower when LiJdering had been removed: hence, in industrial practice, the usual procedure of temper rolling before sheet forming might be disadvantageous in those applications in which Liiders bands (stretched strains) on the product could be tolerated. The close correlations obtainable for the same or similar materials in different conditions confirm the usefulness of the Yoshida test for comparing these materials with respect to the onset and growth of wrinkles, whereas the test appears less useful for rating the wrinkling behavior of different types because of unaccounted factors. 11 r e f . - - A A A.M. Szacinski, and P.F. Thomson. J. Mech. Work. TechnoL, June 1984, 10, (1), 87-102, [in English]. ISSN 0378-3804.
5 2 - 1 7 0 9 Sublayer Defects. The phenomenon of sublayer defect propagation during the process of direct extrusion is studied. Effects of the initial length of the feed stock billet and percent reduction in area on the percentage of the billet extruded are considered It is shown that shorter billets allow larger percentages of the billet to be extruded before the sublayer defect occurs. The depth of the sublayer defect is dependent on the initial length of the billet: for long billets the sublayer is close to the surface, while short billets result in a sublayer buried deep in the extrudate.--AA J. Sculac, and B. Avitzur. ,I. Mech. Work. Technol., June 1984, tO, (1), 77-86, [in English]. ISSN 0378-3804. B e n d i n g o f W o r k - H a r d e n i n g M e t a l s Under the Influence o f Axial Load. Stretch-forming operations, where bending moment and axial load
52-1711
are applied simultaneously to a work-hardening material, are widely used for the fabrication of airframe and automotive structural components. Determination of the combinations of axial load and bending moment to produce a given deformation is an important industrial problem, not only to achieve the desired shape, but also to select the appropriate machines to produce this shape. Elastic--fully plastic analysis of bending of beams under the influence of axial load is presented for work-
J. APPLIED METALWORKING
hardening material. The variation of the applied bending moment with the axial force for the fully elastic, e l a s t i c - - p l a s t i c , and fully plastic cases is given both in analytical and graphical form. Results for the case when n = O and those reported by Johnson and Yu for e l a s t i c - - p e r f e c t l y plastic (nonworkhardening) material are c o m p a r e d . - - A A A. EI-Domiaty, and A.H. Shabaik. J. Mech. Work. Technol., June 1984, 10, (1), 5766, [in English]. ISSN 0378-3804.
52-1712 Investigation of Dynamic Phenomena in the Drive of a Pilger Mill for the H o t R o l l i n g o f T u b e s . In a hot pilger mill for seamless tubes, fatigue failure occurred of the shaft on which the motor rotor, the flywheel and one hub of the coupling were seated. Experimental tests have been carried out and a mathematic model of the spring-mass system of the rolling mill drive has been developed. It was determined, by calculation, that the backlashes and elasticities of the coupling have the greatest effect upon the variations and values of the loads. The conditions which the coupling should fulfill were also defined. After a redesigned coupling had been mounted, measurements were carried out and it was found that while the max. loads of the coupling had decreased by 40%, the vibrations causing cyclic variations of the loads still remained. After a check, it appeared that the new coupling was too rigid, but because of the design requirements it was impossible to increase its elastic flexibility. The dependence of the vibrations on the coupling mass was investigated; it was established that an increase in its moment of inertia of 15% is sufficient to decrease considerably the amplitude of vibrations and to cause some limitation of their frequency. As a result of the investigation, the phenomenon of the formation of fatigue cracks of the shaft has been eliminated and the life of the driving-unit parts has been increased.--AA W. Dobrucki, R. Gregorczyk, A. Swiatoniowski, and S. Zawada. J. Mech. Work. Techno/., June 1984, 10, (1), 3-27, [in English]. ISSN 0378-3804.
52-1714 Evaluation of Recuperation and Stock Preheating for Reducing Fuel Consumption in Reheat Furnaces. A parametric study relating furnace waste gas temp. (stock preheating) and combustion air preheat temp. (recuperation) for a steel reheat furnace has been conducted. The results show that by combining stock preheating and recuperation, synergistic effects are obtained compared to the possible benefits of using recuperation or stock preheating individually. The results also show a practical limit, where any additional increase in furnace size and recuperator size has an insignificant effect on fuel consumption.--AA P. Shefsieh. Iron Steel Eng., July 1984, 61, (7), 38-40, [in English]. ISSN 00211559.
5 2 - 1 7 1 5 Crop Shear Optimization and C o n t r o l . A new noncontact, digital, flying crop shear control system has been placed in operation which uses two solid-state linear camera systems located close to the entry of a crop shear. One camera system determines bar position with the other system optimizing the cropping point. Payback is estimated within six months based on yield improvements obtained at a European hot strip m i l l . - - A A P.W. Loose. Iron Steel Eng., July 1984, 61, (7), 41-48, [in English]. ISSN 00211559. 52-1717 Bigger Aluminum Forgings b y K o b e . Until recently, Japan did not have the capability for large AI forgings. They are now being produced by Kobe on its new 8000 metric ton precision closed-die forging press to meet the needs of aircraft and other industries. Some important design concepts, principal specifications, working details, capabilities, features and improvements brought about by this press are outlined. It is also capable of performing regular no-draft forging for which demand is rapidly increasing. Die requirements in no-draft forging are discussed. Some typical parts forged on this press from AI alloys 2014 and 7075 are shown.--S.K.B. K. Takada, and A. Fukuda. Am. Mach., July 1984, 128, (7), 99-101, [in English]. ISSN 0002-9858,
52-1719 Superplastic Forming of Titanium and Aluminum Alloys for Aerospace Applications. Several AI alloys (7475, Supral 100) and Ti alloys
52-1724 Seizure Mechanism in C o l d Extrusion and Forging. To examine the seizure mechanism in cold extrusion and forging, a bifurcating extrusion-type friction testing machine has been manufactured. This friction testing method was devised to simulate the frictional surface in the process accompanied by a remarkable surface expansion which influences markedly the seizure phenomena in extrusion and forging. Using a commercially pure AI as the work metal, in frictional characteristics, and in particular the seizure mechanism, have been investigated under a lubricated condition with a mineral oil of higher viscosity and a dry frictional condition. Under the lubricated condition, the frictional surface was remarkably expanded > 26 times; nevertheless no seizure was observed throughout the extruded travel. On the other hand, under the dry frictional condition, the seizure is initiated at the region where a virgin surface is exposed or the relative slip displacement exceeds a critical value. It was observed that even in the dry frictional condition, a smooth burnished metal surface could be obtained if the surface expansion ratio and the relative slip displacement are lower than a critical value. 16 ref.--AA N. Kawai, H. Saiki, and T. Nakamura. ,I. Eng. Mater. TechnoL (Trans. ASME), July 1984, 106, (3), 257-263, [in English]. ISSN 0094-4289. 52-1725
Superplastic Deformation of Strongly Textured T i - - 6 A I - - 4 V .
I.--Stress and Strain Anisotropy. Stress and strain anisotropy of a strongly textured T i - - 6 A I - - 4 V alloy bar during auperplastic deformation at 880 and 9 2 8 ~ has been investigated. After ~ 0.9 superplastic strain at 9 2 8 ~ the deformation tended to become isotropic. The anisotropic superplastic deformation w a s found to be dependent upon the aligned microstructure and not influenced by the original iv-phase crystallographic texture. The room-temp, anisotropy before and after superplastic plastic deformation was controlled by the original u-phase texture, which was still present even after 1.48 strain (344% elongation) at 9 2 8 ~ 21 ref. --AA D.S. McDarmaid, A.W. Bowen, and P.G. Partridge. J. Mater. ScL, July 1984, 19, (7), 2378-2386, [in English]. ISSN 0022-2461. 52-1729 Study of the Hydrostatic Coextrusion of Aluminum and Copper. A study of the hydrostatic coextrusion of AI and Cu has been conducted. The primary concern was predicting the development of stresses during extrusions under different processing conditions of die angle, extrusion ratio and cladding. Two aspects of the investigation were the experimental determination of extrusion pressure and residual stresses in axisymmetric hydrostatically extruded solid AI, solid Cu and Cu-clad At rods and a computer simulation of the process using an e l a s t i c - - p l a s t i c finite element program. Experimental and simulation results show that the extrusion pressure varies linearly with the natural logarithm of the extrusion ratio and with the volume fraction of the core. The experimental data for all billet configurations lie between the least squares line through the simulation data and the upper bound lines of Avitzur and of Hartley. A new technique for measuring residual stresses, based on Sach's boring-out method, was developed. The simulations showed that lower die angles promote a more uniform metal flow and lower residual stress magnitudes. Extrusion defects like central bursting and surface c r a c k i n g are due to u n f a v o r a b l e s t r e s s d i s t r i b u t i o n s during e x t r u s i o n . (DA8405385),--AA R. Srinivasan, and State University of New York. Diss. Abstr. Int., June 1984, 44, (12), Pp 229, [in English]. ISSN 0419-4217.
52-1731 Method of Making Products of Aluminum Alloys Suitable for Drawing. A method of making sheets of AI alloy suitable for drawing comprises: casting the alloy between cylinders to form a strip; subjecting the strip to mechanical cleaning to enable most of the particles deposited on the surface and the thick oxide layer formed during casting to be eliminated; reforming an oxide antigalling layer on the surface of the strip by heat treatment at elevated temp. in air intermittently over a period of 4-8 h at a temp. of 520-550~ or continuously over a period of 1-10 min at 600-620~ subjecting the strip coated with the layer to the rolling operations to convert it in a sheet with a thickness ~ 300 #m in a series of passes optionally separated by annealing treatment; cutting disk from the sheet; and subjecting disk to deep drawing and ironing. F.-R. Boutin, J. Kubie, and SCAL Societ~ de Conditionnements en Aluminium. Off. Gaz., 10 Apr. 1984, Patent no. US4441933 (USA), 30 Apr. 1982. ISSN 0360-5132.
( T i - - 6 A I - - 4 V ) showing superplastic properties are important for aerospace application. This offers chances to fabricate complex shaped components in one piece and one step. After a short review to the metallurgical basis of superplasticity and diffusion bonding of these alloys the relevant processing parameters are presented. Parts from Ti and AI alloys are shown for space, helicopter and aircraft applications. These parts have been designed to SPF and fabricated. The process (e.g. oven or press) and the manufacturing process (e.g. design and material of the forming tool) have been optimized to cost and quality for each type of part. The state of production is r e p o r t e d . - - A A J. Berggreen, and P,-J. Winkler. Materials and Processes, Vol. 1 {Prec. Conf.], Monteux, Switzerland, 12-14 June 1984, Society for the Advancement of Material and Process Engineering, P.O. Box 2459, Azusa, Calif. 91722, U.S.A., 1984, (Met.A, 8410-72-0649) Pp 11, [in English].
strength cold rolled steel sheet having a yield point of ~ 26.1 k g / m m 2, a yield ratio of ~, 0.6 and an ~ value of r 1.6 and excelling in secondary workability comprises heating to ~ 1100~ a steel slab, then hot rolling the heated steel slab at a finishing temp. of ~ the Ar 3 point and coiling the hot roiled steel strip at 850~ subsequently cold rolling the resultant hot rolled steel sheet at a reduction rate of < 70% and annealing at a t e m p , of ~ Ar 3point, N. Takahashi, M. Shibata, Y. Furuno, and Nippon Steel Corp. Off. Gaz., 10 Apr. 1984, Patent no. US4441936 (USA), 9 Apr. 1980. ISSN 0360-5132.
52-1720 Hydrogen Enhancement of the Ductility of Heat Resistant Titanium Alloys. (Translation). See Met. A., 8311-52-1380.
52-1733 Parameters of the Deformation Region in H e l i c a l R o l l i n g o f Continuous Section Rods. (Translation). See Met. A, 8401-52-0010.
V.K. Nosey, B.A. Kolachev, and E.I. Pavlov. Russ. MetalL, 1983, (1), 112-115, [in English]. ISSN 0036-0295.
Ya,S. Shvartsbart, and V . N Zhuchin. Russ. MetalL, 1983, (2), 67-71, [in English]. ISSN 0036-0295.
52-1721 Mathematical Simulation of the Influence of an Active Lubricating Medium on the Stressed State of the M a t e r i a l in R o l l i n g o f Thin Foil. {Translation). See Met. A., 8406-52-1028.
5 2 - 1 7 3 4 Increasing the S t a b i l i t y o f the Rolling--Drawing Process W i t h Rolls Enclosing the Strip. (Translation). See Met. A., 8401-62-0011.
52-1732 High-Strength, Low-Yield-Point, Cold-Rolled Steel Sheet or Strip Suitable for Deep Drawing. A method for the manufacture of a high-
S.I. Kovalev, V.I. Savenko, and E.D. Shchukin. Soy. Mater. Sci., 1983, 19, (6), 514518, [in English]. ISSN 0038-5565.
V.N, Vydrin, N.V. Sudakov, and B.A. Chaplygin. Russ, Metall., 1983, (2), 72-75, [in English]. ISSN 0036-0295.
52-1722 O p t i m i z a t i o n o f the Production of High-Strength Reinforcing Wire. (Translation). See Met A., 8406-52-1029.
52-1735
EM. Kireev, I.I. Dikii, R.I, Petrivskii, and G.M. Krasovskaya. Soy. Mater. ScL, 1983, 19, (6), 564-568, [in English], ISSN 0038-5565.
J. APPLIED METALWORKING
Temperature Calculation During Hot Rolling. (Translation).
See Met. A., 8401-52-0012. I.I. Novikov, K . M Klimov, and Yu.S. Burkhanov. Russ. MetalL, 1983, (2), 75-80, [in English]. ISSN 0036-0295.
VOL. 4, NO. 1, JULY 1985
59
52-1736 Influence of Tube Manufacturing T e c h n o l o g y on Microdeformation Distribution in Extension. (Translation). See M e t A , 8401-52-0013, A.A. Vsinshtein, and V.A. Aleshin. Russ. Metall., 1983, (2), 145-148, [in English]. ISSN 0036-0295.
52-1745
Metal Forming Technology: Some British Developments. Four recently developed ranges of equipment are briefly described: (i) computer numerically controlled metal folding and tube bending machines; (ii) automated feeds that can be added to existing non-automated presses; (iii) a press brake with a 20hole punching attachment; (iv) a three-station unit for the punching; angle cropping, mitring, bar shearing and cropping, radius cropping, bending, and notching. --T,W. E. Ford. S. Aft'. Mach. ToolRev., Sept. 1983, 16, (9), 6, 26, [in English]. ISSN 00360848. 52-1746
Four-Phase Development of Wire Rod Lines. In the late fifties the picture was dominated by wire lines with two-high twisting stands and horizontal/vertical finishing stands. The sixties saw the advent of new methods and machines. The twist-free 45 ~ block was widely adopted. Modified heattreatment methods brought about a marked improvement in the wire quality. Heattreatment methods were developed directly from the rolling heat. The seventies brought improvements in the equipment behind the block. Rolling speeds are increasing and process computers are being introduced into the wire rolling mill. The aim of future development is further rationalisation.--AA F. Beste, M. Grootaarts, R. Sch~fer, and K. Wilcken. Wire World Int., July-Aug. 1983, 25, (4), 139-142, [in English]. ISSN 0043-6046. 52-1747
P r o g r e s s in the Production o f H e a t i n g C o n d u c t o r W i r e s . Many advances in the production of heating conductor wires came about only as a result of progress in the technology of measurement and control. New methods of melting supplied larger ingot shapes and, more important, castings with improved material characteristics. The developments also led to larger production weights in rolling. The more effective control of rolling temperatures end of cooling resulted in the production of wire of greater uniformity of structure. There has also been significant progress in the preparation of the wire for d r a w i n g . - - A A H. Frinken. Wire World Int., July-Aug. 1983, 25, (4), 143-145, [in English]. ISSN 0043-6046.
52-1748
Drawing and Winding o f F i n e C o p p e r Wire, The most important production engineering advances in the drawing and winding of fine copper wire have taken place during the last ten years. The increasing use of continuously cast and rolled wire rod was accompanied by the advent of large coil weights of up to 10 tonnes and winding speeds of up to 40 m / s . Automatic spool exchange was introduced on the coil packers and this was followed by the development of spoolless coils. Natural diamonds were increasingly superseded by synthetic diamonds for the manufacture of dies. Multiple wire drawing is being extensively u s e d . - - A A H. Matousek. Wire Worldlnt., July-Aug. 1963, 25, (4), 146-149, [in English]. ISSN 0043-6046. 52-1749 Manufacturing Advances in C o l d F o r m i n g F r o m W i r e in Coil. The production of formed components directly from steel wire in coil has made considerable progress during the last 25 years. Appreciable impetus was supplied by the knowledge that solid forming not only saves energy and materials but is above all extremely economical. Advances in production are due to the one hand to further developments in the sphere of the steels to be fabricated and on the other to the continued perfection of new formed components. Further developments in the lield of formed components have a direct influence on machine design. There has furthermore been a significant increase in the variety of shapes, in the size of the components and in the attainable degree of p r e c i s i o n . - - A A H.D. Feldmann. Wire Worldlnt., July-Aug. 1983, 25, (4), 150-153, [in English]. ISSN 0043-6046. 52-1750
Investigations of the Process of Rolling Low-Ribbed Tubes. Of the various materiasl used for heat exchangers, three types of alloys, CuNiFe, CuZnAI and FeCrNiTi, were chosen for the investigation. Tool design, dimensions, metal deformation and causes of faults and failures are examined. Plasticity and strength of the tube material govern the type of rolls. Means of improving tool life are suggested. The basic calibration parameters of tools for rolling the three alloys are tabulated.--G.A.S. J. Bazan, J. Richert, S. Newak, A. Pasierb, and K. Swiatkowski. Copper Top., Mar. 1964, 9, (1), 1-5, [in English]. A s y m m e t r i c P l a s t i c F l o w o f Anisotropic Sheet During Deep Drawing. The plastic flow of anisotropic sheet during deep drawing may be re52-1777
garded as a two-stage deformation process, both stages occurring simultaneously. The first stage d e f o r m a t i o n is a x i - s y m m e t r i c flow controlled by normal anisotropy. The second stage deformation or asymmetric flow is due to planar anisotropy and is respondible for the change in shape of the rim of the flange of a partially drawn cup from circular to hypotrochoid. Strain distribution due to second-stage deformation was calculated. It was found that the hypotrochoid represents a curve on which the principal shear strain is constant. Analysis of experimental data indicated that plastic strains due to symmetric and asymmetric components are not independent. For example, the principal shear strain, "Taax, due 1o asymmetric flow is proportional to the circumferential strain, ~N, due to the axi-symmetric component (first-stage) of deformation. 17 r e f . - - A A S. Emsni. Sheet Met. Ind., Apr. 1984, 61, (4), 201-207, [in English]. ISSN 00373435. 52-1783 Firth-Derihon: Forgings for Aerospace. The Firth-Derihon company is historically a producer of acre-engine blades, discs, bearings, gears, etc., in heat-resisting, stainless, and alloy steels, and subsequently of Ti and superalloy components for compressors and of gas turbines and closed-die and press forgings for the automobile and other industries. Aerospace applications still, however, account for some 60% of the output, and approx. 25% of the forgings are
60
VOL. 4, NO. 1, JULY 1985
exported. On-site production of the drop, press, and upset forgings is outlined and the presses, heat-treatment, etc. equipment at the company's Sheffield and Darley Dale works is described. A Rotoform orbital forging press producing very thin precise components up to 6 in. dia. from difficult materials to tolerances closer than with conventional units is particularly illustrated and discussed and reference made to the projected installation, within a 10 000 ft 2 extension at Darley Dale, of machining facilities comprising computerized and non-computerized turning unit. --J.R. R.W. Dove. Met. Bull Men., Apr. 1984, (160), 43, 47, 49, [in English]. ISSN 03734064.
5 2 - 1 7 8 4 P r i n c i p a l C r i t e r i a for Design and L a y o u t o f a n Extrusion Press P l a n t for Heavy Metal. Product-type, production-programme, billet-weight, and other factors influencing the design end economy of extrusion plant are reviewed and practical data presented for the case of a 25-29 MN indirect-extrusion press for brass rod and wire production. The basic arrangement and operating sequence of the press and ancillary plant are illustrated and described, together with run-out equipment for single- and double-strand working and the straightforward extrusion of 32-60 mm die. products and lengths exceeding that of the coiling table. The line requires only five operatives, the specific duties ot whom are outlined. Reasons for the significantly lower (20-25%) extrusion costs as compared with a modern direct press of identical size are extensively listed.--J.R. F.J. Zilges. Metal/. Plant Technol., 1983, 6, (3), 34-36, 39-41, [in English]. ISSN 0171-4511. 52-1787 Promoting Pace, Productivity and P r e c i s i o n , [ S t a m p i n g Techniques]. Copeland and Jenkins has evolved into a leading international supplier of precision stamped parts for the electronics industries. In particular, it has developed high speed presswork enabling intricate components (e.g. Pb frames) to move into the realms of high volume low cost processes. The company's tool making skills and facilities were key factors in the success. An account is given of press shop investment (17 high speed machines), material handling, toolmaking, tool design, techniques and procedures, a new NC wire erosion machine and the high standard of quality eontrol.--J.M.S. Sheet Met. Ind., Mar. 1984, 61, (3), 125, 126, 129, [in English]. ISSN 0037-3435.
52-1788
R o l l f o r m i n g W i t h o u t C r a c k i n g . Commonly used sheet coatings (copolymers and polyesters) are vulnerable to aggreaive chemical environments, exhibiting accelerated deterioration. For roll formed components corrosion is usually initiated at a point of fold. The problem can b e solved by applying the principle that certain polymers and polyesters undergo a transition from the brittle to elastic state at the 'glass transition point' or Tg. Its relevance to rollforming was investigated to establish material and operational parameters. Work on four polyester and three silicone polyester grades indicated 60 ~ < "fg < 60~ Consequently, temp. was maintained at 85 ~ - 100~ throughout the entire rollforming operation. Artificial ageing and a c c e l e r a t e d c o r r o s i o n testing confirmed a significant improvement.--J.M.S. G. Quinchon. Sheet Met. /nd., May 1984, 61, (5), 277-278, [in English]. ISSN 00373435.
52-1789
Use of Oxygen Enrichment for Steel Reheating Furnaces.
Following computer predictions and flame-tunnel studies indicating direct end indirect fuel savings by O - e n r i c h m e n t of reheating-furnace combustion air, a microprocessor-controlled enrichment system was installed on a five-zone slabreheating furnace serving the hot-strip mill at the Port Talbot works of the BSC. During the initial commissioning the benefits were clearly evident, savings equivalent to 6-9.5 % of the total furnace fuel input, or to 1.0-1.6 therms/t, being recorded for O applied to the preheat zones at the rate of 7 mJ/t. air-preheat and slab-rolling temp. were maintained, the furnace refractories were apparently unaffected, and there was no rise in the skid-cooling of flue-gas t e m p . - - J R . G. Boydell, A. Felski, S. Grainger, and D.P. Jenkins. Steel Times, Apr. 1984, 212, (4), 160-161, [in English]. ISSN 0039-095X.
52-1792
D i r e c t Wire Cooling System. The economic conditions prevailing over the last few years have confronted the wire industry with many problems. The first logical tendency in order to reduce production costs was to raise drawing speeds in order to reduce the number of machines and operators for a given production but, the wire temperature rise is a direct function of drawing speed, and the mechanical characteristics of high carbon steel wire rapidly deteriorate when the wire temperature rises beyond the generally accepted temperature of 180~ In order to stay within such limits, drawing speeds were often reduced, and therefore the machine's available power was not fully used. This is particularly true for recent machines with indirect water cooling when drawing prestressed concrete or spring w i r e . - - A A D. Petkovic. Wire Ind., May 1984, 51, (605), 409-410, [in English]. ISSN 00436011. 52-1793 E f f e c t o f Controlled Cooling on D r a w a b i l i t y o f W i r e R o d . Cooling of coiled and spaced-out steel-wire rod in static and blasted air, salt baths, fluidized sand beds, and cold and boiling water is discussed in terms of the C content, scale formation, UTS, and the microstructure, and therefore the drawability, obtained. Controlled accelerated cooling can significantly reduce the scaling, give strengths comparable with those of Pb-patented material, decrease the lamellar cementite spacing, and suppress the eutectoid ferrite precipitation to favour the sorbitic structure appreciably improving the drawability, while delayed cooling gives structures and mechanical properties approaching those of the spheriodized or annealed states. Other aspects reviewed include direct coupling of heat-treatments with rolling, and enhancing the drawability of rods with C contents and dia. greater than 0.4% and 13 mm. 29 ref.--J.R. W.-D. Brand. Wire World Int., Mar.-Apr. 1984, 26, (2), 53-56, [in English]. ISSN 0043-6046.
52-1794
Lubrication and Phosphate Treatment Combined in C o l d F o r m i n g , Soap lubricants on phosphate coatings particularly combine with the latter, giving intense surface anchoring of, say, Zn stearate, which in conjunction
J. APPLIED METALWORKING
with an approx, similar-thickness Na-soap film facilitates extensive forming. The phosphate coatings can also be combined with solid lubricants such as MoS2 in dispersion or powder form, and can be applied by methods other than dipping. For cold solid forming of wire coils on multistage presses, phosphate-coating thicknesses equivalent to 7-15 g / m 2 are achievable with nitrate/nitrite or chlorate/ nitrate processes, and the soaping is generally combined with oil lubrication on the press. Recommended treatments for other forming conditions are also outlined, and oxalation instead of phosphating of high-alloy steels (e.g. 9~ compositions), which are inadequately attacked by H3PO 4 during the primary pickling reaction, is discussed. Methods for determining the coating thickness in terms of weight/unit area are described, and procedures for the cases of phosphate, oxalate, and aluminate coatings on steel, alloy steels, and AI, respectively, are tabulated. Surface microstructures obtained with accelerated nitrate/nitrite and chlorate/nitrate treatments are illustrated.--J.R. G. Siemund. Wire World Int., Mar.-Apr. 1984, 26, (2), 75-77, [in English]. ISSN 0043-6046. 52-1797 Many Jobs Are Better Swaged. Rotary swaging delivers up to 5000 blows/min and forms, reduces, or tapers ferrous and non-ferrous tubes or bars ranging from 0.008 to 6 in. dia. The grain structure of the workpiece is improved, the UTS of mild and stainless steels and other alloys can be increased, and an attractive brushed-finish effect is imparted. Hot-swaging can enhance the ductility of W and other brittle materials to an extent to permit drawing. The basic and ancillary equipment and some products are illustrated, and are described with reference to end, butt, taper, and angle swaging and push pointing.--J.R. A.J. Thompson. Chart. Mech. Eng., Jan. 1984, 31, (1), 26-29, [in English]. ISSN 0306-9532.
52-1801
CV R o a d - W h e e l Production From Flat S h e e t . Commercial vehicle wheels can be made from flat sheet using only spinning machines, without the need of presses or rim rollers. Hot rolled descaled flat sheet steel is formed into a circular ring on a four-roll ring roller, with the ends then welded together. The manufacture of tapered bead seat rims and drop-center rims using the technique of flow forming is described. Sketches show disk contours and details of manufacture are provided.--J.J.P. G. Pollk6tter. Automot. Eng. (UK), Feb.-Mar. 1984, 9, (1), 50-52, [in English]. ISSN 0307-6490.
52-1802 A Model for the Hot or Warm Forming of Metals With Special Use of Deformation Mechanism Maps. A finite element model is described for analyzing metal flow and heating of AI (> 99% purity) during large deformation processes such as hot rolling. Particle thermomechanical histories are evaluated relative to the spatial coordinates of the computational domain. The stress and temp. histories are compared to deformation mechanism maps to determine the consistency of constitutive equation assumptions. 35 r e f . - - A A P.R. Dawson. Int. J. Mech. ScL, 1984, 26, (4), 227-244, [in English]. ISSN 00207403.
52-1803
Rate Effects in S t e a d y Forming Processes o f P l a s t i c M a t e r i a l s . Drawing and extrusion processes, of viscoplastic solids such as Cu through wedge-shaped and conical dies are analyzed. Radial velocity profiles and small deviations from the uniform flow field are assumed within the working zone. Material behavior is governed by the Bingham solid model. Explicit expressions for the stress field within the working zone are derived. The results are restricted to long and tapered dies. An optimum die angle exists where the driving stress attains a rain. The dependence of that angle on wall friction, Bingham number and geometrical reduction is analyzed in detail. The validity of the analysis is supported upon comparison with existing analytical and experimental investigations. 10 r e f . - - A A D. Durban. Int. J. Mech. Sci,, 1984, 26, (4), 293-304, [in English]. ISSN 0020-7403. 52-1804
Cost-Effective Foundry M e l t i n g . - - i . Major developments which influence Fe melting are discussed, Energy, melting equipment, melting practices and cupolas are considered. Melting cost factors, energy measurement, twotuyere operations, recuperation, upgrading cupola efficiency, oxygen enrichment and reduction of downtime for refractory repair and dropping the bottom are detailed. 13 r e f . - - C . M . L S . J.C. Miske. Foundry Manage. Technol., Aug. 1984, 112, (8), 22-25, [in English]. ISSN 0360-8999. 52-1805
Extrusion Method Using H o t L u b r i c a n t . A method for hot lubricated metal extrusion in which a billet of a metal selected from the group consisting of Cu and a Cu alloy is extruded into a tubular form by means of die and mandrel with an organic lubricant interposed between the billet and die and mandrel, comprises feeding air into the extruded tubular product through a feed passage in the mandrel to burn off the carbide of the lubricant deposited on the inner surface of the extruded tubular product, the air being fed at a rate of Q falling in the range of 1.8d x R x V < Q _< 14.2d x R x V, where i.d. of the product in cm, R is the extrusion ratio, V is the billet extruding speed in cm/s. M. Nishihara eta/., and Kabushiki Kaisha Kobe Seiko Sho. Off. Gaz., 1 May 1984, Patent no. US4445350 (USA), 29 Nov. 1980. ISSN 0360-5132. 52-1806
Induction Pipe Bending Vs. Conventional Techniques.
Features of induction pipe bending are discussed and compared with conventional pipe bending techniques. In induction bending, a narrow band of the pipe is heated to forging temp., after which a radial arm rotates the pipe to the desired bend radius. Advantages include design flexibility, elimination of heat soaking periods, and "infinitely" variable bend radius from 1-1/2 dia. and up and the ability to meet strict requirements for pipe ovality and wall thinning. A wide range of materials can be bent, including carbon and alloy steels, AI, Ni and MoneI.--G.P.K. P. Hartley. Fabricator, July-Aug. 1984, 14, (5), 1, 20-21, [in English]. ISSN 01928066.
J. APPLIED METALWORKING
52-1807
Shape C u t t i n g S t e e l : Comparing Three Methods. Three steel cutting m e t h o d s - - o x y f u e l flame, laser (oxygen-assisted) and plasma a r c - - a r e described. Each process has disadvantages and advantages. Recommendations are presented for the appropriate use of each method.--G.P.K. J. Karow. Fabricator, July-Aug, 1984, 14, (5), 34-35, (in English]. ISSN 0192-8066. 52-1808 improving F l a t n e s s o f C o l d R o l l e d C o r r o s i o n R e s i s t a n t S t e e l . (Translation). See Met. A., 8406-52-1088, L.A. Agishev, R,F, Maksutov, and A.R. Fisher. Steel USSR, Nov. 1983, 13, (11), 502-503, [in English]. ISSN 0038-9218.
5 2 - 1 8 0 9 Method o f M a n u f a c t u r i n g Cladding Tubes o f Z i r c o n i u m - B a s e d Alloy for Fuel Rods for Nuclear Reactors. In a method ol manufacturing cladding tubes of a Zr-based alloy for fuel rods for nuclear reactors, the Zr-based alloy contains 1.2-1.7% Sn, 0.07-0.24% r e , 0.05-0.15% Cr, 0-0.08% Ni, balance Zr and impurities, The Zr-based alloy is extruded and the extruded product is subjected to cold rollings and at least one annealing, intermediate annealing, between two consecutive cold rollings and a /5-quenching prior to the last cold rolling. The improvement is that the extruded product is/3-quenched prior to a cold rolling, after the cold rolling at least one intermediate annealing is performed at a temp. of 500610~ the intermediate annealing being performed prior to a further cold rolling. G. Vesterlund, E.T. Anderson, and Santrade Ltd. Off. Gaz., 22 May 1984, Patent no. US4450016 (USA), 10 July 1981. ISSN 0360-5132.
52-1810
Basic Research on Cold R o l l i n g o f I n v o l u t e Splines and Gears. ( P a m p h l e t ) . For theoretical and practical analyses of the "Grob" profile-rolling process, which is a cold rolling process for the maufacturing of tooth-profiled products, certain simulation models were developed on the bases of computation methods pertaining to the theory of plasticity. These models help when computing the forming forces aand the stresses acting on a workpiece during the forming process. The slip-line field theory, the finite-element method and the visiopiasticity method were applied to a mathematical evaluation o1 the forming operation. A comparison of theoretically determined parameters with their corresponding experimental values (using 2024 AI and 1045 steel) proved that the assumptions made for developing the simulation models were permissible. 9 r e f . - - A A K. Lange, and N. Kurz. Metals Congress [Proc. Conf.], Detroit, Mich,, U.S.A., 16-20 Sept. 1984, American Society for Metals, Metals Park, Ohio 44073, U.S.A., 1984, Metals/Materials Tech. Series Paper No. 8409-001, Pp 9, [in English].
52-1813
Computer-Aided Roll Design and D r a f t i n g . The major features of a nonturnkey CAD/CAM system with coordinate measuring machines and its association with process data acquisition and control system in a roll design work place are described. On-line coordinate measuring machines are designed for shape measurement and analysis of rolled samples; their capabilities insure accurate prediction of metal flow and quality of finished products in combination with the process analysis by DACS and skilled designers. The steel products discussed in this system are rails, sheet pilings, wide flange beams, other sections, seamless tubes, welded pipes, wire rods, upset products and screw thread parts of oil t u b e s . - - A A H. Kozono. METEC 84 (Steel Rolling, Second International Conference) [Proc. Conf.], DUsseldorf, Federal Republic of Germany, 25-27 June 1984, Verein Deutscher EisenhiJttenleute, Postfach 82 09, D-4000 DUsseldorf 1, Federal Republic of Germany, 1984, (Met.A., 8411-72-0693) Pp 13, [in English]. D e v e l o p m e n t o f Roll Passes for S p e c i a l S t r u c t u r a l Sections Using Computer-Aided Design Techniques. A computer-based roll pass eval52-1816
uation method has been developed to simulate the hot rolling of complex structural sections and thereby reduce the number of mill trials normally required during new section development. The method, implemented on a computer-aided design/ computer-aided manufacturing (CAD/CAM) system, involves the use of incremental roll-bite opening profiles to graphically study complex metal flow from entry to exit of a roll bite. Application of the technique by Bethlehem Steel Corp. has resulted in a 30% reduction structural section development costs. 9 r e f . - - A A M.M. Vyas, and C.J. Romberger. METEC 84 (Steel Rolling, Second International Conference) [Proc. Conf.], Diisseldorf, Federal Republic of Germany, 25-27 June 1984, Verein Deutscher Eisenhiittenleute, Postfach 82 09, D-4000 DUsseldorf 1, Federal Republic of Germany, 1984, (Met.A.. 8411-72-0693) Pp 14, [in English].
52-1820
A T r i b o l o g i c a l S t u d y o f S h a p e R o l l i n g . For the systematic development of a shape rolling oil, a high-speed test mill was developed to evaluate lubricity and a small laboratory-scale hot strip test mill 1o evaluate antiwear efficiency has been constructed. Using these test mills, the lubricity and the antiwear efficiency of shape rolling oils and their components were evaluated. These components were mineral oils, fatty oils, fatty acids and phosphorus compounds. Addition effect of fatty acids and P compounds to lubricity developed on only a small number of functions and did not depend on a type of a function. Some mineral oils had a bad effect on roll w e a r . - - A A J. Kihara, K. Doya, and K. Nakamura. METEC 84 (Steel Rolling, Second International Conference) [Proc. Conf.], DUsseldorf, Federal Republic of Germany, 25-27 June 1984, Verein Deutscher Eisenh(ittenleute, P o s t f a c h 82 09, D - 4 0 0 0 DUsseldorf 1, Federal Republic of Germany, 1984, (Met.A. 8411-72-0693) Pp 9, [in English].
52-1826 A n a l y s i s o f Microstructural and Processing Parameters During H o t R o l l i n g o f High-Strength Carbon S t e e l W i r e R o d s . The relationship is analyzed between rolling conditions and austenite structure and grain size evolution for high-strength carbon steel wire rods. This is essential to improve product properties by control of rolling and cooling processes. The analysis has entailed the development of an integrated model describing austenit~ grain size evolution as a function of rolling and associated temp. conditions of stock. Results are reported of preliminary applications at a wire mill. 10 r e f . - - A A A. Mascanzoni, M. Ghersi, A. Crispoldi, B. Guerrieri, and M. Paolicchi. METEC 84 (Steel Rolling, Second International Conference) [Proc. Conf.], DUsseldorf, Fed-
VOL. 4, NO. 1, JULY 1985
61
eral Republic of Germany, 25-27 June 1984, Verein Deutscher EisenhiJttenleute, P o s t f a c h 82 09, D-4000 DUsseldorf 1, Federal Republic of Germany, 1984, (Met.A., 8411-72-0693) Pp 15, [in English].
52-1827 Controlled Rolling and Cooling Techniques for S t e e l Wire R o d - - N e w Products and Their Characteristics. Steel wire rods are usually heat treated by annealing, quench tempering and patenting after hot rolling. When these processes can be eliminated, it can result in a significant saving of energy. At Kobe Works, techniques of controlled rolling and cooling for steel wire rods have been improved. High grade Cr and C r - - V steel wire rods manufactured by the newly improved techniques have many specifications in the as-rolled condition, such as high ductility, high drawability, small deviation of tensile strength and small strain aging during cold forging. They can be drawn or worked without heat treatment.--AA A. Sannomiya, T. Oshiro, and K. Minami. METEC 84 (Steel Rolling, Second lnternational Conference) [Proc. Conf.], Dtisseldort, Federal Republic of Germany, 25-27 June 1984, V e r e i n D e u t s c h e r Eisenh(Jttenleute, P o s t f a c h 82 09, D-4000 DUsseldorf 1, Federal Republic of Germany, 1984, (Met.A, 8411-72-0693) Pp 14, [in English].
52-1828 Influence o f R o l l i n g Temperature on Microstructure and Properties o f a 0 . 1 4 C - - 0 . 8 5 C r - - 1 . 0 M n - - O . O 2 N b Case Hardening Steel. The steel was melted in an arc furnace, continuous cast to 100 x 100 mm billets and industrially and laboratory rolled at 1180-760~ The mechanical properties of as-rolled steel depend little on the rolling temp. and are independent of this temp. after normalizing. At low temp. a part of austenite remains unrecrystallized during rolling. That produces in the steel a heterogeneous as rolled microstructure with the average grain size diminishing when the rolling temp. decreases. During the rolling Nb in solution influences the recrystallization of austenite. After normalizing the average grain size is independent of the rolling temp. and the number of coarse bainite grains is increased when the temp. is lowered. 18 r e f . - - A A F. Vodopivec, D. Kmeti(~, F. Vizjak, G. Manojlovi(~, and F. Hailer. METEC 84 (Steel Rolling, Second International Conference) [Proc. Conf], DUsseldorf, Federal Republic of Germany, 25-27 June 1984, Verein Deutscher EisenhUttenleute, Postfach 82 09, D-4000 DUsseldorf 1, Federal Republic of Germany, 1984, (Met.A., 841172-0693) Pp 14, [in English]. 52-1830
Electromagnetic and Electrohydraulic Forming Processes.
Electromagnetic and electrohydraulic forming belong to the family of 'high-energy rate forming processes' (HERF), characterized by the release of a large amount of energy in a short time to deform the work metal at a speed ranging between 30 to 300 m / s . The electromagnetic and electrohydraulic forming systems with their applications are described. These are more suitable for the production of small components with good dimensional accuracy and surface finish. Significant research has been carried out on these techniques where no direct contact between the tool and the workpiece is needed. 36 r e f . - - A A T. Behera, and S. Misra. Too/Alloy Steels, Jan. 1984, 18, ( t ) , 21-24, [in English]. ISSN 0377-9408. A Report on the Investigation and Prevention o f Decarburization o f S t e e l S u r f a c e s in t h e O i l - F i r e d Soaking Furnace. 52-1831
Attainment of neutral carbon potential plays the key role in the development of appropriate methods to prevent decarburization in the soaking furnace. Decarburization preventive methods can be classified as those which prevent direct contact between decarburizing agents and C in the steel and those which decrease the activity of the decarburizing agents to a proper level so that reactions do not proceed forward at the soaking temp. Methods of decarburization prevention are presented. 7 ref.--C.M.L.S. V. Satin. Too/Alloy Steels, Feb. 1984, 18, (2), 51-53, [in English]. ISSN 0377-9408.
52-1833 Recent Advances in Hot Working: Fundamental Dynamic Softening Mechanisms. Important aspects of the fundamental mechanisms of hot working, dynamic recovery and recrystallization and their influence on alloying additions are considered. The fundamental mechanisms responsible for the low rate of strain hardening during high-temp, deformation and for a steady state of flow at high strains are confirmed to be: dynamic recovery, which limits the accumulation of dislocations through annihilations and operates at all strains in all metals, and dynamic recrystallization, which eliminates dislocations through the migration of grain boundaries and which operates beyond a critical strain when the dislocation density becomes high enough to give rise to the nucleation and growth of new grains. These softening processes are retarded by the presence of solute atoms and second-phase particles which reduce the mobility of dislocations and high-angle boundaries. As a result of the high strains imposed there is much more microstructural change than during creep loading. 143 ref.--C.M.L.S. H.J. McQueen, and J.J. Jonas. J. App/. Metalwork., July 1984, 3, (3), 233-241, [in English]. ISSN 0162-9700.
52-1834
An Assessment of Powder Metallurgy Today and Its Future
P o t e n t i a l . The present level of technology is reviewed in four areas of powder metallurgy: hot forging/forming (P/F), cold forging of sintered preforms, injection molding and sintering of metal powder/plastic mixtures and high-temp, sintering. Some historical background on the factors that have slowed the market acceptance of P / F are reviewed as a guide to understanding future growth. Several examples of current c o m m e r c i a l l y produced parts such as cams and torque converters are cited for each technical area. Mechanical properties of P / M 316L steel are presented showing the effects of high vs. normal temp. sintering. 55 ref. --AA L.F. Pease, II1. J. Appl. Metalwork., July 1984, 3, (3), 242-256, [in English]. ISSN 0162-9700.
52-1835 The Cold Upsetting and Free Surface D u c t i l i t y o f Some Commercial S t e e l s . The results of three different upsetting tests on four commercial steels (1045, 1146, 1541 and 4340) are presented. The specimen geometry is shown to have a marked effect on the free surface ductility. The so-called collar test obviates the need of a grid of lines on the free surface of the specimen
62
VOL. 4, NO. 1, JULY 1985
from which the axial, ~z, and hoop, ~,, strains are usually determined. The collar test results in reduced fracture strains vis ~ vis those achieved when compressing a circular cylinder. Consequently, fracture can be induced earlier when compressing more ductile materials. It is demonstrated that the fracture strains from the three different upsetting tests do not lie on a straight line fracture locus, as proposed by Kuhn. A knowledge of the c,-~z strain path can lead to an evaluation of the stress history on the equatorial free surface of an upset specimen. In turn, the stress history permits the assessment of various ductile fracture criteria. Two models were examined, neither of which suited all the experimental data. A max. shear stress fracture criterion appeared to be more appropriate for the present set of experiments. The deleterious effect of MnS inclusions on the fracture strains is exhibited by comparing the behavior of AISI 1045 and 1146 steels. 12 r e f . - - A A R. Sowerby, and N. Chandrasekaran. J. App/. Metalwork., July 1984, 3, (3), 257263, [in English]. ISSN 0162-9700.
52-1836
Roll Pressure Modeling of Multipass Warm R o l l i n g o f Carbon S t e e l . For various reasons, ferrous warm rolling has been considered in the last 15 years to be a potentially valuable manufacturing process. However, no systematic approach has been undertaken to assess intrinsic manufacturability as indicated by such p a r a m e t e r s as roll s e p a r a t i n g f o r c e and energy or p o w e r consumption. The purpose of this investigation is to characterize experimentally the effect of various process variables on the contact area-compensated roll separating force (separating pressure). AISI-SAE 1105 and 1059 steel billets were warm rolled at temp. between 300 and 700~ with various thickness reductions/ pass up to a short transverse strain of ~ - - 1 at a strain rate of 10 s - 1 . Two approaches were used to model in predictive fashion the influence of important warm rolling variables on the separating pressure. The first approach entailed the use of a least squares regression method to produce an empirical equation for the separating pressure. A second approach utilized a semiempirical warm working flow stress equation along with the theoretical slab method and a roll flattening concept. Good agreement was found between the experimental and predicted roll pressures. 30 r e f . - - A A E.V. Subramanian, and D.L. Bourell. J. Appl. Metalwork., July 1984, 3, (3), 264271, [in English]. ISSN 0162-9700. 52-1837 Correlation of Tensile Properties With Plane-Strain, Limiting Dome Height. While no single test can predict the formability of sheet metal under all modes of deformation, the plane-strain limiting dome height (LDHo) has been shown to correlate with material performance during stretching. However, because LDH o values are a relatively new measure of formability, and require specialized equipment to measure, such data are not commonly available. Thus it was considered desirable to determine whether a reasonable correlation exists between LDH o and tensile properties. The latter can be measured more readily or, alternatively, are routinely generated by suppliers. A comparison of LDH o and transverse tensile data from 19 steel samples, including dual-phase, AI-K and HSLA, 11 AI samples (7075, 3003, 6061), and a Zn sample demonstrated that LDH o correlates best with the total elongation. Further, all the data can be represented by a straight line whose equation is: LDHo(mm) - 10.0 + 0.508 x [total elongation (%)] with a standard error of estimate of 1.62 mm for 50.8 mm gage length specimens of ASTM E-8 configuration. Additional refinement of the goodness-of-fit through incorporation of planar anisotropy was investigated for some of the steel samples. It was found that i' (as opposed to r 0 or rgo) yielded the greatest improvement in goodness-of-fit and that a high i=was detrimental to a high LDHo value. 11 r e f . - - A A R. Stevenson. J. AppL Metalwork., July 1984, 3, (3), 272-280, [in English]. ISSN 0162-9700.
52-1838
Stretch Flanging o f " V " - S h a p e d Sheet Metal Blanks. A mathematical model of the stretch flanging of sheet metal blanks which are initially curved in the shape of a "V", is described. By assuming that all intermediate flange surfaces are developable and the effect of tool friction is negligible, the deformation in the flange is equivalent to that of an in-plane stretching operation. Strain distributions in the latter are shown to be conveniently calculated by e l a s t i c - plastic finite element analyses. To assess the applicability of~the model, an existing flanging apparatus was used to produce specimens for a variety of flange configurations with AKDQ steel, HSLA-60 steel and 2036-T4 AI. Comparison of the calculated and measured strain distributions along the free edges of these specimens show that the present model is reasonably accurate to be useful in feasibility studies of the design of sheet metal parts. 7 r e f . - - A A N.-M. Wang, L.K. Johnson, and S.C. Tang. J. AppL Metalwork., July 1984, 3, (3), 281-291, [in English]. ISSN 0162-9700. 52-1839 A Comparison of Correlations Between Press Performance and Dome Tests Results Using Two Dome Test Procedures. Two dome test procedures were compared by seeking correlation of the test results with press performance in a small hood outer panel tool set. The first procedure involves selecting the sample width in the dome test so that the critical minor strains in the panel and the dome test are matched. In the second procedure the dome test sample width which yields the min. dome height is used and that height is taken as a general measure of near-plane strain stretchability. The minihood tools were "tuned" by adjusting blank shape, blank holder load, tool radii, etc., so that a slight neck consistently occurred when a "typical" lot of 6010-T4 AI auto body sheet (ABS) was formed. The tools were then used to rate 24 lots of 6010-T4 as "good" or "bad". The correlation between the dome test results and press performance was slightly better for the second procedure (min. dome height), because lot-tovariability in the critical minor strains in the panel and the dome test caused the match to be less than perfect for the other procedure. It was concluded that the rain. point procedure is a viable test method, which is highly attractive because it does not require gridding. The effects of punch speed and lubrication on dome test results were also studied. Punch speed was found to have no effect on dry test results using the min. point procedure. Punch speed did affect lubricated test results and different alloys were found to respond to changes in punch speed differently. 9 ref.--AA J.M. Story. J. Appl. Metalwork., July 1984, 3, (3), 292-300, [in English]. ISSN 01629700.
J. APPLIED METALWORKING
Temperature Field in a H o l l o w C y l i n d e r W i t h a Moving Isothermal Boundary. (Translation: V R / 2 5 0 2 / 9 4 ) .
52-1840
M.G. Baranov, A.G. Nikitin, and S.V. Pochernyaev. Fiz. Khim. Obrab. Mater., 1983, 17, (4), Pp 4, [in English]. ISSN 0015-3214. 52-1841 T h e E f f e c t o f Thermomechanica! Treatment on the Structure and Properties o f a Maraging Stainless Steel. (Translation: V R / 1 9 2 4 / 81). V.G. Prokoshkina, L.M. Kaputkina, M.L. Bernshtein, G.S. Krivonogov, and V.A. Varganov. Heat Treatment and Physics of Metals (Termicheskaya Obrabotka i Fizika Metallov), 1979, (5), Pp 7, [in English].
52-1842 The Stress--Strain State of Metal During Rolling-Drawing. (Translation). See Met. A., 8409-52-1633. V.F. Potapkin, V.A_ Fedorinov, and A.V. Satonin. Steel USSR, Nov. 1983, 13, (11), 503, [in English]. ISSN 0038-9218.
52-1843 Combined Influence of the Deformation-Rate Parameters of Rolling During High-Temperature Thermomechanical Treatment on the S t r u c t u r e and Mechanical Properties of Steel. (Translation). See Met. A., 8409-52-1634. V.T. Zhadan, V.A. Trusov, and I.E. Oratovskaya. Steel USSR, Nov. 1983, 13, (11), 506, [in English]. ISSN 0038-9218. 52-1847 Hydrostatic Extrusion of Nonferrous Metals. Research has been carried out with an experimental hydrostatic extrusion press, type QEH 12, recently installed by the Swedish company ASEA in the Forschungsinstitut ftJr NEMetalle Freiberg to solve problems of materials and deformation engineering and to develop new technologies of producing special semiproducts from nonferrous metals. First findings from extrusion experiments carried out with 99.5% AI as a model material are reported and compared with published data. The influence of the variables on the relationship between extrusion pressure and reduction was also studied. 21 r e f . - - A A G. H~ussler, G. Schreiter, J. Schlegel, and W, Hennig. High Pressure in Science and Technology. II.--Fluids, Engineering and Safety [Prec. Conf.], Albany, N.Y., U S . A . 24-29 July 1983, Elsevier Science Publishing Co., Inc., 52 Vanderbilt Ave., New York, N.Y. 10017, US.A., 1984, (Met.A. 8411-72-0699) 299-305, [in English].
52-1848
Condie Process. The process of conventional hydrostatic extrusion limits the length of the billet that can be extrudded to a length somewhat shorter than that of the chamber. Production units are also limited to pressures of 8000 K g / c m 2. Thus, the reduction that can be affected in one pass of hydrostatic extrusion of mildly tough materials like low-carbon steels or Cu is limited to 75% R.A., if the extrusion is performed at room temp. For subsequent passes, each previous extrudate must be cut to suitable length so it will fit again into the chamber. The Condie process provides the means to perform extrusion through several dies, one die at a time, in one loading of the chamber. In the present model, only two dies are loaded into the chamber together with the billet. A short length is first extruded through the first die, while the second die is kept free to move idly with the extrudate. Then extrusion through the first die ceases and the billet is forced to extrude through the second die. 8 r e f . - - A A N. Ritter, and B. Avitzur. High Pressure in Science and Technology. IL--Fluids, Engineering and Salety [Proc. Conf.], Albany, N.Y., U.S.A., 24-29 July 1983, Elsevier Science Publishing Co., Inc., 52 Vanderbilt Ave., New York, N.Y. 10017, U.S.A., 1984, (Met.A., 8411-72-0699) 307-310, [in English]. 52-1849 Cavity Healing by Application of Hydrostatic Pressure to SuperplasUcally Formed 7 4 7 5 A l u m i n u m . Superplastic strains up to 750% have been demonstrated in 7475-AI previously subjected to thermomechanical processing to reduce the average grain dis. to < 10 /am. Formation of intergranular cavities during superplastic forming (SPF) can limit the superplastic ductility and degrade the mechanical properties of formed parts. Application of hydrostatic or background pressure during forming has been shown to reduce or eliminate cavitation. A demonstration that cavities created during SPF of 7475-AI can be healed by applying a suitable hydrostatic pressure subsequent to forming is reported. --AA P.J. Meschter, P.S. Pao, and R.J. Lederich. Scr. Metal/., Aug. 1984, 18, (8), 833836, [in English]. ISSN 0036-9748.
52-1851
Formability and Workability of Metals: Plastic Instability and
F l o w L o c a l i z a t i o n . ( B o o k ) . A monograph is presented which examines the interaction of forming conditions and intrinsic material properties. The purpose of the examination is stated as being the definition of the conditions under which it is impossible to distribute deformation uniformly during metalworking. The work also deals with the occurrence of flow localization under bulk forming conditions and flow localization in metalcutting, ballistics and geology. Numerous ref.--C.J.H. S.L. Semiatin, and J.d. Jonas. American Society for Metals, Metals Park, Ohio 44073, U.S.A. 1984, (Met.A., 8411-72-0703) Pp 299, [in English].
52-1854 The Role of Texture on the Edge Tearing of Fal~'icated Products. Tensile tests were performed on both standard and circularly waisted AI sheet specimens. The alloy used, AA8007, is characterized by a fine grain size and a strong crystallographic texture. Simple crystallographic strain analysis could qualitatively predict the neck profile after the initiation of instability. The observed directionality of collar cracks in heat exchanger fin stock correlated well with the above analysis. 15 r e f . - - A A S. Saimoto, H. Sang, and L.D. Kenny. Can. Metal/. O., Apr.-June 1984, 23, (2), 217226, [in English]. ISSN 0008-4433. 52-1855 F l o w and Fracture o f a M u l t i p h a s e Alloy MP35N for Study o f W o r k a b i l i t y . The flow and fracture of MP35N (35 Co, 35 Ni, 20 Cr, 10 Me) has been studied by uniaxial compression and plane strain bending in the temp. range 1000 to 1200~ and strain rate range 0.01 to tO s -~. This covers the normal bar
J. APPLIED METALWORKING
rolling production conditions ( ~ 1100~ and 1 to 5 s--l). The strain to fracture in plane strain bending was found to increase with increasing strain rate, roughly coinciding with the increase of the strain to the peak stress in the flow curves. Within most of the temp. and stain rate ranges investigated and under plane strain bending deformation conditions, microvoid nucleation was found to be concurrent with or greatly enhanced by the onset of dynamic recrystallization. Under these deformation conditions, flow concentration or localization along the soft layers of newly recrystallized grains oriented along the max. shear stress directions near the surface generated microvoid nucleation and damage, in effect overriding the stress relieving and crack isolation effects normally associated with the occurrence of dynamic recrystallization. As the temp. was decreased toward 1000~ and the strain rate was increased toward 10 s - 1 , an apparent transition to a microvoid nucleation mode by wedge cracking was observed, even at the max. rate of 10 s - 1 . A further decrease in deformation temp. to 9OO~ at a strain rate of 10 s - 1 , h o w ever, removed all evidence of microvoid nucleation (of the wedge type or otherwise) and any trace of dynamic recrystallization within the max. strain i m p o s e d in the plane strain bending tests. 22 r e f . - - A A G. Fitzsimons, and H.A. Kuhn. Metal/. Trans. A, Oct. 1984, 15A, (10), 1837-1847, [in English]. ISSN 0360-2133. M o d e l i n g o f Dynamic Material Behavior in H o t Deformation: Forging o f T i - 6 2 4 2 . A new method of modeling material behavior which ac-
52-1856
counts for the dynamic metallurgical processes occurring during hot deformation is presented. The approach in this method is to consider the workpiece as a dissipator of power in the total processing system and to evaluate the dissipated power co-content J ~ f~ c.da from the constitutive equation relating the strain rate (~) to the flow stress (a). The optimum processing conditions of temp. and strain rate are those corresponding to the max. or peak in J. It is shown that J is related to the strain-rate sensitivity (m) of the material and reaches a max. value (Jmax) when m = 1. The efficiency of the power dissipation (J/Jrnax.) through metallurgical processes is shown to be an index of the dynamic behavior of the material and is useful in obtaining a unique combination of temp. and stain rate for processing and also in delineating the regions of internal fracture. In this method of modeling, no a prioriknowledge or evaluation of the atomistic mechanisms is required and the method is effective even when more than one dissipation process occurs, which is particularly advantageous in the hot processing of commercial alloys having complex microstructures. This method has been applied to modeling of the behavior of Ti-6242 during hot forging. The behavior of ~ + /~ and fl preform microstructures has been examined and results show that the optimum condition for hot forging of these preforms is obtained at 9 2 7 ~ and a strain rate of 10 - 3 s-- f. Variations in the efficiency of dissipation with temp. and stain rate are correlated with the dynamic microstructural changes occurring in the material, t 6 ref.--AA Y.V.R.K. Prasad et aL Metall. Trans. A, Oct. 1984, 15A, (10), 1883-1892, [in English]. ISSN 0360-2133.
5 2 - 1 8 6 6 Low-Temperature Rolling Saves Energy in the Rolling o f W i r e and Bar. In a conventional rod mill, energy consumption is ~ 650 kWh/ton. More than 80% of that is used to heat the billets to 1150~ Reduced rolling temp. can save energy. A theoretical study of energy consumption and full-size tests carried out on medium-carbon steel showed that ~ 180 kWh/ton can be saved if rolling temp. is 750~ compared to conventional rolling. No bite problems occurred and material properties are in good agreement with Swedish standards. Low-temp. rolling of spring steel, ball bearing steel, tool steels and stainless steels showed that these steel grades can be rolled at 800-950~ without trouble. Energy savings reach 85-130 kWh/ton, 16 r e f . - - A A S.-E. Lundberg. METEC 84 (Steel Rolling, Second International Conference) [Prec. Cent.t, DUsseldorf, Federal Republic of Germany, 25-27 June 1984, Verein Deutscher EisenhiJttenleute, Postfach 82 09, D-4000 DiJsseldorf 1, Federal Republic of Germany, 1984, (Met.A, 8411-72 0693) Pp 12, [in English].
52-1867
A S t u d y on Rolling Finish of Gear (End E f f e c t s ) . In the rolling finish of gears, the tooth profile of gear is affected by the end effect at tooth tip or root. In the present study a compression test between a die roller and rectangular bars is performed at five points having different distances from the end of the test piece. The range subjected to the end effect is unaffected by the width of the test piece. The increase o! deformation due to the end effect varies almost linearly with the increase of compressive load at every loading position but independently of the width of the test piece. 3 r e f . - - A A Y. Terauchi, M. Sirashi, and T. Matsuyama. Bull. Jpn. Soc. Mech. Eng., Feb. 1984, 27, (224), 333-340, [in English]. ISSN 0021-3764.
52-1902
Expanding Skew Rolling Mill. The invention relates to expanding skew rolling mills in which working rolls are arranged around a mandrel and inclined 1o two perpendicular axes containing the mandrel axis to roll a hollow pipe over the mandrel. According to the invention, the working rolls have hyperbolic working surfaces which cooperate with the tapered section of the mandrel to define a convergent roll gap through which the pipe is driven. After the tapered section, the mandrel is formed with a further tapered section in which the taper reduces. This region allows for equalization of the pipe material, and norma|ly defines a nonconvergent roll gap. K.-H. Brensing, R. Kummerling, M. BeHmann, W. Knauf, and Mannesmann AG. 26 Apr. 1984, Patent no. GB2128120A (UK), 30 Sept. 1983. 52-1903 Producing Seamless Pipes by R o l l i n g . The invention relates to the production of thin-walled seamless pipes from solid billets wherein, a billet is heated; pierced; longitudinally roughed; expanded; sized; and cooled. The longitudinal roughing device consists of a skew rolling mill a n d / o r a plug rolling mill, normally the latter. K.-H. Brensing, R. Kummerling, O. Steinhauer, and Mannesmann AG. 26 Apr. 1984, Patent no. GB2128121A (UK), 30 Sept. 1983.
52-1904
A Tube Expanding and Grooving Tool and Method. A method and a tool for expanding and forming grooves on the inside surface of a tube are disclosed. The tool comprises an axially extending mandrel, a centering portion
VOL. 4, NO. 1, JULY 1985
63
and a grooving portion. The centering and grooving portions of the tool are both secured to the mandrel, with the grooving portion located axially rearward of the centering portion. The centering portion radially projects outward of the mandrel, and the grooving portion is coaxial with and radially projects outward of the central portion of the tool. The central portion defines a smooth annular surface to engage and partially expand the tube, to guide the tube onto the grooving portion, and to maintain the grooving portion centered within the tube. The grooving portion defines an outside surface to expand the tube further, and includes an external fin to form a groove on the inside surface of the tube. R.H. Zimmerli, A.T. Lim, and Carrier Corp. 2 May 1984, Patent no. GB2128522A (UK), 13 Sept. 1983.
52-1905
LOW Cycle Fatigue Crack Elimination for Integrally Bladed
D i s k s , Stress relief for the rim of an integrally bladed rotor made from a forging preform is provided by forming a plurality of radially extending circumferentially spaced-apart slots around the periphery of the preform. The slots are forged closed in a subsequent forming step. An oxide layer on the slot surfaces prevents the surfaces from bonding together when forged closed. The blades are formed between slots during the forging or by machining after forging. R.L. Athey, and United Technologies Corp. 13 June 1984, Patent no. GB2130927A (UK), 3 Nov. 1983. 52-1906 Sprocket Wheel for Use in Mining Machines and Conveyors. A sprocket wheel for chain driving a n d / o r guidance systems in mining machines and conveyors is forged in an alloy steel of nominal composition 0.7 to 1.0 wt.% Mn, 0.7 to 2.2 wt.% Cr, 0.3 to 0.6 wt.% Me, 0.5 to 2.2 wt.% Ni, 0.45 wt.% max. C and remainder Fe. By austenitising the forging for at least one hour at about 860~ quenching in oil and tempering if required at about 250~ its core strength is adjusted to the range 1400-1600 N/ram ~ while by subsequent surface hardening, preferably carried out inductively, a hardness of 55 to 60 Rockwell C is attained in a layer about 2 mm thick. With a pitch wide diameter D of about 100 mm and precision forging by closed-die a tolerance of 0.5 mm is possible. R. Berchem, and Berchem and S c h a b e r g GmbH. 13 June 1984, Patent no. GB2131048A (UK), 28 Nov. 1983.
52-1907 Tapered Two-Piece Metal Containers. A stepped tapered container body is produced by: (a) advancing an elongate punch axially towards a die having a co-operating die orifice defined by an appropriately shaped working surface; (b) introducing a blank of sheet metal into the path of the punch so as to be engaged at its central part by the punch, and at its outer parts by the die; and (c) causing the punch to enter the die orifice and thereby draw the outer parts of the blank over and in contact with the working die surface, wherein to form the stepped tapered side wall portion of the container body, and simultaneously therewith subjecting that surface of the blank that faces the punch to fluid (via ducts) at a high pressure sufficient to resist radially inward movement of the outer parts of the blank then being drawn over and lying in contact with the die working surface, thereby to inhibit development of longitudinally-extending wrinkles in the stepped, tapered side wall portions being formed. J.T. Franek, P, Porucznik, and Metal Box Co Ltd. 20 June 1984, Patent no. GB2131334A (UK), 31 Jan. 1983. 52-1908
Water-Soluble Metal Working Lubricants. A metal working watersoluble lubricant composition c o m p r i s e s a water-soluble polymer compound whose counter anion is acidic phosphorus-containing compound or boric acid and the water-soluble polymer compound is selected from cationic or amphoteric addition polymers, ring-opened polymers, polycondensation products and salts or quaternary ammonium salts of natural polymer derivatives, the polymers having at least one basic or cationic nitrogen atom on one molecule thereof with an average molecular weight of 1000 to 10 000 000. The composition has a load resistance equal to or higher than known liquid lubricants which contain mineral oils, beef tallow etc., and shows an excellent lubricating performance when applied to a metal working surface. H. Nagamori eta/., and KAO Corp. 20 June 1984, Patent no. GB2131449A (UK), 3 Nov. 1983. 52-1912
Fundamentals of Programmed Forging. (Translation: BlSl
2 1 9 6 4 ) . See Met. A., 8405-52-0909. H.J. Pahnke. StahlEisen, 6 June 1983, 103, ( t 1), 547-552, [in English]. ISSN 03404803.
52-1913
Mathematical Determination of Dynamic Loads on Hot Rolling
M i l l Drive Components. (Translation: BlSl 22252). See MeL A., 8407-521175. H. Gudehus. StahlEisen, 18 July 1983, 103, (14), 690-696, ]in English]. ISSN 03404803.
52-1914 Vibration Prevention of Steel Strip by the Air Cushioning Method. (Translation: BlSl 22867). See Met. A.. 8407-52-1244. Y. Shimokawa et al. Tetsu-to-Hagand (J. Iron Steel Inst. Jpn.), July 1983, 69, (9), 1167-1174, [in English]. ISSN 0021-1575.
52-1915
Production of Thin Plate by Double Reduction. (Translation:
B l S l 2 2 7 7 2 ) . See Met. A., 8407-52-1231. Zb. Ku~mifski, and K. Wilk. Wiad. Hutn., 1983, 39, (4), 98-102, [in English]. ISSN 0043-5139.
5 2 - 1 9 2 6 A Theoretical Analysis of the Bending Into Cylindrical Dies of Metal Strips. Based on experiments on the bending of metal strips into cylindrical dies using a semi-circular ended punch a theoretical analysis of this metal forming process is presented to predict the punch l o a d - - p u n c h travel characteristic and the clearance between the punch pole and the mid-point of the strip. Elastic/ plastic and rigid/plastic material idealizations are employed, and the effect of friction between the strip and the die is also considered. The theoretical predictions show good agreement with the experimental results and are useful for designers. --AA
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VOL. 4, NO. 1, JULY 1985
T.X. Yu, and W. Johnson. Prec. Inst. Mech. Eng. C, Mech. Eng. ScL, 1984, 198, (8), 99-!08, [in English]. ISSN 0263-7154.
52-1927
Stamping Rectangular Plates Into Doubly-Curved Dies.
Shallow spheroidal shell segments have been press formed from rectangular plates by stamping between a die and matching punch that have two degrees of curvature. Experiments on mild steel, Cu and AI plates that were not clamped in the die have measured the punch force, contact regions and final curvature distribution; and have observed plate buckling for a range of die curvature ratios and plate sizes. An analysis based on a rigid/plastic material idealization and decoupled inplane forces and bending moments has been correlated with these experiments. The sequence of deformation modes has been identified; initially these are bending but in later stages, in-plane forces predominate. 14 r e f . - - A A T.X. Yu, W. Johnson, and W.J. Stronge. Prec. Inst. Mech. Eng, C, Mech. Eng. Sci., 1984, 198, (8), 109-125, [in English]. ISSN 0263-7154.
52-1929 Design and Manufacture o f C o l d Roll Forming Rolls by C o m p u t e r . Following dramatic improvements in roll production costs given by a CNC lathe, Metform Engineering Ltd., acquired an additional three machines. The profiling of smaller batches of rolls was particularly advantageous, Information relating to the finished profile is fed into the computer which then calculates the profile of each individual roll in the set and also produces the necessary drawings. The computer also reduces the time and cost of feasibility studies into customer enquiries. The computer can print out stock requirements for a whole roll set. Metform has now installed a machining centre for the production of components (e.g. roll stands) used in the construction of roll forming lines.--J.M.S. B.J. Faulkner. SheetMet. Ind., June 1984, 61, (6), 318, 321,325, [in English]. ISSN 0037-3435. 52-1930
Advances in Pipe-Bending Techniques. After mentioning the main reasons why pipe is required to be bent, advances that have been made in pipe-bending technology and techniques are considered. Special reference is made to subjects such as labour-intensive production, deficient design of pipework, learning from metal cutting operations, the data centre (the 'missing link'), benefits of CNC bending and some aspects of cost effectiveness. Also suggested are some future trends.--AA H. Addison. Sheet Met. Incl., June 1984, 61, (6), 337, 339, 340, [in English]. ISSN 0037-3435. 52-1931
Tube Manipulation Today. The merits of different types of tubebending techniques, namely the mandrel-type machine, the press bender and the rotary compression bender, are compared. The advent of modern control systems has made the mandrel-type bender a more effective but also a more complicated and sophisticated machine relative to the press bender. A checklist for product designers advising them on selecting suitable bend radii, wall thickness, etc. and on avoiding 180 ~ bends, bends at tube ends, etc. is given.--J.M.S. T. Venables. Sheet Met. Ind., June 1984, 61, (6), 340-342, [in English]. ISSN 00373435. 52-1932 Tubes, Pipes, Bars and Sections--Their Manipulation and Processing. Information provided by a number of manufacturers provides a guide to the subject and various aspects of it. Descriptions are given of inspection systems (eddy-currents, ultrasonics), typical machines for tube and section manipulation, numerical control systems, tube to tube plate welding machines, section bending systems and tube manufacturing equipment. These illustrate the fact that the technologies and techniques involved in the processing and manipulation of tubes, pipes, bars and sections are closely allied.--J.M.S. Sheet Met. Ind., June 1984, 61, (6], 342-349, [in English]. ISSN 0037-3435.
52-1933 Simplified Pole Production. A new technique for the manufacture of poles for such applications as supporting overhead cables and street lights and in piling operations has been developed in Sweden. The pole is manufactured in a special rolling mill which can be used for different types of steel and AI sheet. The first mill, recently commissioned, manufactures poles from stainless steel sheet (thickness _< 1.5 mm) to give a maintenance-free product. The capacity is 2 poles/ min. The poles can incorporate punched holes to make them lighter. Poles manufactured in AI or ordinary steel sheet can be surface treated. Some aspects of cost are briefly considered.--J.M.S. Sheet Met Ind., June 1984, 61, (6), 350, [in English]. ISSN 0037-3435. 52-1934 Quality [ T u b e ] F i t t i n g s and Finishes From Coombs Wood [BSC]. Coombs Woods is essentially a jobbing plant employing some 500 workers in finishing welded tube lengths produced at the BSC's Corby works and in supplying ancillary flanges, tees, elbows, and other fittings. The products are normally in the varnished or galvanized conditions, but other surface protections are also applied and high-density polyethylene cladding is an important aspect of the plants activities The plant is the largest UK producer of fittings and supplies wroughtsteel and other components in various sizes and configurations and in compliance with releant British Standards. High- and low-pressure Victaulic, Carlton, and other proprietary joints are also produced, principally for the National Coal Board. The works are also a major supplier of street furniture such as transmission posts, sprayed-AI-protected traffic signposts, and lighting columns, details of which are given. An effective quality-assurance programme meeting the requirements of BS5750, Part 2, and British Gas, British Telecom, National Coal Board, etc., specifications is maintained.--J.R. Steel Times, June 1984, 212, (6), 247, 249, [in English]. ISSN 0039-095X. 52-1936 The Manufacture of High Quality Steel Wire Rods Using the Newly Developed Cooling Process Kobe Kakogawa Patenting. ( T r a n s l a t i o n ) . See Met, A., 8311-52-1460. A. Sannomiya, E. Takahashi, and S. Shimazu. Kobelco Tech. Bull., 1981, 1023, Pp 5, [in English].
J. APPLIED METALWORKING
5 2 - 1 9 3 7 8000 tf Precision Die Forging Press and Forging Technology for Aluminum Alloys. (Translation). See Met, A., 8303-52-0392. K. Takada, and A. Fukuda. Kobe/co Tech. Buff., 1983, 1050, Pp 5, [in English].
Rolling Doubled 6 x 6 5 (Translation). See Met. A., 8307-52-0967. 52-1938
mm Strip on the 400 M i l l .
V.P. Slednev, V.B. Chum, V.V. Boriskin, F.A. Pisarenko, and E.S. Dmitriev. Metallurgist (USSR), Jan. 1983, 27, (1), 24-26, [in English]. ISSN 0026-0894.
52-1939 Drawing Multiple-Finned (Translation). See Met. A., 8309-52-1254.
Heat-Exchanger
Tubes.
V.I. Sokolovskii, V.S. Parshin, S.V. Paryshev, G.P. Moiseev, and Yu.G. Khoroshikh. Metallurgist (USSR), Feb. 1983, 27, (2), 60-61, [in English]. ISSN 0026-0894. 52-1940
Optimum D i e - P l a t e A n g l e s in B r i g h t - D r a w i n g Steel. (Translation). See Met. A., 8309-52-1255. Yu.S. Zykov, I.A. Volkov, K.V. Sidorov, Yu.M. Pudinov, and N.A. Shchetinin. Metallurgist (USSR), Feb. 1983, 27, (2), 64-65, [in English]. ISSN 0026-0894.
Mastering the Commercial Production o f H o t - S i z e d S t e e l on the 350 Mill. (Translation). See Met. A., 8311-52-1477. 52-1941
Yu.P. Vorob'ev, and E.P. Nikolaev. Metallurgist (USSR), Apr. 1983, 27, (4), 139141, [in English]. ISSN 0026-0894.
Pressure Regulation in the Chamber of Continuous Furnaces at a 3600 Plate Mill. (Translation). See Met. A., 8405-52-0955. 52-1944
M.S. Babitskii, N.V. Goncharov, I.N. Zinchenko, V.I. Bondarenko, and P.T. Krivenko. Metallurgist (USSR), Dec. 1983, 27, (12), 412-415, [in English]. ISSN 00260894.
Deep Drawability and Recrystallization Texture o f Rephosphorized Aluminum-Killed High Strength Cold-Rolled Steel. (Translation). See Met. A., 8302-52-0275. 52-1945
T. Shimomura, S. One, K. Oskawa, and K. Matsudo. Trans. Iron Steel Inst. Jpn., Sept. 1982, 22, (9), 732-738, [in English]. ISSN 002t-1583.
Strength and Structural Changes Under High Strain-Rate H o t Deformation of Carbon S t e e l s , For high-speed continuous rolling, such as in 52-1946
wire rod mill and hot strip mill, behaviour of various carbon steels under high strain* rate hot deformation were investigated. For the purpose, a compression type hot deformation simulator of the following performance was developed: maximum strain rate, 300 s - - l ; minimum time interval between each deformation, 15 ms; and maximum strain, over 2. A high speed rolling mill was also used, and a stran rate of 800 s - ~ was obtained by this mill. A technique of two-pass rolling was also developed. Using these experimental devices, steels of 0.05 to 0.8105 C were tested in the temperature region between 800 and 1100~ The main results obtained were as follows: (1) The features of stress--strain curves did not change essentially with the increase in strain rate. The dynamic recrystallization of austenite determined the form of the curves. (2) In the simulator experiments, the maximum stress ~m, the steady state stress ,%, and the mean resistance to deformatoin kfm, were all satisfactorily described as a function of the Zener--Hollomon parameter, Z, with an activation energy of 63 800 kcla / mol and with an exponent of Z lying between 0.09-0.17. The grain diameter of recrystallized austenite also seemed to be described as a function of Z. (3) In the rolling experiments, kfm was also well described as a function of Z, as k~rn = CZ r provided that the calculated finishing temperature be taken as the temperature of deformation, kfrn and r both showing a fair agreement with those obtained from the simulator experiment. (4) The effects of successive deformation on the stress, with a short interval of 0.5 s and below, are nearly the same as those of single deformation, provided the overall strain is the same. Accordingly, the above conclusions (1) and (2) should also apply to the cases of successive deformation as a rough approximation. 13 r e f . - - A A H. Yada, N. Matsuzu, K. Nakajima, K. Watanabe, and H. Tokita. Trans. Iron Steel Inst. Jpn., Feb. 1983, 23, (2), 100-109, [in English]. ISSN 0021-1583. 52-1947 D e v e l o p m e n t o f New Processes for Control of Internal Deformation and Internal Stress in H o t Free Forging of Heavy Ingots. For developing an optimum free forging process to close and consolidate internal cavities in heavy ingots by direct forging alone, internal deformation and internal stress were investigated with plasticine models. First, a method to simulate the material behaviour with the existence of a large temperature gradient was established. The forging processes used were the following: (1) the conventional process which uses symmetrical upper and lower anvils; (2) a process called the FM process in which the upper anvil is of the usual type but the lower anvil is flat and larger than the dimension of the material to be forged; (3) a process called the FML process where the lower anvil is the same as that of the FM process and the upper anvil is smaller than the dimension of the material to be forged; (4) the so-called JTS forging process which uses the same combination of anvils as that of the FML process and is carried out with a large temperature gradient in the material. Among these processes, the conventional process can effectively cause a large deformation rate at the center and the use of wide anvils in any process is also effective for a large deformation even without a temperature gradient in the material. For attaining compressive stress, that is, a higher hydrostatic stress at the center, it is effective even without a temperature gradient to raise the value of the parameter w ! h (w: width of anvil, h: height of forging material) or to carry out unsymmetrical reductions such as that in the FM process and the FML process. A tri-axial compressive stress state is considered to be effective for closing and consolidating the central c a v i t i e s . - - A A I. Tamura, S. Watanabe, K. Watanabe, and K. Nakajima. Trans. Iron Steel Inst. Jpn., Feb. 1984, 24, (2), 101-106, [in English]. ISSN 0021-1583. 52-1948 P l a s t i c I n s t a b i l i t y o f Sheet Metals Under Simple and Complex S t r a i n P a t h s . Forming limit diagrams (FLDs) in simple and complex deformation paths are determined using a theoretical model of localized necking due to an initial heterogeneity of the sheet. The influence of the strain path upon the formability of the sheet is investigated using different types of FLDs under complex strain
J. APPLIED METALWORKING
paths. The effect of material strain hardening and strain-rate hardening is examined for several strain paths. The influence of the imperfection level on the FLDs is presented. Computer simulation of the evolution of rheological parameters during deformation and their dependence on the strain path is carried out. The model is compared with previous experimental work, and good agreement is obtained between theoretical results and experimental forming limit diagrams. The mathematical model developed in this work is shown to be a powerful tool to understand and predict the plastic behaviour of metal under simple and complex strain paths. 34 ref.--AA A. Barata da Rocha, and J.M. Jalinier. Trans. Iron Stee/Inst. Jpn., Feb. 1984, 24, (2), 132-140, [in English]. ISSN 0021-1583. 52-1951 T o r n - C o r n e r D e f e c t in B i l l e t s Rolled From Continuously C a s t Blooms, Investigations carried out into a defect involving the corners of billets rolled from continuously cast blooms, which broke open during the rolling process are summarized. As it was believed that the defect must be connected with the formation of subcutaneous blowholes in the bloom, the investigations were directed towards an understanding of the roles of the three gases involved in the process. In an extensive trial program, samples were taken from the heat at all stages of processing and from all the raw materials and alloys. The main sources of nitrogen were found to be reblows, pick-up from the alloys added to the ladle (especially graphite) and open-stream casting. The major source of hydrogen was moisture in the alloys, especially high-carbon ferromanganese and silicomanganese. Further, it was established that the moisture content of the alloys is closely related to the appearance of the defect in steels with a C content ~ 0.20%; 72% of all the defects were present in this type of steel. Most of the remaining defects were found in steels w i t h a C c o n t e n t . 0.60%, where the N content was substantially higher than in the Iower-C steels. It is suggested that the defect arises from the combined effect of O, N and H. Its occurrence in low- and high-C steels is triggered by the formation of subcutaneous blowholes when the critical O level for carbon monoxide blowholes is lowered by the presence of excessive amounts of H and N, respectively. 7 r e f . - - A A L.W. Helle, and W.F. Smith. J. S. Aft. Inst. Min. Metafl., Apr. 1984, 84, (4), 94-102, [in English]. ISSN 0038-223X. 52-1952 D e t e r m i n a t i o n o f the Constants in the Z e n e r - - H o l l o m o n Hyperbolic Equation for High-Temperature Deformation. A numerical method of determining the constants in the Z e n e r - - H o l l o m o n hyperbolic equation for high-temp, deformation is described. A characterizing temp. is introduced to normalize the Zener--Hollomon parameter. It was found that the temp. most sensitively affects the optimization condition for the least-squares estimation. Using this technique, the material constants in the constitutive equation were determined for 77 available items of experimental data for six different materials (steels, Ni-, Cu-, AI- and Zn-base alloys). The apparent activation energies for each material thus obtained differed by a factor of two between the largest and the smallest ones, but the smallest were nearly equal to those for bulk self-diffusion of the relevant materials. The characterizing temp. for these materials appeared to be in proportion to the melting temp. with an average proportional factor of 0.78. 28 ref. --AA K. Tanaka, T. Nakamura, Y. Hoshida, and S. Hara. Res Mech., 1984, 12, (1), 41-57, [in English]. ISSN 0 1 4 3 - 0 0 8 4 52-1954 Secondary Hardening Steels for Tools for Cold Deformation M e t a l s . ( T r a n s l a t i o n ) . See Met. A., 8405-52-0832. A.V Besprozvannykh, and G.A. Vorobeva. Russ. Metal/., 1983, (3), 122-125, [in English]. ISSN 0036-0295. 52-1956 I n f l u e n c e o f Material Properties on the Buckling Behavior o f Sheet Steel During Press Forming. (Pamphlet). The objective of this research program has been to develop a reproducible test method for measuring the body buckling tendency of a range of steels, identifying the important material properties and relating the results from the test to the performance on industrialtype pressings. The testpiece consisted of a conical pressing, produced from a 325 mm dia. circular blank, having an unconstrained wall region where buckling can occur in a magnitude related to the properties of the steel under test. The most meaningful measure of buckling propensity was ;;,e percentage increase in the circumferentiallength of the conical wall due to the presence of buckles. A total of 57 different steels were tested, including low-carbon A-K and rimming mild steel, rephosphorized and HSLA high-strength steel and high-strength dual-phase steel. Buckling level was found to be proportional to strength and inversely proportioned to n value and r value. The buckling response of dual-phase steel can be variable due to large variations in n value with strain. 13 r e f . - - A A A B . Haberfield, M.W. Boyles, and E.L. Morris. Commission of the European Communities, Boite Postale 1003, Luxembourg, 1984, EUR No. 8997, Pp 77, [in English]. D e v e l o p m e n t o f Steels for the Fastener and Cold Forging Markets by Testing Under Fastener Production Conditions. (Pamphlet). 52-1958
A commercial cold heading machine has been instrumented to monitor the punch forces and displacement. Single and two-blow upsetting tests have been developed. This has allowed a direct assessment of the cold forging formability and ductility of several materials under different conditions. The effect of surface defects in cold upsetting was erratic. Further examination led to the conclusion that surface defects do not act as stress raisers in cold heading and the concept of a limiting defect depth for all materials is meaningless. However, it was shown that the surface strain path could vary significantly during cold heading. Therefore, surface defects may act as strain discontinuities and alter the strain path. The performance of spheroidized low c a r b o n - - b o r o n cold heading steels was improved by wire drawing to a cold reduction of ~ 45%, in agreement with the expected torsional ductility of the material, but it had no correlation with the lensile ductility. Energy curve determinations showed that the yield strength of cold heading steels was not represented by the 0.2% proof stress values. Heading tests on various alloying additions showed that small Cr additions do not change the failure rate. Since Cr influences the carbide morphology, it was argued that small Cr additions may allow the development of an 'as-rolled' cold head steel. The failures involved
VOL. 4, NO. 1, JULY 1985
65
in upsetting were interpreted by a thermally-aided shear instability criterion. 28 ref.--AA A.F. Turner, C.S. Betteridge, and J. Avery. Commission of the European Communities, Boite Postale 1003, Luxembourg, 1984, EUR No. 8998, Pp 133, [in English].
D J . Williams, and E. Appleton International Machine Tool Conference [Proc. ConL], Birmingham, England, 26-28 June 1984, IFS (Conferences) Ltd., 35-39 High St., Kempston, Bedford, England, 1984, (Met.A., 8412-72-0738) 319-336, [in English].
52-1960
52-1974 Flexibly Automated Production in Closed Die Forging and Ring R o l l i n g . Wide ranges of different forgings in small-run jobs demand versatil-
Relation Between Limiting Drawing Ratio and Plastic Strain
R a t i o . Theoretical aspects of the relationship between the limiting drawing ratio and the plastic strain ratio are discussed. An expression for the limiting drawing ratio (LDR) is derived by using a generalization of Hills' yield criterion. Good agreement between calculated values of the R-LDR relation and experimental data for cubic and hexagonal metals (mild steel, Cu, AI, brass) was obtained. 8 ref. --G.P.K. D.N. Lee. J. Mater, Sci. Left., Aug. 1984, 3, (8), 677-680, [in English]. ISSN 02618028.
52-1963 Distortion in Field Bends of Large-Diameter Pipeline Pipe and the Relationship to Regulatory Standards. The field bending history of largedia. pipeline (X60 and X70 steels) is reviewed and the strain distribution measured on 42 in. dia. pipe is reported and related to the current regulatory standards. T h e assumption in industry is that these standards are based on calculations which asaurae that there are strains due to bending that are produced by relatively uniform compressive and tensile strains. It was found that these strains vary by a factor of at least four when measured in the field. Suggestions for further study and a revised approach to regulatory requirements are presented, 12 r e f . - - A A A. Palynchuk. International Conference on Pipeline Inspection [Prec. Conf.], Edmonton, Alberta, Canada, June 1983, CANMET, Energy, Mines and Resources Canada, 555 Booth St., Ottawa, Ont., Canada K1A 0G1, 1984, (Met.A., 8412-720728) 395-411, [in English].
52-1964
Product Redesign Achieves Weight Savings in Forged Parts.
The German firm. Franz Mayer GmbH (Plettenberg), installed a high-speed mechanical forging press (Maxipres from National Machinery Co., Tiffin, Ohio). The press has a powered adjustment of shut height which permits closer tolerances and provides for flange redesign to achieve weight savings. A sketch of the hydraulic wedge-adjusting system is provided and details of the press and the manufacturing adjustments for the lighter weight flange are described.--J.J.P. T.J. Drozda. Manuf. Eng., S e p t 1984, 93, (3), 1OO-102, [in English]. ISSN 03610853.
52-1966
Water-Based Metalworking Lubricants. Today's water-based metalworking lubricants, referred to also as cutting or grinding fluids, are far different from those considered to be the ultimate in performance only ten years ago. They are complex solutions or emulsions of agents designed to minimize friction and remove heat; to protect against corrosion; to keep the solution stable; to lubricate and reduce surface tension; to provide extreme-pressure lubrication; to control growth of bacteria; and to protect the environment in which operators must work. Synthetic, or chemical, cutting fluids contain no mineral oil. Instead, they rely on water-soluble compounds for lubricity. Semisynthetic fluids contain some mineral oil in addition to chemical additives. Water-based cutting fluids and the various agents that are compounded into their concentrates are discussed. 24 ref. --AA R.P. Hunz. Lubr. Eng, Sept. 1984, 40, (9), 549-553, [in English]. ISSN 0024-7154. 52-1967 Lubrication in the Manufacturing of Drawn and Ironed Aluminum Cans. The role of lubrication to the draw and iron process for the manufacturing of A l t w o - p i e c e cans is e x a m i n e d The development of a unique lubricant. s p e c i f i c a l l y f o r m u l a t e d for the d r a w and iron p r o c e s s , is detailed. Characteristics of oil-base and synthetic-base lubricants and their lubrication compatibility with metal, tools, equipment and each other are discuased. 9 ref. --AA J . E Knepp. Lubr. Eng., Sept. 1984, 40, (9), 554-560, [in English]. ISSN 0024-7154.
52-1970 A Model for the Hot or Warm Forming of Metals With Special Use of Deformation Mechanism Maps. A finite element model is described for analyzing metal flow and heating during large deformation processes such as hot rolling. Particle thermomechanical histories are evaluated relative to the spatial coordinates of the computational domain. The stress and temp. histories are compared to deformation mechanism maps to determine the consistency of constitutive equation assumptions. 35 r e f . - - A A P R . Dawson. Int. J. Mech. Sci., 1984, 26, (4), 227-244, [in English]. ISSN 00207403.
52-1971 Rate E f f e c t s in S t e a d y Forming P r o c e s s e s of Plastic Materials. Drawing and extrusion processes of v i s c o p l a s t i c solids through wedge-shaped and conical dies are analyzed. Radial velocity profiles and small deviations from the uniform flow field, are assumed within the working zone. Material behavior is governed by the Bingham solid model. Explicit expressions for the stress field within the working zone are derived. The results are restricted to long and tapered dies. An optimum die angle exists where the driving stress attains a min. The dependence of that angle on wall friction, Bingham number and geometrical reduction is analyzed in detail The validity of the analysis is supported upon comparison with existing analytical and experimental investigations. 10 r e f . - - A A D. Durban. Int. J. Mech. Sci., 1984, 26, (4), 293-304, [in English]. ISSN 0020-7403.
52-1973 Developments in Metalforming--an Overview. Recent developments in metalforming are reviewed. The advances considered to be most significant to the future application of metalforming processes in manufacturing industry are discussed. These are examined in three particular areas of superplastic lorming, isothermal forging and rubber pad forming. The first is the application of new technologies to tools for metalforming processes, followed by consideration of the impact of new control techniques on the metalforming industry in process control and process and factory automation and recent developments in process understanding and in novel metalforming processes and materials that are reaching the marketplace. 104 r e f . - - A A
66
VOL. a, NO. 1, JULY 1985
ity and flexibility of competitive production plants including short change-over times with frequently varying programs. This has to be accomplished in a differenl way with regard to mechanization and automation as compared to high-volume production. This should include on-line heat treatment and quality control. Saving of energy and reduction of waste material are two other major objections. Plant layouts show versatile closed die forging lines which can produce one forging in a number of different steps or can be split up into several independent units producing different forgings simultaneously. The possibilities in forging annular parts are highlighted by closed die forging, by use of a preforming ring mill and by ring rolling. Rolling of crown wheels, roller bearing races, flanges and jet engine rings in dia. from 150 to 1500 mm and grades ranging from carbon steels to superalloys are discussed.--AA H-J. Marczinski. International Machine Tool Conference [Proc. ConL], Birmingham, England, 26-28 June 1984, IFS (Conferences) Ltd., 35-39 High St., Kempston, Bedford, England, 1984, (Met.A. 8412-72-0738) 379-391, [in English]
52-1975
To Make a Better S t e e l . A description is given of a rotary forge facility in t h e U . S This forge, one of only three in the world, can accept ingots u p t o 251/2 in. in dia. weighing as much as 17 600 lb. It has a product capacity of 10 tons/h. Over-all, rotary forging allows for much higher productivity and a more precise, metallurgically sound product with the uniformity and consistency often not achievable with conventional forging. The primary applications are for the difficult-to-forge superalloys and high-speed s t e e l s . - - D . O . N H. Marshall Mod. Mach. Shop, Sept. 1984, 57, (4), 90-98, [in English]. ISSN 00268003. 5 2 - 1 9 7 7 Update on High Horsepower Conditioning Systems. Proposed Standards and Comparisons. The problems encountered in evaluating the costs and performance of high horsepower steel conditioning systems are discussed. The large number of variables that can make valid comparisons difficult are recognized. After proposing standard equations for describing effective condi tioning techniques, the standards are used to evaluate the cost effectiveness of high horsepower bloom conditioning in a hypothetical analysis. The conclusion is drawn that technology permits lower-cost high speed conditioning using high OPhorsepower.--AA R.F. Obear. Abrasive Eng Soc Mag., Summer 1984, 6-11, [in English].
52-1978
Horsepower Influence in Conditioning Grinders. Through the use of low horsepower (HP) grinders, in combination with oplim=zed conditioning parameters, the conditioning costs in European steel mills have been reduced by 9 40%. Close tolerances on grinding depth allow for yield losses in 0 2 - 0 3 % range when spot grinding carbon steel billets. Programed spot grinding allows accurate defect removal with min y i e l d l o s s . - - A A A. Wahlander Abrasive Eng. Soc Mag., Summer 1984, 12-14, [in English]. 52-1980 Future Shock for Pipe Fabrication'?. Capacitor discharge shock treatment exemplifies the innovative technology needed to modernize the pipe industry to meet more cost-effeclive foreign competition. The need for innovation to survive is stressed. Potential metalforming applications of capacitor discharge, long utilized elsewhere, are described, predicting 70-80% cost reduction.--J V.R. J. Gillanders. Fabricator, S e p t 1984, 14, (6), 20-21, [in English]. ISSN 0 1 9 2 - 8 0 6 6 52-1981 Body Construction Techniques. Steel F o r m i n g . New materials. designs and technology continuously necessitate new automotive body construetion techniques. Designing to combat vibration, facilitate manufacture, overcome springback from substituting higher strength steel and for reinforcing are discussed. Press brakes, plunge forming, hot pressing, high-strength steel forming, boxing-in side frames and weld bonding are described. Sheet pressing and drawing covers computerization, press types, tool development and high-strength steel problems. Cargo vehicle construction trends are o u t l i n e d - - J . V . R . M Jacobsen. Automot. Eng. (UK). Aug-Sept. 1984, 9, (4), 42-45. 48-51, [in English]. ISSN 0307-6490. 52-1983 T i - 1 5 - 3 Foil: Properties and Applications. Ti-15-3 is a new all-~ alloy capable of economical production as foil. The cold rolling behavior of Ti-153 and its aging response are discussed. A preliminary cost comparison with T i - 6 A I - - 4 V foil is made. Certain a p p l i c a t i o n s and potential a p p l i c a t i o n s are discussed.-- AA A.G, Hicks, and HW. Rosenberg. Beta Titanium Alloys in the 1980's [Prec. Conf], Atlanta, Ga., U S A . , 8 Mar. 1983, The Metallurgical Society/AIME. 420 Commonwealth Dr., Warrendale, Pa. 15086, U.S.A., 1984, (Met.A., 8412-72-0744) 231237, [in English] 52-1984
Isothermal Forging of Beta and Near-Beta Titanium Alloys. Hot die/isothermal forging technology of ~ and near-p' Ti alloys, such as T i - - t 0 V - 2 F e - - 3 A I and Transage 175 ( 1 3 V - - 7 S n - - 2 Z r - - 2 . 5 A I ) , has emerged rapidly and offers both the forger and the forging user unique advantages in Ti alloy forging applications. Beta and near-by' Ti alloys are more amenable to net and near-net forging shape fabrication than current (~-~5alloys due to their lower forging temp. and flow stresses. These alloys are also submittable to thermomechanical processing (TMP) to achieve excellent combinations of properties with ultimate strengths from 965 to t 3 t 0 MPa. Hot die/isothermal forging of fl and near-fl Ti alloys provides a degree of sophistication and control in TMP processing not achievable in conventional die forging. Hot die/isothermal forging technology for net and nearnet shape fabrication and processing-property relationships achieved in hot die/ isothermal forging and TMP of such alloys are reviewed. 9 r e f . - - A A G.W. Kuhlman, R. Pishko, J.R. Kahrs, and J.W. Nelson. Beta Titanium Alloys in the 1980's [Proc. ConL], Atlanta, Ga., U.S.A., 8 Mar. 1983, The Metallurgical Society/
J. APPLIED METALWORKING
AIME, 420 Commonwealth Dr., Warrendale, Pa. 15086, U S.A., 1984, (Met.A, 8412-72-0744) 255-280, [in English].
AIME, 410 Commonwealth Drive, Warrendale, PA 15086, U.S.A., 1983, (Met.A, 8412-72-0765) 498-509, [in English].
52-1985 Cold Forming Titanium 15-3 A l l o y . Fabrication techniques currently used for Ti usually entail elevated-temp, forming with high associated facility, tooling and processing requirements and costs. Development of a metastable ~'t alloy T i - - 1 5 V - - 3 C r - - 3 A I - - 3 S n , which has attractive structural properties and which is formable at room temp. allows production cost reduction and utilization of available equipment.--AA A Shames, M. Rosenblum, and W.B. Treple Beta Titanium Alloys in the 1980's ]Prec. Cent], Atlanta, Ga., U.S.A., 8 Mar. 1983, The Metallurgical Society/AIME, 420 Commonwealth Dr., Warrendale, Pa. 15086. U.S.A., 1984, (Met.A., 8412-720744) 307-329, ]in English].
52-2002
62-1986
Formed T i - - 1 5 V - - 3 C r - - 3 A I - - 3 S n Tankage. The development of low-cost Ti aerospace lankage is described, accomplished through the use of formed Ti-15-3tank shell elements. A major reduction ( 4 50%) in the cost of Ti tankage for aerospace systems is expected to result. This technology takes advantage of the excellent formability of the ~ Ti-15-3 Ti alloy, developed under U.S. Air Force sponsorship, to draw-form tank shells in conventional press equipment. It will replace the traditional machined T i - - 6 A I - - 4 V forgings used for these tanks ,n the past, which are expected to become prohibitively expensive for the larger tanks required in the future. Bell Aerospace Textron, under contract to the U.S. Air Force Rocket Propulsion Laboratory, has fabricated complete tanks of formed Ti15-3 hemispheres and has completed a test program which verified that their structura~ integrity was equivalent, or superior, to the same tank design fabricateo from the T i - - 6 A I - - 4 V alloy. Cost studies have confirmed that major cost reductions are possible. Propellant exposure tests over a 12 month period indicate compatibility with commonly used aerospace propellants.--AA AE. L e a c h Beta Titanium Alloys in the 1980's[Proc. ConL], Atlanta, Ga.,U.S.A., 8 Mar 1983, The Metallurgical Society/AIME, 420 Commonwealth Dr., Warrendale, Pa. 15086, U . S A . 1984, (MetAl, 8412-72-0744) 331-347, [in English]. 52-1992
The Production of Stainless Steel Spinnings in the UK. Manual
spinning is an old established metal working technique and has been applied to stainless steel for many years for the production of relatively shallow cylindrical, conica~ or h e m i s p h e r i c a l c o m p o n e n t s . Power s p i n n i n g - - a more r e c e n t development--requires the use of a hydraulically powered tool and the operation is faster and more easily controlled than manual spinning. This article briefly describes spinning techniques for stainless steel and gives details of the UK companies engaged in this p r o c e s s . - - A A Stainless Steel Ind., July 1984, 12, (68), 8- tO, [in English]. ISSN 0306-2988.
52-1993
Texture and Cleavage in Molybdenum. It is of considerable technological importance to establish how far textures introduced into controlledrolled steels by finish rolling at low temperatures may affect the fracture strength. The purely textural effect is difficult to isolate in such steels because of anisotropy associated with grain shape, inclusions and pearlite banding Consequently, an investigation was carr,ed out using Me, a b.c.c, single phase material showing good structural homogeneity, as a model. Texture development was studied using crystallite orientation distribution function analysis to identify a suitable processing route leading to a sharp texture with a suitable distribution of 1100} cleavage planes. The behaviour of a sharply textured specimen was analysed by taking fracture specimens from various orientations in the plate. The energy absorbed in impact showed a positive correlation with the density of 100 planes in the crack direction, but the extent of the variation was less than would have been expected had crack propagation been the controlling step in the fracture process 26 ref. --AA PI. Welch, and G.J Davies Textures Mtcrostruct, Oct. 1983.6, (1), 21-37, [in English]. ISSN 0730-3300 52-1994 Deformation and Recrystallisation Textures of Polycrystalline Nickel, The development has been analysed of the primary recrystallisation texlure in samples of polycrystalline Ni rolled to various degrees of reduction. A great similarity between the texture characteristics of Cu and Ni has been found. Regularities Of cube texture development were established and compared with results of texture and microstructure investigations obtained by other authors 20 ref. --AA J. Pospiech, J Jura, A MLicklich, K. Pawlik, and M. Betzl. Textures Microstruct., Oct. 1983, 6, (1), 63-79, [in English]. ISSN 0730-3300.
52-1995
Investigation on Direct Cooling in Drawing Steel Wire. The de-
formation of metals is accompanied by an increase of temperature which leads to a change in their mechanical properties depending on the level and duration of temperature A rise in temperature of about 300~ and an action time of less than 1 s is usually causes a change in strength and ductility. For this reason many methods of cooling have been used for a tong time especially in wire drawing. The methods range from direct block cooling to a new system of direct wire cooling, applied immediately after drawing, developed by Y Nakamura (Wire. J., I976, 9 . 5 9 ) . - - A A O. Paweiski, and R. Keuper. Wire Ind, June 1984, 51, (606), 465-468, 473, [in English]. ISSN 0043-6011.
52-2001 Effects of Non-metallic Inclusions on the Quality of Tyre Cords. The presence of undeformable non-metallic inclusions in very fine wire exerts an adverse effect on the quality characteristics of that wire, particularly with respect to die life, breakage frequency and fatigue life. To improve these aspects it was found that the non-metallic inclusion index must be kept below 20. In order to achieve this not only must the size and number of undeformable inclusions be reduced but these undeformable inclusions must also be replaced by deformable inclusions. The Capped Argon Bubbling (CAB) process is described and found to be quite effective in eliminating non-metallic inclusiOnS. The non-metallic inclusions obtained by this process are mostly manganese sulphide or rhodonite (MnSiO2) which are d e f o r m a b l e . - - B G . M . T Sate, M Murakami, a n d H Sato. M e c h a n i c a l W o r k i n g a n d S t e e I P r o c e s s i n g XX ]Prec. Conf], Houston, Texas, U.S.A., 27-29 Oct 1982, Iron and Steel Society of
J. APPLIED METALWORKING
Improved Lubrication for Cold R o l l i n g . Customer demand for more difficult to roll steel gauges and chemistries has made cold rolling mills explore ways In maintain and improve productivity and quality in order to remain competitive in today's steel marketplace. Roll suppliers and lubricant suppliers must be evaluating changes in technology that can help the cold mill operator meet this demand. Nalco Chemical Company has developed a lubricant package that combines a new lubricating molecule with a unique emulsifier package, resulting in a dramatic improvement in cold rolling performance. This paper reviews the role that lubricants play in cold reduction, describes features and technology of the recent development, and presents some mill data that highlights the success of the technology--AA C.S. Kennedy. Mechanical Working and Sfee~ Processing XX ]Prec. ConL], Houston, Texas, U.S.A., 27-29 Oct. 1982, Iron and Steel Society of AIME, 410 Commonwealth Drive, Warrendale, PA 15086, U.S.A., 1983, (Met.A., 8412-72-0765) 224232, [in English]. 52-2003 M e a s u r e m e n t of Residual Stress State in Rolls. Residual stresses, inherent in the manufacture of a roll, can significantly influence mill performance. Therefore, the measurement of the magnitude of these stresses is of considerable interest to both roll manufacturers and users. This paper discusses methods of measurement of residual stresses in rolls. An X-ray technique for forged steel rolls and a center-hole drilling method using air-abrasive drilling for cast rolis are described 7 r e f . - - A A P.J. Horvath, and J.M. Chillon. Mechanical Working and Steel Processing XX ]Prec. ConL], Houston, Texas, U.S.A., 27-29 Oct. 1982, Iron and Steel Society of AIME, 410 Commonwealth Drive, Warrendale, PA 15086, U.S.A., 1983, (Met.A., 8412-72-0765) 233-250, [in English].
52-2005 R e s i s t a n c e to D e f o r m a t i o n in the E x p e r i m e n t a l a n d Production Rolling of Superalloy Plate. This study was undertaken to determine efficient rolling procedures for seven types of materials including superalIoys. stainless steels, and a titanium alloy. This was accomplished by determining the relative resistance to deformation in hot rolling for each material over a temp. range. Qualitatively, the alloy with the most resistance to deformation of the alloys tested is Inconel 625 followed by Hasfelloy C-276, Hastelloy X, Hastelloy G, Haynes Alloy No. 20, stainless 904L, and T i - - 6 A I - - 4 V . The mean yield stress in hot plane homogeneous compression is experimentally determined from data recorded during rolling. Regression analysis is used to develop equations to relate mean yield stress and temp. The effects of strain rate and strain state on the results is reviewed, which leads to a comparison of experimental rolling mill data with production rolling mill data and elevated temp. strength t e s t s . - - A A M.W. Nichols. Mechanical Working and Steel Processing XX ]Prec. ConL], Houston, Texas, U S A . , 27-29 Oct. 1982, Iron and Steel Society of AIME, 410 Commonwealth Drive, Warrendale, PA 15086, U.S.A., 1983, (Met.A., 8412-72-0765) 343357, [in English].
52-2007 Systems to Measure, Weigh and Mark Tubular Products, Fully automatic systems are described for measuring and weighing tubes, for stencilling, stamping and color band coding, and for preparing bundle tags, work order tallies, shipping documents and tracking reports. Although particularly useful in finishing lines, certain components of these systems are also used in the milling process.--AA B. Ocampo. Mechanical Working and Steel Processing XX ]Prec. ConL]. Houston, Texas, U S.A., 27-29 Oct 1982, Iron and Steel Society of AIME, 410 Commonwealth Drive, Warrendale, PA 15086, U.S.A., 1983, (Met.A, 8412-72-0765) 413428, [in English]. S2-2009
Microalloyed Hot Roiled Bars for Hot Forging Applications.
Energy conservation and cost savings can be realized by elimination of the heat treatment of forgings by the use of hot rolled microalloyed steel bars. 8 r e f . - - A A J.H Bucher. Specialty Steels and Hard Materials ]Prec. ConL], Pretoria, South Africa, 8-12 Nov. 1982, Pergamon Press, Headington Hill Hall, Oxford OX3 0BW, England, 1983, (Met.A, 8412-72-0780] 201-205, [in English].
S2-2010 Data Sheet: a N o m o g r a m for Calculation of Pressures for Cold Forward Extrusion of Short Steel Tubes. A summary is presented of the data sheet published by the International Cold Forging Group. This gives a method of determining the maximum extrusion pressure for cold forward extrusion of short tubes, both as an empirical formula and as a nomogram.--T W. W. Thompson Met. Australas., Mar. 1984, 16, (2), 10-11, [in English]. ISSN 00476897.
52-2013 The Continuous Car T y p e Furnace (CCT Furnace), a N e w Continuous Reheating F u r n a c e for Roiling Mills and Forge Plants. A new furnace concept is described by means of which blooms, slabs and billets can be reheated up to 1280~ at a specific heat consumption of 1175 k J / k g . Some 30 m long and heated with natural gas and air preheated to approx. 5 3 0 ~ the feature of the design is the furnace hearth which consists of individual cars with ceramic benches. The cars form a chain within the furnace, replacing the conventional furnace bottom. Lifting and lowering platforms are situated at either end of the furnace and one additional car is in a waling position under the unheated heat retaining hood in the under floor return tunnel. The ceramic benches eliminate the use of a water cooled transportation system. The stock is loaded onto a steel finger grid whilst the car at the other end of the furnace is being unloaded by the discharge machine. The empty car is lifted by the platform under the finger'grid, and the load transferred. A pusher then pushes this car into the furnace, the unloaded car being thus pushed from the furnace onto the lowering platform, which then removes it into the tunnel. Thus the charge is loaded into the furnace one car at a time and one car is always available for reloading. As the stock does not move during its passage through the furnace it is claimed that the amount of scale removed from the charge in minimal - - J . W
VOL. 4, N O . l, JULY 1985
67
H. Patalon. Metall. Plant TechnoL, 1984, 7, (3). 140, 144, [in English]. ISSN 01714511.
52-2014
Fine Solutions for B l a n k e d Components. The use of microalloyed high tensile fine-grain steels offers new possibilities for fine blanking. Mechanical properties and blanking behaviour are compared for hot rolled strip in UQ380 (O. 15% C, 0.11% St, 0 8 9 % Mn, 0.01% P, 0.016% S, 0.061% AI, 0.16% Ti) and a mild steel (St 50-2). Parts made from UQ380 were free from tears. Further studies wilh cold rolled fine grain steel UQ560 (0.14% C, 0.1 I % Si, 0.05% Mn, 0.010% P, O 0 1 8 % S, 0.03% AI, 0.14% Ti) showed again that sample pressings were entirely free from tears after fine blanking. Mechanical properties and microstructures are presented and discussed. Severe work hardening during fine blanking gives a high hardness, so that subsequent heat treatment is not necessary --C.J.E. F. Birzer. Metalwork. Prod., Aug. 1984, 12B, (8). 34-35, 39, [in English]. ISSN 00261033. 52-2015
New Process for Super Elastic N i - - T i Alloy. Furukawa Electric has developed a new cold working method to manufacture super elastic Ni--Ti alloy by heat treating the worked-alloy between 400-500~ No other details are given.--B.C. New Mater./Jpn., 1983, 1, (1), 8, [in English]. 52-2017 An Innovative Processing Technique. A briel overview of the new metal processing technique, named Clustercoil, is presented. Metal coils slit by the Clustercoil process are not completely slit into separate strips. Instead, an array of specially notched rotary knives slits the foil into two or more multiples, at the same time leaving tiny connections at uniform intervals along the length of the coil. When the metal is recoiled onto the rewinder, the individual rolls or multipls are still joined but ready to be broken off one at a time. The special features of Clustercoil machine, which are quite different from conventional slitting machines, are briefly described and the sequence of operation is illustrated. The improvements claimed for the process are listed. Clustercoil slitting can be used for C steel, stainless steel, AI, Cu, brass and Ti. The ways in which the process can benefit the coil coating industry are examined.--J.M.S. Sheet Met. Ind., July 1984, 61, (7), 366-386, [in English]. ISSN 0037-3435. 52-2018 speeds(eg
P r o c e s s i n g Lines for M e t a l Strips. With higher processing 1 0 0 0 f t / m i n ) the attachment of a new coil at the end of the preceeding one can still take 3 min and existing expensive equipment is inadequate. A 'spiral looper' has been developed which is a transient strip accumulator of variable capacity (entry and exit speeds independently controllable from 0 to max.). The strip is stored in the form of two adjacent coaxial coils (either with a vertical or a horizontal axis). The two spiral coils are of opposite hand (right and left) and their inner consolutions are joined together so that the two coils form one continuous length of strip material. Enormous quantities of strip can be stored, so there is more than sufficient time for welding coils together.--J.M.S. T. Sendzimir, and M.G. Sendzimer. Sheet Met. Ind., July 1984, 61, (7), 393, [in English]. ISSN 0037-3435. 52-2019 The Application of Forming Limit Curves in Cup Drawing. The limitations of simulative drawability tests and sheet metal formability prediction from fundamental mate, ial properties has led to a continuing reliance on empirical methods assisted in recent years by the lorming limit curve (FLC) approach. The deformation occurring during cup drawing can be presented lo advantage using the triangular co-ordinate system originated by Hsu and the limitations of simulative tests are thereby illustrated. The FLC and trial draw deformation patterns in triangular co-ordinates have been used to solve an industrial cup drawing problem 13 r e f . - - A A T.C. Lee, W.B. Lee, and C.D Irving. Sheet M e t Ind, July 1984, 61, (7), 410-412, [in English]. ISSN 0037-3435. 52-2035
The Influence of Cold-Working on the Damping Capacity of
A I - - Z n A l l o y s . Effect of cold-working on the damping capacity of furnace-cooled or water-quenched A I - - Z n alloys with 0-100% Zn was studied by varying the reduction in area. Measurements of the logarithmic decrement ~ and the rigidity modulus G were carried out by the inverted torsion pendulum method at a frequency of 1 H z The hardness Hv and the specific weight S were measured by a microVickers hardness tester and by the Archimedean method, respectively Except for the water-quenched alloys with 70-90% Zn, the heat-treated alleys have generafly a low value of h. The magnitude of ~ in the alloys subjected to the heat-treatmenl should be attributable to the viscous flow at the grain-boundary between the hard <~ and the soft fl phases. Upon cold-working, the ~ of any alloys, especially alloys with 50-70% Zn, considerably increases with reduction in area. The increase in fi must be mainly due to the increased boundary effect resulting from grain refinement. The hardness of the alloys with 10-70% Zn water-quenched from 673K is considerably higher than that of the furnace-cooled alloys. On the other hand, the furnace-cooled alloys with 80-90% Zn show a Hv value higher than the waterquenched ones. With approach to the eutectoid composition, the Hv value after cold-working decreases. The alloys water-quenched from 573K or furnace-cooled from 573 and 673K increase in G with Zn content, while those after waterquenching from 673K yield a minimum value at 50% Zn. The G value after coldworking is nearly constant up to 40% Zn and increases rapidly with Zn content above 40%, regardless of the prior heat-treatment. The S increases with Zn conlent, but its value is generally as small as 4.8 M g / m 3 even for the A I - - 7 0 % Zn alloy. 27 r e f . - - A A H. Masumoto, M. Hinai, and S Sawaya. Trans. Jpn. Inst. Met., Oct. 1983, 24, (10). 681-688, [in English]. ISSN 0021-4434.
52-2037
Controlling Vibrations During Fine Wire Processing. During processing of fine Cu or AI wire, the wire will be moving in its axial direction as for instance in the drawing machine, the continuous annealer and in the spooling unit Typical wire drawing (axial) speeds used in modern fine wire drawing machines during production of wire will be 40-50 m/s. On its way through the production equipment the wire will be passing along the periphery of numerous capstans and
68
VOL. 4, NO. 1, JULY 1985
pulleys and through numerous dies where the wire cross-sectional area is reduced to make the wire thinner. Finally the wire passes lhrough the annealer and is accumulated on a reel in the spooler. 13 r e f . - - A A H. Olsen, and H. Valberg. Wire Ind., Mar. 1984, 51, (603), 187-189, [in English]. ISSN 0043-6011.
52-2038
Rolling of S h a p e s Using Large Drafts. Rolling of bars and shapes is carried oul at average elongations of ~ = 1.3-1.4 or even less. The draft which produces this elongation is usually below ~n = 0.4. The draft acts, first of all, in forming the cross-section of a bar, but rarely in elongating or as breaking down. This occurs at preliminary material processing or as a preparation for shapes. In the breaking down passes smaller drafts are used, in the elongating passes drafts reach ~n = 0.5. An increase of drafts in the shaping roll passes would shorten the rolling cycle and lower production c o s t s . - - A A J. Mazurkiewicz, E Waleczek, and N. Nalepa. Wire Ind., July 1984, 51, (607), 521523, [in English]. ISSN 0 0 4 3 - 6 0 1 1 52-2039 The Influence of Ingot Quality on the Quality of Seamless Tubes. (Translation: BISI 2 3 0 4 4 ) . See M e t A , 8409-52-1646, W. Kubinski et al. Hutnik (Katowice), Sept. 1983, 50, (9), 309-313, [in English]. ISSN 0019-5669.
52-2040 The Upsetting of Flanges W h e n Rolling Beams in Rolling Trains With Universal Rolling Mill Stands. (Translation: BISI 2 2 9 0 4 ) . See Met. A., 6307-52-0934 J. Chvostek, and V. Vasicek. Hutn. Listy, Feb. 1983, 38, (2), 88-92, [in English] ISSN 0018-8069.
52-2044 E f f e c t o f Rolling Conditions on Bonding Behaviour in Cold Clad Rolling by Planetary Mills. (Translation: BISI 2 2 3 6 1 ) . See M e t A , 8408-52-1361 T. Shirota, and T. Dendo. J Jpn. Soc. Technol. Plast., May 1983, 24, (268), 480485, [in English]. ISSN 0038-1586.
52-2046 Use of Process C o m p u t e r for the Control of Thickened Ends in Stretch Reducing Mills. (Translation: BISI 2 2 9 1 2 ) . See Met A, 8404-520815. L. Hunger. StahlEisen, 1 Nov. 1982, 102, (22), 1115- 1120, [in English] ISSN 03404803.
52-2047 Investigations on Strip Flatness in a Tension-Flex Levelling Machine. (Translation: BISI 2 2 5 5 8 ) . See Met A , 8408-52-1454 H. Thies et al. Stahl Eisen, 24 Oct. 1983, 103, (21), 1073-1078, [in English]. ISSN 0340-4803
52-2056
Electrical Upsetting Method. A method of electrical upsetting the ends of cylindrical metal workpieces is disclosed in which a clearance is provided between the anvil electrode and the inner peripheral surface of the shaping die so that wear to the shaping die resulting from high temperature oxidation can be avoided by supply 1o the clearance of an inert gas before, during and after the upsetting operation The workpiece is pushed into the die against the anvil electrode. currenl passes from the anvil through the workpiece to generate heat. and the workpiece is upset to conform to the die as the anvil electrode retracts towards the end of the die. T Nihei, T Maki, K. Sakuma, and Honda Giken Kogyo. 1 Aug 1984, Patent no. GB2133727A (UK), 20 Nov 1981 52-2059 Continuous Extrusion of Metals. A continuous extrusion machine has a rotating wheel with a peripheral groove which defines an arcuate passageway with a cooperating shoe The pressure in the metal in front of an abutment continuously extrudes a metal product through a die. The abutment tip and adlacent wheel parts are cooled directly by a i e t of cooling fluid (e.g water) issuing from a nozzle carried on the shoe. Flash extruded through clearance gaps between cooperating wheel and shoe surfaces is intercepted and broken off in short lengths by teeth proiecting from the wheel. The radial depth of the passageway progressively decreases near the abutment so as to improve the metal flow pattern adjacent to the abutment in the case of particulate or comminuted f e e d s t o c k A system automatically controls the tension in the metal product where it is subsequently threaded and drawn through another die so as to change its cross-section, whereby to prevent the tension in the extrusion product exceeding a safe value below the yield stress tension for the particular temperalure at which the extusion product leaves the extrusion d i e J. East, l. Maxwell, and MetaI Box Co Ltd. 15 Aug 1984, Patent no GB2134428A (UK), 12 Apr. 1983. 52-2060 A Method o f W i d e n i n g a F l a t Metallurgical Product. The invention relates to a method of widening, by rolling, a flat product, consisting of introducing it at an angle of incidence of I/ ~" 0 to a line normal to the roll axis into a roiling mill of the planetary of pendulum type, which has a rolling reduction such that only one of the operating cylinders, which are situated on the same side of the product, is in contact with it Between cylinders the product is realigned to compensate for lateral shift. F Boulin, and Cegedur Sociele de Transformation de rAluminfum Pechiney 30 Aug. 1984, Palent no. GB2135224A (UK), 14 F e b 1984. 52-2062
Method for the Manufacture of Metal Products. The method for manufacturing metal products by means of plastic deformation provides for forming a metal layer on the surface of a stock in order to facilitate its deformation, and the plastic deformation is effected through pressure shaping. The material to be used in order to form the said layer is characterized by superptastic properties at a temperature lower than the melting point of the stock material and forms a separating (lubricating) layer between the contacting surfaces of the workpiece and shaping tool. The treatment is effected at a temperature and at a rate of deforma-
J. APPLIED METALWORKING
tion which are appropriate to the superplastic state acquired by the coating layer material. For cold plastic deformation, the coating layer material comprises (in w1.%) Zn 35-76, Ni 0 , 5 - 2 l, balance Cd; for extrusion at deformation temperatures from 20 1o 300~ it consists of Zn 70-98 and AI 2-30; while for extrusion at deformation temperatures of 400 to 700~ it comprises Cu 30-62 and Zn 38-50. N.P. Barykin et aL. and Ufimsky Aviatsionny [nstitut Imeni Ordzhonikidze. 5 Sept. 1984, Patent n o GB2135617A(UK). 27 May 1983,
52-2063
Sheet Metal P a l l e t s . A sheet metal workpiece e.g. of low-carbon steel is formed Io have a plurality of relatively large diameter but relatively shallow cup like depressions in a first draw operation, to have the shapes of the cup-like depressions changed in a subsequent draw operation and to form the base of the central cup-like depression into a secondary cup-like depression in a further draw operation to form a pallet R J Dunk, and Precision Tool and Gauge Ply Ltd (Australia). 19 Sept. 1984, Patent n o GB2136336A (UK), 12 Mar. 1984.
monwealth Dr., Warrendale, Pa., 15086, U.S.A., 1984, (Met.A, 8801-72-0013) 2332, [in English].
52-0038 Development of Udimet 7 2 0 for High-Strength Disk Applications. Udimet 720 is a cast-wrought Ni-base superalloy which was originally used for land-based gas turbine blades. Work is being done to develop this alloy for high-strength disk applications. Hot tensile tests were performed to define temp. and strain rate parameters for conventional, hot die and superplastic forging, This information was used to select forging parameters for disk-type pancakes. Heat treatmenls were developed to produce mechanical properties suitable for disks. Microslruclure and hot tensile properties are reported for various heat treatments. Tensile and stress rupture properties of U720 compare favorably 1o high-strength P / M disk alloys. The production of fine-grained U720 billet by use of the VADER (vacuum arc double electrode remelt) process offers the potential 1o produce large disks from a cast-wrought high-strength superalloy. 7 r e f . - - A A F . E Sczerzenie, and G.E. Maurer. Superalloys 1984 [Prec. ConL], Champion, Pa., U.S.A., 7-11 Oct. 1984, The Metallurgical Society/AIME, 420 Commonwealth Dr., Warrendale, Pa., 15086, US.A., 1984, (Met.A., 8501-72-0013) 573-582, [in English].
52-2091 Hot Rolling .Process for Metal Powder Strip. The production of strip metal from metal powder feedstock provides a process route with savings in capital and operating costs. The common method of production is described and compared with a new and alternative method where green powder rolled strip is sintered using glow discharge electron beam (GDEB) heating. The process has been developed by the Electricity Council's Capenhurst Research Centre in Chester in conjunction with Davy McKee (Sheffield) Ltd. When a high voltage is applied to a special electrode in a moderate vacuum a glow discharge is formed and causes the eleclrode system to generate a beam of electrons Any kind of workpiece passing through 1he beam is heated by electron bombardment. The prototype has been used successfully 1o produce stainless steel strip from powder and the equipment can be used for a wide range of metals and alloys - - C . J M Met Powder Rep., Aug. 1983, 38, (8), 452-453, [in English]. ISSN 0026-0657.
Forming Strip and Wire. The forming of metal strip and wire parts by multiple-slide units and spring toilers is reviewed. Multiple-slide machines can form light-gage strip at less cost/part, require less space and allow easier maintenance of t o o l i n g A description of the basic process and mechanical devices of multiple-slide units and spring coilers is presented and advantages/limitations are discussed. A list of equipment manufacturers is included. Metals used for flat and coiled springs are: carbon steels, C r - - V , C r - - S i , austenitic stainless steels, Inconels 600, 625, 718 and X750, phosphor bronzes, beryllium bronzes, Monels 400 and K500 and some grades of brass.--G.P.K. Am. Much., Oct. 1984, 128, (10), 103-114, {in English] ISSN 0002-9858.
52-0005 Augmented Roll Forming Lines Create Ready-to-Assemble Parts. Steel products of augmented roll forming lines are reviewed Topics dis-
52-0043 New Approaches Improve High-Speed Metal Stamping. Methods of improving high-speed metal stamping operations are discussed. Top-
cussed are a "T" shaped grid element, automotive sunroofs, file drawer bodies, special purpose shelving panels, bumper jack columns, baseboard heaters and development of flexible fabrication for multiple shapes from one line. Advanced electronic controls and cost effectiveness are discussed.--C.M.L.S. Mod Met, Sept. 1984, 40, (8), 46, 48-49, 52, 54, [in English]. ISSN 0026-8127.
52-0014
Forming Technology--a Design Parameter for the Eighties. In auto body design, it may be possible to use forming operations in the design process to selectively develop material strength to meet load, deflection and permanent set performance requirements. The original study emphasis was on dualphase s t e e l particularly for buckling sensitive components. Hat-shaped sections of mild and HSLA steels, including those with beaded surfaces, were loaded in four-point bending Load deflection results showed that weight reduction can be achieved through geometry modifications and also by coordinating manufacturing processes with design requirements. The bend-and-straighten forming operation provides significantly more useful material strength in the final component than would be anticipated Conclusions concerning load capability, yield strength, act u a l v s theoretical stillness and effect of beads are emphasized. Sketches of test specimens and graphs of results are provided.--J.J.P. M.T. Vecchio. Body Eng., Spring 1984, 12. (1), 15-16, 18-20, [in English] 52-0021 Deformation of Nonmetallic Inclusions During Steel Rolling. (Translation). See Met A., 8 4 0 5 - 5 2 - 0 8 7 6 G I Belchenko, and S I ISSN 0036-0295
Gubenko Russ
Metall, 1983, (4), 66-69, {in English].
52-0022 E f f e c t o f Cold Working and Annealing on the Structure o f a Decarburized Low-Carbon Steel. (Translation). See Met A, 8405-52-0833. V I Movchan. and N A Grudneva. Russ. MetalL, 1983, (4). 70 73. [in EnglishL kSSN 0036-0295
52-0023 Trajectories of Cracks in Fields of High Plastic Deformation. (Translation). See Met A, 8410-52 1758 N.A Chelyshev, V . Y a Lylus. and G A Chervov SteelUSSR, D e c 1983, 13, (12), 554-555, [in English] ISSN 0038-9218.
52~
Observations on the Manufacture of Steel Cartridge Cases.
The forces required for forming cartridge cases of hardening steel ( 9 0.3% carbon) are very high with corresponding effect on the machinery required, the tools are more highly stressed, special equipment is required for heat treatment, hardening and tempering, the hardened cases undergo distortion (especially inside the bottom of the case) and must be reworked to achieve the close tolerances re quired A l [ o f t h e s e factors increase the manufacturing costs. Instead of prescribing hardened steel cartridge c a s e s for certain t y p e s of highly s t r e s s e d ammunition, the cold forming concept should be properly investigated with conclusive tests - - J H B E Brodner Armada Int. July-Aug, 1984, 8, (4), 231-233, [in English}.
52-0037
Microcast-X Fine-Grain C a s t i n g - - a Progress Report.
Microcasl-X =s a new casting process which produces a uniformly fine-grain-size material (ASTM 3-5). The process, currently in development by Howmet Turbine Components Corp,, has been successfully demonstrated with components ranging from forging preforms up 1o 500 Ib to turbine disks, blades and vanes The finegrain size leads to improved uniformity in properties, chemistry and precipitate morphology compared lo conventionally cast or VAR materials, Initial forging trials have been conducted by Wyman-Gordon and clearly demonstrate the excellent forgeability of Microcasl-X products in comparison with conventionally cast forms. Hot die and isothermal forgings have been produced with flat dies in one and two steps with upsets up to 80% without cracking. Alloys thus far screened include Ren~ 95, MERL 76, IN 718 and C I 0 3 . - - A A J.R. Brinegar, L.F. Norris, and L. Rozenberg. Superalloys 1984 [Prec. ConL], Champion, Pa., U.S.A., 7 11 Oct. 1984, The Metallurgical Society/AIME, 420 Corn-
J. APPLIED METALWORKING
52-0040
ics considered include press speed, press feed systems, equipment reliability and manpower costs. Manufacturing techniques described include progressive die and transfer die operations --G.P.K D Boerger, and D Hemmelgarn Fabricator, Oct. 1984, 14, (7), 16-18, [in English]. ISSN 0192-8066.
52-0046
Warm Forging. I.--Advantages and Limitations. Warm forging is a forming operation in which the billet is preheated before deformation and the process conditions are such that some work hardening of the product is achieved. Major benefits of warm forging over hot forging are energy savings, close tolerances, elimination of cleaning to remove surface oxides, elimination of the machining envelope and decrease in labor, tooling and capital investment costs. The warm forge letup, can be varied to achieve the amount of work hardening required. The process encourages automation and leads to productivity increases. Warm forging requires increased attention to almost every area of manufacturing operations. Post-forging handling may have to be upgraded.--J.H.B. O Novelli, andR,J Shipley Precis. Met., Oct. 1984, 4 2 , ( 1 0 ) , 17-18, [in English). ISSN 0032-714X. 52-0048 The Application of C u - - B e - - N i - - Z r Alloys for Sparkless Tool Production. After homogenization, ingots of Be-5 alloy (patented alloy) are hot extruded in the form of plates and rods. These semiproducts are used for hand tool production. Depending on size, form and other characteristics, the plates and rods are cold or hot forged (die or free forging) and heat t r e a t e d The finished tools are regularly tested for hardness, momentum and safety. The hardness ranges from 230 to 330 HV and momentum is equal to that required for steel tools. --AA A Mihallovic, and Z. Kovacevi6. Pr. Inst. Met. Niezelaz, 1981, 10, (4), 174-176, [in English]. ISSN 0 1 3 7 - 5 8 9 X
52-0052 The Concept and the Theoretical Fundamentals of a New Combined Process of Rolling and Extrusion. C f ibid, p 321. In the past decade a series of conlinuous extrusion processes has been developed, including the poorly understood Extrolling-process, which may be considered as a combined rolling and extrusion technique. An analysis of the combined process of rolling and extrusion has assumed specified phases and zones occurring in this process which are crucial in the distribution of unit pressures and the magnitude of total pressure of metal on the rolls. A simplified theoretical analysis was carried out and has allowed the distribution of unit pressures to be described by relationships developed, as well as the total pressure of metal on the die and on the rolls. The distribution of unit pressures to be described and the magnitude of total pressure on the rolls depend on the flow yield stress of metal being extruded and on the geometrical parameters of the deformation region, and to an equal extent on the extrusion stress of metal extruded through the die. 19 r e f . - - A A R. Grzyb, and Z. MisioJek, Arch Hutn., 1983, 28, (3), 305-319, [in English). ISSN 0004-0770.
52-0053 The Experimental Investigations on the Force Parameters and Metal Flow in the Combined Process of Rolling and Extrusion. C f ibid., p 305. In this paper the results are discussed and an analysis of experimental investigations on the combined process of roiling and extrusion is carried out. The distribution el unit pressures and total pressures of melal on the rolls has been experimentally established. These pressures are dependent On such process parameters as the length of contact arc projection Id, the diameter of product being extruded d and on the distance between the die and the roll axis plane The stress of extruding metal through the groove closing die may be described with considerable accuracy for the isothermal process run by an empirical relationship a~ = ap (A,/J=. + B), where A and B depend on specified process parameters..The argument that the magnitude of the total elongation factor in this process is dependent on the maximum values of pressures on the die a m and is higher the larger are the length of contact arc projection Iu and lhe ratio of roll radius R to the groove area b x h~ was experimentally verified.--AA R. Grzyb, and Z. Misio}ek. Arch. Hutn,, 1983, 28, (3), 321-340, [in English]. ISSN 0004-0770.
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69
52-OO64 C o m p u t e r Modelling of Hot Working P r o c e s s e s . The development at Sheffield of process modelling is traced. Initially this was concerned with predicting temp. distributions generated during hot extrusion and hot rolling operations, but the principles of finite difference modelling have also been applied to upset forging and compression testing. Separately, the modelling of microstructural evolution during multi-pass working operations from the basis of laboratory test data was developed. These two aspects-have been combined and the effects of microstructure, temp. and other engineering variables on flow stress have been incorporated to produce a model of hot rolling which predicts microstructural changes at each stage of the process and takes account of their effects on rolling loads and power requirements. 25 r e f . - - A A C.M. Sellars. Perspectives in Metallurgical Development [Prec. Conf.], Sheffield, England, 16-18 July 1984, The Metals Society, 1 Carlton House Terrace, London SW1Y 5DB, England, 1984, (Met.A., 8501-72-0044) 209-217, [in English].
tortes in 1971 to the present, at which time it has established itself as having many industrial applications in the extrusion of solid and hollow sections from many nonferrous metals, in rod or particulate form, together with the potential for extruding direct from molten metal. Consideration is given to energy-saving aspects, especially when extruding from particulated metals, not only as an alternative to conventional press extrusion from billets, but also as an extension to powdermetallurgical technology. Of particular relevance is the application of Conform to the reclamation both of prime metal waste from manufacturing operations and of used scrap. Irretrievable disposal and remelting to ingot and billet for subsequent fabrication are taken as the bases for assessing the energy savings attainable by integrating Conform with various pretreatments. 10 r e f . - - A A J.A. Pardoe. Met. Technol., Aug. 1984, I 1, (8), 358-365, [in English]. ISSN 03071893.
52-0160
52-0074 Hot D e f o r m a t i o n and D y n a m i c R e c r y s t a l l i z a U o n of A I - 5 M g - - O . 8 M n Alloy. The AA 5083 alloy was deformed in torsion in the ranges 300-500~ and 0.1-1s - 1 to a strain of 5. The flow stress as a function of strain rose to a maximum value then gradually decreased towards a steady state and had a dependence on temperature and strain rate of the traditional form with an activation energy higher than that for pure AI. Optical microstructures of specimens quenched after working ranged from elongated grains at 3 0 0 ~ to recrystallized grains at 500~ Transmission electron microscope subgrain structures from all conditions of working were more recovered at higher temperatures and lower strain rates. The subgrain diameters are smaller than those in commercial AI mainly as a result of the increased density of particles and this is in agreement with observations in extrusions. Since the degree of recovery is not substantially less than in commerical AI, one is led to confirm the theory that the dynamic recrystallization is caused by particles of . 0 6 ,urn. 45 r e f . - - A A H.J. McQueen, E. Evangelista, J. Bowles, and G. Crawford. Met. ScL, Aug. 1984, 18, (8), 395-402, [in English]. ISSN 0306-3453.
52-0085 Formation of Ridging Related to the B a n d e d Segregation Pattern of C h r o m i u m and Carbon on Ferritic Stainless Steel Sheet. Ridging phenomenon is a surface defect undesirable for deep drawing applications of ferritic stainless steels. A stripe pattern is frequently observed parallel to the rolling direction and appears as narrow banded areas when the strip or sheet of these steels is severely e t c h e d In the present paper, correlation of the ridging and the stripe pattern is discussed, and the origin of the stripe pattern was examined in 18% Cr stainless steel sheet. It is shown that there is a close resemblance between the stripe pattern and the ridging in terms of the periodicity, the directional characteristics, and the nature of the macro- and microscopic structural compound. The stripe pattern has its origin in the hot rolling stage when partition of Cr and C in<~ and-,( phase proceeds. Debris of 3, particles is retained with deplelion of Cr in the elongated form in the final product. Local variation of Cr content resuits in the development of the stripe pattern. 20 r e f . - - A A K. Suzuki, S. Asami, and K. Suzuki. Trans Iron Steellnst. Jpn., Sept. 1983, 23, (9), 731-737, [in English]. ISSN 0021-1583
52-0086 A n a l y s i s of R e s i d u a l S t r e s s (Translation). See M e t A., 8402-52-0266.
in Hot R o l l e d
H-Beams.
H. Yoshida, T. Sasaki, N. Kondo, T. Tanaka, and T. Hashimoto. Trans. Iron Steel Inst. Jpn., May 1984, 24, (5), 401-407, [in English]. ISSN 0021-1583.
52-O109 System for Heating Metal Dies by L o w - F r e q u e n c y Magnetic Induction. A new system developed by Naito Electric Co. Ltd. is designed to heat extrusion moulding dies for AI products to the optimum extrusion temp. as quickly as possible. It consists of the die holding mechanism, induction coil, air compression cylinder for moving electrodes up and down, and a hydraulic cylinder. The die ring is heated by low-frequency magnetic induction and the dies part directly by passage of electricity. It is claimed that dies are heated uniformly and quickly, with reduced heating costs compared with conventional furnaces. Thermal efficiency is improved to 94%, initial capital cost is lower, and maintenance easy. The system can be incorporated in a production line --E.J.S. Jpn. Incl. Technol. Bull., Apr. t984, 12, (1), 14, [in English]. ISSN 0385-8542.
52-01 10
High-Speed Bar and Band Steel Corrugating Machine. A highspeed 'Lattice Machine' marketed b y U e n i s h i T e k k o C o Ltd. is designed to corrugate into fixed dimensions steel materials such as round bars, square bars, and flat band steel up to several metres long in ~ 10s. The workpiece is conveyed to the centre of the machine, where the gate type upper mechanism if lifted by action of a hydraulic cylinder. Several arms linked together at a fixed spacing grasp the workpiece, enablingit to be corrugated Corrugation shape is determined b y s e t ting the number of arms in linkage and the stroke of the hydraulic cylinder. Workpieces up to 19 mm z sectional area and 5500 mm long can be treated. Manual or automatic operation is possible and the links can be changed e a s i l y . - - E J.S. Jpn. Ind. TechnoL Bull., Apr. 1984, 12. (1), 14-15, [in English]. ISSN 0385-6542. 52-0111 Variety of Quality Materials Produced by Hot Hydrostatic Pressure Extrusion. Kobe Steel Ltd employ a unique hot hydrostatic pressure extrusion process in which metallic materials are pressurized in the periphery of billets heated to 1200~ via a visco-ptastic pressurizing medium. Structural materials can be rapidly processed by the action of the billet's uniform deformation and surface reduction effects. Advantages claimed are production of composite materials with uniform metal compound ratio and excellent metallurgical bonding over entire lengths, powder metallurgy products with high density and homogeneity, and productoin of high quality grooved pipes, sections, and other parts. Typical applications are N i - - C u alloy pipes for heat exchangers, phosphor bronze pipes for quality bearings, T i - - C u clad conduction rods for diaphragm type electrolysis systems, and superconducting w i r e s . - - E J . S . Jpn. Ind. TechnoL BulL, A p t 1984, 12. (1), 23-24, [in English]. ISSN 0385-6542.
52-0142 C o n f o r m Continuous Extrusion P r o c e s s - - I t s Contribution to Energy Conservation. The introduction includes a brief resume of the development of the Conform process, from its invention at the UKAEA Springfields Labora-
70
VOL. 4, NO. 1, JULY 1985
How the Micro Can Help Sheet Metal D e s i g n e r s . - - X . Basic computer program computes the dimensions required to construct a pattern for a breeches piece between two branches of equal dia. and a main pipe of the same or different dia. Data required are: outside dimensions for the dia., distance from the branch centre to the joint line, height of the breeches piece, and metal thickness.--D.E.J. A. Ashlon. Weld. Met. Fabr., July-Aug. 1984, 52, (6), 248, [in English] tSSN 00432245. 52-0161
Metal Forming Lubricant and Method of Use Thereof. A composition for use as a lubricant in metal forming operations using black plate steel comprises in wt.% 2.5 to 3.75 % terpene phenolic resin, 0.3 to 2.5% esterified styrene maleic abhydride, 2.5 to 3.75% synthetic polymethylene wax, 0.3 to 2.0% unsaturated fatty acid, 0.3 1o 2.0% amines, 0.05 1o 0.5% potassium hydroxide, 24.0 to 32.0% of a compound comprising an anion from Group Vlb of the Periodic Table and a cation selected from Group Via, 8.5 to 11.5% synthetic wax emulsion and the remainder distilled water. The above composition is useful in the formation of twopiece cans from a black plate steel blank which is drawn and ironed to produce an elongated can b o d y The composition is applied, prior to the drawing, to the portion of the black plate steel which becomes the exterior of the can body. D.J. Sargent, and E / M Lubricants Ltd. 17 Oct. 1984, Patent no. GB213802A (UK), 21 June 1982. 52-0162
Manufacturing Seamless Steel Pipe. A seamless steel pipe having a particularly fine grain structure is produced using steel of the following composition: 0.02-0.12% carbon, 1.3-2 2% manganese, 0.001-0.01% sulphur, 0.010.04% titanium, 0.02-0.06% niobium, 0 . 0 0 3 - 0 0 0 8 % nitrogen, 0.03-0.05% aluminiurn, the remainder being Fe, unavoidable impurities and individually or in any combination with themselves or the iron: upto 0.3% molybdenum, upto 0 5 % nickel, 0.001-0.003% boron The production method comprises heating a rolled or continuously cast rod to a drawing lemperature of 1150 to 1220~ pre-forming in one or more production stages to a hollow body with substantially the finished wall thickness; reheating the body for 5 to 20 min. at 700 to 850~ longitudinal rolling to the finished pipe dimensions; and subsequent cooling. M. Graf, l. VonHagen, D. Vespermann. andMannesmannAG tOOct. 1984, Patent no. GB2137539A (UK), 27 Mar. 1984. 52-0163 Expanding Tubes in Tube Plates. A one-stage method of (and apparatus for) expanding small metal tubes (less than 50 mm in outside diameters) into holes in metal tubeplates including walls of drums and headers (eg. condensers) is disclosed It uses elastomeric body compressed axially in the tube and which expands radially to expand the tube and to stress the tube and the annular zone of the tubeplate around the tube beyond their respective elastic limits substantially throughout the axial distance equal to the axial separation of the axially outermost limits of annular supports arranged about end protions of the elastomeric body. The supports each comprise an annular array of pieces bonded to the elastomeric body. The pieces separate uniformly 1o transmit substanlailly uniform pressure to the tube Typically, tubes of brass, cupronickel or ferritic stainless steel can be expanded into, e.g. mild steel, by this method. C.A. Herrod, and Northern Engineering Industries PIc (UK). 30 Aug. 1984, Patent no. GB2135223A (UK), 9 Feb. 1984 52-0166 F u n d a m e n t a l s o f P r o g r a m m e d Forging. (Translation). See Met. A , 8405-52-0909 H J Pahnke Metall. Plant TechnoL, 1983, 6, (5), 92-101, [in English] ISSN 0171451 t
52-0180
Control of Steel Chemistry for Producing Deep Drawing Cold
Rolled Steel Sheets by Continuous Annealing. The influence of carbon content in both low- and extra-low-carbon steels on producing deep drawing cold rolled steel sheets by continuous annealing is discussed. Steel containing 0.0150.035% C, which can be produced by a bottom blown converter without degassing, is desired to obtain the good formability and good aging resistance that results from a larger grain size. Recent steelmaking technology has progressed to produce extra-low-C steels with C .. 0.003% by using a bottom blown converter and a reformed RH degasser. Using this new IF steel with Nb or Ti, deep drawing cold rolled steel sheets with excellent formability have been produced. Deep drawable high-strength steel can be produced by the addition of phosphorus. Bake hardenability can also be achieved by the dissolution of NbC at high soaking temp. 9 r e f --AA T. Obara, S. Satoh, M. Nishida, and T. Irie. Scand. J. Metal/., 1984, 13, (4), 201213, [in English] ISSN0371-0459.
52-0189 Cold Formed Parts Yield Impressive Cost Benefits. Rising materials costs and the need for repetitive high-quality provide the impetus for innovation in small cold formed parts and special fasteners. The introduction of automated assembly systems is an example. By combining three basic forming t e c h n i q u e s - - u p s e t t i n g , forward e x t r u s i o n and backward e x t r u s i o n - manufacturers can eliminate many separate metalforming operations The cold forming operations and the characteristics of the common materials (carbon steels, Cr steels, Me steels, stainless steels, Cr alloys, Ni alloys) are outlined.
J. APPLIED METALWORKING
Benefits of cold forming, its economics, design guidelines and tolerances are discussed. Cold forming becomes extremely versatile when combined with secondary operations, which are outlined.--S.K.B. ManuL Eng., Nov. 1984, 93, (5), 43-48, [in English]. ISSN 0361-0853.
52-0191 Influence of Nonlinear Strain Paths on the Forming L i m i t Diagrams of a D e e p - D r a w i n g Quality Steel and a Dual-Phase Steel. Forming limit diagrams were determined experimentally for a deep-drawing quality steel (SS 1147) and a dual-phase steel (DP580) with a tensile strength of 580 MPa. Conventional straight strain paths and strain paths consisting of two linear segments were studied. The primary deformation stage, when two stages were utilized, was either uniaxial tension or equibiaxial stretching. Significant increments in the forming limit could be obtained for final states of deformation close to plane strain by first drawing (uniaxial tension) and then stretching biaxially instead of using a single straight strain path. To understand the behavior of the forming limit diagram the flow properties and the strain rate sensitivity were measured during monotonic loading and loading with composite strain paths. These data and other information on the behavior of materials, like anisotropy of plasticity, particle contents and void growth at particles, were used in a model of the forming limit diagram The theory could reproduce experimental results in a satisfactory way and was used to predict forming limit diagrams for cases which were not studied experimentally. 18 r e f . - - A A A. Metander, and E. Schedin. HSLA Steels, Technology and Applications [Proc. ConL], Philadelphia, Pa., U.S.A., 3-6 Oct. 1983, American Society for Metals, Metals Park, Ohio 44073, U.S.A., 1984, (Met.A., 8502-72-0072) 223-237, [in English].
52-0192 Mechanical-Forming Properties and the Microstructures of Direct Off the Rolling Mill Processed Dual-Phase Steels. In processing lowcarbon dual-phase steel grades directly off the hot rolling mill a wide range of strength levels can be developed by metallurgical and thermornechanical processes acting in combination. Several ingots with a chemical analysis ranging from 0.05-0.06% carbon, 0.03-1.45% St, 1.59-2.40% Mn, 0.48-0.87% Cr and 0.0030% max. boron were processed to hot bands in thicknesses ranging from 2.3 to 4.3 mm either using a normal finishing temp. just above Ar 3 or by finishing in the (~ + ~) region with reductions of 23 and 59%. The analysis of the mechanical properties has revealed that small variations in hardenability of the steel or processing significantly alters both the texture and the microstructure of t h e dualphase steel grades through the banding of the martensitic--bainitic constituent. Of the processing parameters finishing temp. just above Ar 3 and coiling temp. 560~ are required for obtaining dual-phase steels with 8 0 / 2 0 ferrite martensire structure directly from the rolling heat. 18 r e f . - - A A C.M. Vlad, G. Ahrndt, and K. Hulka. HSLA Steels, Technology and Applications [Proc. Conf.], Philadelphia, Pa., U.S.A., 3-8 Oct. 1983, American Society for Metals, Metals Park, Ohio 44073, U.S.A., 1984, (Met.A., 8502-72-0072) 329-339, [in English].
52-0193
Roll Forming HSLA Steels. Roll forming of HSLA steels is discussed, with emphasis on bending radius, springback and material flow. S t r e s s - strain diagrams showing discontinuous and continuous yield points, the undesirable effects of residual stresses in roll formed materials and the relative strength, cost and potential weight saving of various cold-rolled sheet steels (AISI 1010, 40X0 and 60XK) are discussed. Typical products utilizing roll formed HSLA steels include automotive and aircraft components, railway rolling stock and military equipment. 18 ref.--J.A.M. G.T. Halmos. HSLA Steels, Technology and Applications [Proc. ConL], Philadelphia, Pa., U.S.A., 3-6 Oct. 1983, American Society for Metals, Metals Park, Ohio 44073, U.S.A., 1984, (Met.A., 8502-72-0072) 515-522, [in English]. 52-0194 Automotive Application of Ultra-High-Strength Sheet S t e e l . Thin, ultra-high-strength sheet steels have been designed into systems typically reserved for high-strength low-alloy steels and AI, resulting in significant automobile mass reduction. Bumper impact bars and associated brackets and fascia supports are currently produced from 1300 MPa tensile strength steel 9 1 mm thick. Use of a material with such high strength and limited ductility requires that designs incorporate generous bend radii and a rain. of stretching. Roll forming has proven to be an efficient, reliable process for cold working ultra-high*strength sheet steel. The corrosion protection required by thin-gage sheet steel has been achieved by painting finished assemblies in a Cathodic E-Coat system. Other corrosion coatings are available, including an electrogalvanized finish and a Zn-rich primer.--AA J.C. Kopchick. HSLA Steels, Technology and Applications [Proc. Conf.], Philadelphia, P a , U . S . A . , 3 - 6 O c t 1983, American Society for Metals, Metals Park, Ohio 44073, U.S A , 1984, (Met.A, 8502-72-0072) 523-530, [in English]. Induction Bending o f X Grade Line Pipe Steel for Arctic S e r v i c e . The induction bending process has been successfully used to make production bends in high-strength, large-o.d., heavy-wall Arctic-grade line pipe. This accomplishment followed years of development to arrive at the proper combination of line pipe properties and bending parameters. The proper pipe chemistry must be present to maintain the desired low-temp, toughness of these X-grade pipes after the thermomechanical processing of induction bending. The extensive mechanical testing performed on various line pipes which led to this conclusion is described. Microstructural changes affecting material toughness are also discussed. A problem is described involving embrittlement of the line pipe by Cu present as contamination on the pipe surface. This resulted in cracks on the outer bend dia. during production. Methods to circumvent this liquid metal embrittlement are discussed. Guidelines which will help to insure a successful bend operation of high-strength Arctic-grade line pipe are included. 9 r e f . - - A A CD. Youngren, and R.L. Hipley. HSLA Steels, Technology and Applications [Proc. ConL], Philadelphia, Pa., U.S.A., 3-6 Oct. 1983, American Society for Metals, Metals Park, Ohio 44073, U.S.A., 1984, (Met.A., 8502-72-0072) 855-863, [in English]
respectively) by cold heading, directly from the as-rolled wire rod, without any further heat treatments. Mechanical properties are equivalent if not better, in the case of fatigue, to those of fasteners made of alloy steels by the classical method of annealing, cold heading, quenching and tempering. The high bainitic hardenability of the proposed C - - M n - - N b - - B grade, obtained by the synergistic N b - - B effect, results in fully bainitic structures in bars up to at least 150 mm dia. Controlled rolling of this grade results in mechanical properties of bars (100 to 150 mm dia.) in the as-rolled and air-cooled condition which meet the API L80 requirements for heavy wall drill collars (yield strength > 550 MPa, ultimate tensile strengthS> 685 M P a a n d K C U > 8 daJ/cm2). This grade can therefore substitute quenched and tempered alloy steels ( C r - - M o chiefly) treated to this level of resistance. 18 r e f . - - A A B. H~ritier, Ph. Maitrepierre, J. Rofes-Vernis, and A. Wyckaert. HSLA Steels, Technology and Applications [Proc. ConL], Philadelphia, Pa., U.S.A., 3-6 Oct. 1983, American Society for Metals, Metals Park, Ohio 44073, U.S.A., 1984, (Met.A., 8502-72-0072) 981-989, [in English].
52-O198 Effects of Thickness on the T h e r m o m e c h a n i c a l R e s p o n s e of a Forged Low-Carbon Microalloyed Steel. Work has been done to examine the effect of section thickness on mechanical behavior of a low-carbon microalIoyed steel formed by hot forging. The chemical composition of this steel, containing both Nb and vanadium, had been optimized in a preliminary study by the method of multifactorial planning. Three modes of forging were applied to examine the influence of soaking and finishing temp. The results show that the effects of these two temp. cannot readily be separated, since they are interrelated to some extent. Nevertheless, it appears as if soaking temp. controls primarily the tensile properties, whereas finishing temp. seems to fix the impact value for thicknesses 48 mm Ferrite grain size does not seem to exert a strong influence on mechanical properties when compared to that of Nb and V precipitates. An attempt to classify the chemically optimized steel as a function of thickness according to the standard norm DIN 17102 has also been made. 28 r e f . - - A A H. LUthy, A. Oberli, and W. Form. HSLA Steels, Technology and Applications [Pzoc. ConL], Philadelphia, Pa., U.S.A., 3-6 Oct. 1983, American Society for Metals, Metals Park, Ohio 44073, U.S.A., 1984, (Met.A, 8502-72-0072) 1081-1099, [in English].
52-0199 W e i g h t R e d u c t i o n and Press P e r f o r m a n c e of S t e e l s in Automobile Manufacture. With consumer attention directed at "fuel economy" of passenger vehicles due to continual increases in fuel prices, Ford of Australia has undertaken several programs to achieve continued improvements. One of the most effective of these is the weight reduction program. The major aspects of the weight reduction program for the Falcon range of vehicles, with particular reference to weight reduction through the selection of lighter weight and higher strength steels, are covered. The press performance of these steels is dealt with, highlighting components of complicated section and those which have had a history of inherent pressing problems. The methods by which these problems are solved are discussed along with the techniques used to obtain the best press performance from the s t e e l s . - - A A A. Krstic. SEAISI Q., July 1984, 13, (3), 24-,3e, ]in English]. ISSN 0129-5721.
52-0202 N i c k e l - - Z i n c Alloy Coated Drawn and Ironed C a n . A N i - - Z n alloy plated steel can is comprised of a bottom wall and a seamless sidewall integrally formed by a drawing and ironing process whereby the sidewalls are ironed to a thickness substantially less than that of the bottom wall, the can being drawn and ironed from a flat rolled steel sheet having a N i - - Z n alloy coating plated on each side thereof, the N i - - Z n coating having a thickness within the range of 0.5-5 pin. belore being drawn and ironed, and the amount of Zn in the coating being within the range of ~ 2-12% by wt. J.R. Smith, W.D. Bingte, L.W. Austin, and National Steel Corp. Off. Gaz., 3 July 1984, Patent no. US4457480 (USA), 30 Sept. 1982. ISSN 0360-5132. 52-0203
Method of Forming D&I Cans From Coated S t e e l . A process for forming a drawn and ironed container from flat sheet steel comprises: applying a Ni--Zn alloy coating to both sides of a sheet suitable for drawing and ironing, the alloy coating containing Zn of ~ 2-12 wt.%; drawing the N i - - Z n alloy coated steel into a cup having sidewall and bottom wall thicknesses substantially equal to the thickness of the coated steel; and ironing the sidewall of the drawn cup to reduce the sidewall thickness and increase the height to produce a drawn and ironed can body by supporting the drawn cup on a mandrel and passing the cup through an ironing ring toolpack including at least two ironing ring dies. W.T. Saunders, L.W. Austin, J.R. Smith, W.D. Bingle, and National Steel Corp. Off. Gaz., 3 July 1984, Patent no. US4457150 (USA), 11 Feb. 1982. ISSN 0360-5132.
52-0196
52-0197 HSLA Steels in Wire Rod and Bar Applications. Controlled rolled HSLA steels grades have been developed for applications in two areas typical of long products, i.e. wire rod and bars. The wire rod grades, based on C - - M n - - B , C - - M n - - N b and C - - M n - - N b - - B type compositions are suitable for the manufacture of bolts and fasteners classes 8-8 and 10-9 (800-1000 and 1000-1200 MPa,
J. APPLIED METALWORKING
52-0204 P r o c e s s for Producing Cold Rolled Steel S h e e t s Having Excellent Press FormabiUty and Aging Property. A process for producing cold rolled steel strips having excellent press formability and aging property, comprises continuously casting molten steel containing carbon 0.1% max.; Mn 0.5O/o max.; phosphorus 0.01% max.; AI 0.08% max.; nitrogen 0.005% max.; and boron 0.005%, balance Fe and unavoidable impurities, into steel slabs; continuously hot rolling the slabs with a finishing temp. r A 3 point and a coiling temp. from 600750~ cold rolling the hot rolled strips and subjecting the strips to continuous annealing. H. Katoh, H. Toyota, K. Koyama, K. Komiya, and Nippon Steel Corp. Off. Gaz., 17 Apr. 1984, Patent no. US4443272 (USA), 19 Sept. 1981. ISSN 0360-5132.
52-0210 A P r a c t i c a l M e t h o d for D i r e c t S t e e l T e m p e r a t u r e M e a s u r e m e n t in Reheat Furnaces. A new, reliable method has been developed for the direct measurement of steel temp. in reheat furnaces. Laboratory and mill evaluations have shown that, with proper installation and location, along with adequate maintenance, a 3.9 ~m, reflectance compensated thermometer system can provide accurate, repeatable measurements of in-furnace steel temp. 8 ref. --AA G.R. Peacock, and A.P. Martocci. Iron Steel Eng., Nov. 1984, 61, (11), 47-53, [in English]. ISSN 0021-1559.
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52-0211 Conservation and Recovery of Lubricating and Hydraulic Oils. Significant savings have been achieved through a comprehensive program to conserve and recover lubricating and hydraulic oils. The savings resulted mainly from elimination of disposal costs for oily water and from major reductions in the volume of oils p u r c h a s e d . - - A A V.L. Middleton. Iron SteelEng., Nov. 1984, 61, (.11), 54-56, [in English]. ISSN 00211559. 52-O212 An Advanced Approach to the Dynamic Analysis o f R o l l i n g Mill F o u n d a t i o n s . Based on a computer simulation and analysis of the dynamic load transmitted to table roll bearings and foundations daring rolling and turning down of ingots, it was established that a modified table girder design is more effective in reducing the loading on the concrete foundation than elastomeric shock absorbers. A testing program demonstrated that epoxy grouts have better physical properties than cementitious grouts for this a p p l i c a t i o n . - - A A G. Monaco. Iron Steel Eng., Oct. 1984, 61, (10), 17-25, (in English]. ISSN 00211559. 52-0219 Heat Transfer Aspects of Nonisothermal Axisymmetric Upset Forging. A finite difference solution for the transient heat transfer during axisymmetric upset forging has been developed. The interfacial film between the die and the billet has been included in the analysis, and all modes of heat transfer have been taken inlo account. The results of a parallel experimental study have also been presented. The effects of geometrical and physical characteristics of the billet and the die on the heat transfer process, particularly on die heating, have been systematically investigated. Hot forging tests were performed on Cu, 1042 and 304 steels using H-13 steel forging dies. 15 r e f . - - A A P. Dadras, and W.R. Wells. J. Eng. Ind. (Trans. ASME), Aug. 1984, 106, (3), 187195, [in English]. ISSN 0022-0817.
Mechanisation and Automation of the Press-Forming Processes. (Translation: BISI 2 3 1 6 1 ) . See Met. A., 8311-52-1439.
52-0227
S. Kapinski. Hutnik (Katowice), Jan. 1983, 50, (1), 22-25, [in English]. ISSN 00195669. T h e D i s t r i b u t i o n o f the Deformation in Multi-Ring P a s s e s o f a Push Bench. (Translation: BISI 2 3 0 7 5 ) . See Met. A., 8412-52-2066.
52-0228
J. Kajtoch, and Z. Polek. Hutnik (Katowice), July-Aug. 1983, 50, (7-8), 241-254, [in English]. ISSN 0019-5669. A Numerical Analysis of the Process of Upsetting Round Stock Characterized by A x i a l D i s c o n t i n u i t y . (Translation: BISI 23076). 52-0229
See Met. A., 8412-52-2067. R. Szyndler et al. Hutnik (Katowice), July-Aug. 1983, 50, (7-8), 254-258, [in English]. ISSN 0019-5669. HOW T o Improve the Q u a l i t y o f R o l l e d Products by Removing Defects. (Translation: BlSl 2 3 0 8 4 ) . See Met. A., 8206-52-0691. 52-0230
W. Xu. Iron Steel (China), Nov. 1981, 16, (11), 12-17, [in English]. 52-0232
Problem
of Principles
of Limiting
Ductility
o f Metals.
(Translation: BISI 2 2 7 0 2 ) . See Met. A., 8410-52-1756. V.A. Skudnov. Izv. V.U.Z. Chernaya Metal/., 1983, (12), 38-45, [in English]. ISSN 0363-0797. A n a l y s i s o f Stress State During Drawing of Tubes With No Mandrel. (Translation: BISI 2 2 7 0 3 ) . See Met. A., 8410-52-1760.
52-0248 Quality of Edge Zone and Optimization of Depth of EdgeTrimming of Skelp. (Translation: BISI 23118). See Met. A., 8412-52-2029. O.V. Nosochenko eta/. Sta/', June 1984, (6), 48-49, [in English]. ISSN 0038-920X. Properties of Low-Carbon S t e e l s After Warm R o l l i n g . (Translation: BlSl 2 3 1 2 2 ) . See Met. A., 8412-52-2032. 52-0249
M.L. Bernshtein, and N V . Filatova. Stal', June 1984, (6), 76-78, [in English]. ISSN 0038-920X. 52-0250 The Operation of Plugs Made of Grade WLN S t e e l in PushThrough Tube Rolling Mills. ( T r a n s l a t i o n : BISI 2 3 0 6 2 ) . See Met. A., 841052-1779. T. Trzaska, and A. Trzaska. Wiad. Hutn., Oct. 1983, 39, (10), 307-313, [in English]. ISSN 0043-5139. 52-0252 Deformation Processing of Aluminium Alloy 2 6 1 8 . I . - K i n e t i c s o f D e f o r m a t i o n . Cf. ibid., p 289, Upsetting tests in the temp. range 300-800K at strain rates of 0.02-200/S yield flow curves. The flow stress thus determined is represented as a function of the process parameters and empirical relations. The activation energy and activation volume also enable a limiting hot destrain rate to be established, and a mechanism of dynamic recovery considering the cross-slip of the screw disclocations is proposed. 22 ref.--R.H. K.P. Rao, and Y.V.R.K. P r a s a d Aluminium, Mar. t984, 60, (3), 184-189, [in English]. ISSN 0002-6689. 52-0256 D i f f e r e n t Methods for E s t i m a t i o n o f E x t r u d a b i l i t y . This evaluation of the existing methods for estimating extrudabilify is based on the exit velocity of the metal through the tool. A novel method and a test tool are proposed, based on research into extruded sections of AICuMg 1, for simplified determination without the disadvantages of the existing methods. 14 ref.--R.H. W. Misiolek, and J. Zasadz(nski. Aluminium, Apr. 1984, 60, (4), 278-281, [in English]. ISSN 0002-6689. 52-0257 Deformation Processing of Aluminium Alloy 2 6 1 8 . I I - Development o f a Processing Map. Study of the mechanical properties and the mierostructure of upset testpieces shows that dissolution of particles embeddeal in the matrix occurs at high letup. Ductility is max. in the temp. range 50060OK, whereas homogenizing above 600K followed by fairly rapid quenching causes hardening at room temp. The map thus developed gives the "sate" range in the temp./strain rate diagram in which no material failure during deformation is likely. 16 ref.--R.H. K P Rao, and Y . V R , K Prasad. AluminilJm, Apr. 1984, 60, (4), 289-295, [in English] ISSN 0002-6689. 52-0258 I m p r o v e m e n t s in Extrusion Presses. Extrusion properties of AI are reviewed, and the design and operation of extrusion presses are discussed with particular reference to press drive and control arrangements and run-out and ancillary equipment. The Si chip has permitted a degree of automation not previously considered economically possible, and yield and efficiency have both iraproved. Microprocessors with electronic memory features are being installed to programme run-out operations and provide central control. A press cross-section and a general view of an Al-extrusion production bay are illusfrated.--J.R. K Staniland, and D. Baker. Engineering (London.), S e p t 1984, 224, (8 (Supplement)), vii, ix, [in English]. ISSN 0013-7782.
52-0233
G.L. Baranov. Izv. V.U.Z. Chernaya Metal/., 1983, (12), 59-63, [in English]. ISSN 0363-0797. 52-0234 S t u d y i n g P l a s t i c Deformations by Coordinate Grid Method. (Translation: BISI 2 2 7 0 4 ) . See Met. A., 8410-52-1761. V.A. Kuz'menko eta/. Izv. V.U.Z. Chernaya Metal/., 1983, (12), 63-65, ]in English]. ISSN 0363-0797. I n f l u e n c e o f P r o f i l i n g Method on Deformed State o f B l a n k Metal After Upsetting. (Translation: BISI 2 2 7 0 5 ) . See Met. A., 8410-5252-0235
1763. A.I. Golomidov et al. Izv. V.U.Z. Chernaya Metal/., 1983, (12), 69-71, [in English]. ISSN 0363-0797. M o d e l l i n g o f the Process of Continuous Hot Rolling on a Torsion Testing Machine. (Translation: BISI 2 2 7 6 6 ) . See Met. A., 8411-5252-0236
1873. A.S. Gurov. Izv. V.U.Z. Chernaya Metal/., 1984, (1), 69-72, [in English]. ISSN 03630797. P r o b l e m o f Speed Dependence o f F l o w S t r e s s s in Steels During Cold Upsetting. (Translation: BISI 2 2 8 3 4 ) . See Met. A., 841 t-52-
52-0238
1883. V.E. Vinogradova et aL Izv. V.U.Z. Chernaya Metal/., 1984, (2), 41-46, [in English]. ISSN 0363-0797.
52-0239 Stability During Localized Deformation (Translation: BISI 2 2 8 3 5 ) . See Met. A., 8411-52-1884.
of B i l l e t s .
M.Ya. Brovman. Izv. V.U.Z. Chernaya Metal/., 1984, (2), 46-48, [in English]. ISSN 0363-0797. 52-0244 C h a n g e in t h e Z i n c Layer During Drawing o f Z i n c C o a t e d T h i n High-Strength Steel Wires. (Translation: BISI 2 3 1 6 6 ) . See Met. A., 8108-520939. G. Apel, and R. NUnninghoff. StahlEisen, 20 Oct. 1980, 100, (21), 1247-1253, [in English]. ISSN 0340-4803.
72
VOL. 4, NO. 1, JULY 1985
52-0259 Innovative Design Material. The numerical designation of AI alloys in accordance with their alloying constituents is presented and explained, and the chemical compositions and mechanical properties of the BS 2011, 6063, 6063A, and 6082 compositions particularly meeting engineering requirements are tabulate d These and shape-feasibility factors in extrusion-forming are discussed, 1o gether with extrusion-press characteristics and die design in relation to factors influencing die life. An annotated cross-section through a modern extrusion press is illustrated, and case histories of the production of a container for electronic equipment and a stringer section for a marine pontoon are presented as design examples demonstrating the versatility of AI e x t r u s i o n s . - - J . R H. Spencer. Engineering (London), Sept. 1984, 224, (8 (Supplement)), xi-xiii, [in English]. ISSN 0013-7782. 52-0260 C o m p u t e r - A i d e d E x t r u s i o n . The currently limited use of computeraided design and manufacturing (CAD/CAM) systems among AI extruders in the UK is related with the position that most of these do not cut their own dies. It is therefore improbable that a CAD system could be justified without linkage to a computerized numerically controlled (NC) die-making facility or other given bases, and meanwhile progressive extruders are most likely to concentrate on tightening CAD/CAM links with their toolmakers. Many extrusion-die makers are already using NC wire eroders, but links with the extruders for the transfer of digital data such as in the "Ford Syndrome", an outline of which is given, are still apparently absent, Successful tests of such an approach, in which sections designed using a CAD system were successfully produced at short notice by new suppliers, are reported.--J.R. J Schwiller. Engineering (London.), Sept. 1984, 224, (8 (Supplement)), xxiv-xxv, [in English]. ISSN 0013-7782.
52-0262
Micro-Chip Technology Helps to Transform the Sheet Metal
Sector. The remarkable changes that have taken place in the sheet-metal industry over the last decade with the introduction of computer numerical control are discussed and illustrated. The major applications of CNC in the metal forming market are first, and largest, the turnet press, followed in turn by the brake press, spinning lathes, wire erosion machines, guillotine shears, power presses and complete production lines. The advantages obtained include the capability of combining a number of separate operations into one, improved flexibility, reduced scrap and inspection and increased past consistency. Editing of the program and its storage facility is of major value to the planning section. Examples are given of some of the
J. APPLIED METALWORKING
applications of micro-chip technology to metal forming processes and of the improved results obtained.--J.W. E. Lloyd. Met. Incl, News, Sept. 1984, 5, [in English]. ISSN 0265-8321. 52-0263 W h e n It's W i s e N o t t o W e l d . The activities of Angle Ring Co., U.K, are briefly described. The company specialises in cold rolling steel flats and sections into curved and circular parts, at lower costs than conventional cutting and welding procedures. Typical products are flats rolled on edge into rings, curved sections for building construction, and accurately cambered beams for bridge building.--T.W. Weld. Met. Fabr., Sept. 1984, 52, (7), 284-285, [in English]. ISSN 0043-2245.
52-0264
W i r e D r a w i n g W i t h U l t r a s o n i c V i b r a t i o n . - - I I . An illustrated description is given of the modified drawing machine and the ultrasonic system used to superimpose ultrasonic vibrations to a wire during wire drawing. Tests were carried out on 3.0 mm dia. wires which were initially subdivided into material which could be drawn with suitable lubricants, but without a lubricant carrier coating (Cu--37%Zn, Ni 99.2%, A I - - 5 % M g and N i - - 4 7 % F e alloys) and materials which were only capable of being drawn with the assistance of hydrostatic pressure (NiCrS020, NiCr6015, CrAI205 and NiCr425Ti2.5). Drawing speeds were increased in steps from 0.15 m / s to a max, of 4.5 m/s. At a frequency of 20 kh3 and with oscillation amplitudes between 10 and 20 pm, no applicable reduction in the drawing force was apparent of speeds of 1.5 m / s and above. The percentage drawing force reduction dropped sharply from a max. of up to 34% at a drawing speed of 0.15 m / s to almost zero at 1.5 m/s. As a consequence attempts were made to use ultrasonic vibration at very low drawing speeds to bridge the critical start-up phase and then to continue drawing using a pressure tube which was activated above a certain speed. However no proof was obtained that draws could be made successfully with the aid of ultrasonic vibrations which were not possible by conventional m e a n s . - - J,W. J. Gebhardt, and P. Funke. Wire, Mar.-Apr. 1984, 34, (2), 47-51, [in English]. ISSN 0043-5996. 52-0265 Transverse Extrusion of a Collar on Solid Steel Bodies. Transverse extrusion of a collar or flange is a non-stationary forming process. Using clearly lower forces in comparison with upset forging, with resultant lower die force requirements, and without extreme local tension peaks, collars of up to an external diameter of dl - 2.5 d o may be produced in the most favourable cases. A disadvantage for many applications is the non-parallel surfaces of the collar when forming with counter-acting dies, thus necessitating a calibration process. The future of the process could be in the manufacture of nonrotationally symmetrical secondary shaped elements, as some of the production examples examined prove.--AA W. Schazle. Wire, Mar.-Apr. 1984, 34, (2), 71-74, [in English]. ISSN 0043-5996.
a draw block cowl extending at least partly around the draw b l o c k to form with the draw block a liquid coolant reservoir extending at least partly around the cylindrical surface of the draw block for holding liquid coolant in c o n t a c t with the d r a w block and each of the plurality of turns of wire thereon, and continuously cooling the wire by continuously conducting a water-based liquid coolant into contact with the ferrous wire along the wire path from the die to the draw b l o c k end into the liquid coolant reservoir into contact with the draw block end each of the plurality of turns of wire on the draw block, and bring the wire between e a c h upstream d r a w block and downstream soap box of the plurality of successive drawing stages. J.W. Pamplin, B.R. Aetbury, R. Shillito, and Marshall Richarde Barcro Ltd. Off. Gaz., 14 Aug. 1984, Patent no. US4464922 (USA), 13 May 1982. ISSN 0 3 6 0 - 5 1 3 2 .
52-0276
Counterpreasure Drawing by Using Single Action Press.
Attempts have been made to eliminate the drawbacks of t h e existing hydraulic counterpressure drawing by developing a new drawing setup to be used on a single-action press. In this setup an inverted fluid chamber s e a l e d with a m o v a b l e plug incorporating e stop valve, which can allow release of oil when needed, has been designed. The ram of a single-action press is mounted with this c h a m b e r which can retain oil when filled with a separate pump running continuously. The method is quite simple and economical, though the drawing c y c l e time is not as short as an exclusive press. By using this setup on a mechanical press providing higher speed, enough way is foreseen for reducing the drawing cycle t i m e . - - A A K, Suzuki. and T. Nakagawa. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Rop: pongi, Minato-ku, Tokyo 106, Japan, 1984, (MeLA., 8 5 0 3 - 7 2 - 0 1 0 9 ) 769-774, [in English].
Hydraulic Counterpressure Deep Drawing Assisted by R a d i a l Pressure. The development work, which can improve forming limits of e drawn 52-0277
part by applying liquid pressure on the blank periphery at the time of counterpressure drawing, is described. The liquid pressure is small enough, e.g. only several tens of MPa compared to similar ones proposed in the past, w h e r e the counterpressure is not used and the radial pressure is simply generated due to the punch movement into the fluid chamber. This process is supposed to be economical end simple enough to be introduced into actual production. In the investigation of drawing conditions, such as fluid pressure and clearance for fixed blank holder for AI (A1100) sheets, a significantly higher forming limit, ~ 3.3 for a cylindrical part, and 3.6 for square part, could be achieved as against 2.7 and 2.9, respectively, in normal counterpressure d r a w i n g . - - A A K. Nakamura, and T. Nakagawa. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (MeLA., 8 5 0 3 - 7 2 - 0 1 0 9 ) 775-780, [in English].
52-0278
52-0266 P r e c i s i o n S t r a i g h t e n i n g o f S c r e w s a n d S h a f t s . A new method of providing precision straightened screws, bolts, pins and shafts, capable of meeting the exacting requirements necessary for the new production and assembly methods now used for example in the automotive industry, is described, Essentially the work-piece is placed across a number of rails located parallell to one another o n a bottom platen A top platen, carrying similarly mounted but offset rails, is then lowered to grip the workpiece. A linear motion imparted to the table carrying the lower rails, rolls the workpiece between the upper and lower rails, and as the top platen is inclined slightly downwards at the front any distortion in the workpiece is progressively reduced as it rolls backwards between the rails. At the finish of the table movement any distortion in the workpiece has been eliminated. Any deviations in the workpieces after treatment are caused by the tolerances on diameters and any variations in the properties of the materials of which the workpiece is composed. Workpieces with a hardness exceeding HR50 cannot be treated by this unit. Outputs of 500 600 parts/h can be achieved with manual loading and unloading but this can be increased to about 900 parts/h with automatic loading.-- J.W. V.C.H. Kesber. Wtre, Mar -Apr. 1984, 34, (2), 75-76. [in English]. ISSN 0043-5996. 52-0267 F i n e G r a i n S y n d i e O p e n s Up t h e PCD R a n g e . Despite their successful replacement of tungsten carbide in the larger copper wire sizes, polycrystalline diamond die materials have met substantially stiffer resistance in the smaller size range where for years natural diamond has predominated. The more recent development of fine grain Syndie has, however, whipped up renewed interest in PCD at copper wire sizes as small as 0.2 mm. Here investigational programmes by Pirelli are examined, whose UK plants are finding that Syndie PCD can offer production benefits where natural diamond was once accepted as optimum. --AA S. Herbert. Wire Ind., Oct, 1984, 51, (610), 752-754, [in English]. ISSN 0043-6011.
52-0268 Analysis of the Relationship In Between Longitudinal and Transverse Strains in Sheet Steel in Tensile Tests. (Translation). See Met. A., 8501-52-0035. R.Ye. Gliner, A.V. Skoblo, L.N. Nikolayeva, and M.A. Mayorov. Ind. Lab. (USSR), Nov. 1983, 49, (11), 1200-1202, [in English]. ISSN 0019-8447.
52-0269
Influence of Dopants on Bubble-Formation in Tungsten Wire.
The effect of potassium additions on the formation of bubbles in tungsten wire used for lamp filaments was investigated. The formation of bubbles by K vaporization was confirmed by electric resistance heating followed by Auger electron spectrometry. It was shown that the bubble dia. was a function of the amount of segregated K.--G.P.K. M. Inaba, H. Kagami, and Y. Yuge. J. Mater. ScL Lett., Oct. 1984, 3, (10), 859-860, [in English]. ISSN 0261-8028.
52-0275
Wire Drawing Method and Apparatus. In a method of drawing ferrous wire employing a plurality of drawing stages for continuously drawing the ferrous wire to successively smaller sizes, the improvement comprises, at each of a plurality of successive drawing stages, drawing the ferrous wire through the respective die with a plurality of turns of wire on the respective draw block, providing
J. APPLIED METALWORKING
Electroetimulating P l a s t i c i t y o f M e t a l s . The behavior of metals under high-density electric current is reported. Some work of a practical nature has been done in the area of rolling. The highly cold worked w i r e s of tungsten and W - - R e alloys was shown to be easily rolled to microribbon 20-30 #m thick. The most important stimulating factors are the temp. gradient and local heating in the contact zone and into metal being deformed. The action of t h e s e factors is realized by way of the density electric current and at the same time, intensive cooling. The high-density electric current affects selectively the local p l a c e s of the deformation and crack processes. 33 r e f . - - A A I.I. Novikov, and K.M. Klimov. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Mineto-ku, Tokyo 106, Japan, 1984, (Met.A., 8 5 0 3 - 7 2 - 0 1 0 9 ) 787-792, [in English]. 52-0279 A New T e c h n o l o g y of Pulsatory F o r m i n g and the Technological Tool to Carry It O u t . A new technology within frequency ranges up to 500 Hz is presented. To carry out the process a working prototype hydraulic pulsatory press has been constructed using original design solutions. The dynamics of the construction have been tested within the 5 to 500 Hz range. Several processes carried out with the pulsatory and classical technologies have been tested (using Duraluminum, brass and ferrous alloys). On the basis of the tests on construction and processes, an industrial prototype of a universal pulsatory press PXP 1,00 for powders has been designed and c o n s t r u c t e d . - - A A R. Meszumadski, and Z. Polafiski. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 793-798, [in English].
52-0280 Metal Forming in the Ultrasonic F i e l d . A rigid-viscoplastic model for describing the behavior of metals during forming processes with high intensity supersound is presented. A description of the effect of ultrasonic field on the yield limit and coefficient of viscosity of metals and on the contact friction is given. A detailed treatment is then given for tube drawing by axial ultrasonic oscillation of the plug. A theory is described to determine the drawing stress, the drawing velocity effects, the area reduction and the die geometry. Calculations performed on the basis of the above theory are in good agreement with the experimental data obtained in drawing tubes of AI alloys (2024, AIMg 2 . 5 ) . - - A A N. Atanasiu. A d v a n c e d Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minatoku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 799-804, [in English]. 52-O281 Cold Workability L i m i t s o f 1 1 0 0 Aluminum, 2024 and 7075 Aluminum Alloys in Isothermal and Adiabatic Upsetting Tests. The effects of the strain rate, coupled with temp, rise, on working limits due to ductile fracture are evaluated in cold upsetting of 1100, 2024 and 7075 AI alloy cylindrical billets. Compressions between grooved dies and injection upsetting tests are carried out at room temp. on a programable electrohydraulic testing machine at deformation rates usually reached in mechanical upsetters. Maximum tern. rises of 0.48 Tm are measured at strain rates of 2.5 and 5 / s by thermocouples w e l d e d to the specimen surface; they are found to be in very good agreement with the calculated adiabatic temp. variations. In spite of drastic temp increase, very similar height
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73
reduction values and failure--strain loci are found, either in adiabatic or isothermal deformation conditions for the three metals. 13 ref.--AA P. Bariani. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 857-865, [in English].
52-0282
Failure Maps ( N e g a t i v e P r e a s u r e m S t r a i n - - T e m p e r a t u r e D i a g r a m s ) and Their Application t o Bulk D e f o r m a t i o n Processes. The influence of negative pressure (hydrostatic tensile stress) on workability of materials (7075 AI, T i - - 6 A I - - 4 V , carbon and stainless steels) is studied. Failure maps (negative pressure--strain--temp, diagrams) based on experiments are presented for applications to formability of bulk deformation processing. The failure maps express the characteristics of fracture as a curved surface divided by the dominance of micromechanism of failure in three-dimensional space (fracture strain--negative pressure--temp.). The fracture strain of each alloy decreases under high hydrostatic tensile stress and its sensitivity varies from material to material. It is also shown that the transition of fracture mode depends not only on temp. but also on negative pressure. C o c k c r o f t - - L a t h a m ' s criterion agrees roughly with the failure maps in the case of ductile fracture. An application of the failure maps is attempted for the prediction of internal damage produced during the wire drawing process. 13 ref.--AA M. Shimura, and S. Saito. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 866-871, [in English].
52-0283
Warm
Temper
Forging--a
New
Thermomechanical
T r e a t m e n t . To improve the warm forgeability of carbon steel, a new thermomechanical treatment is developed. In the process, "warm temper forging", a quenched steel billet is heated to a tempering temp. and then is deformed during the tempering process. From tension test and upsettability test on 0.48% plain C steel (JIS $45C), it is found that much higher ductility is produced by the method in which the material is heated in the range from 400 to 600~ for 3 rain and is subsequently deformed. The method is applied to heading on rotary forging. The working limit in warm temper forging is larger than that of the conventional warm forging and the working force is almost the same as that in the conventional warm forging. The warm temper forged product has sufficiently high strength and its residual ductility is much larger than that of the usual tempered steel at the same strength level.--AA K. Kobatake, H. Sekiguchi, and K. Oaakada. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 108, Japan, 1984, (Met.A., 8503-72-0109) 872-877, [in English].
52-0284
Developments of New Precision Cold Die Forging Processes.
Precision cold die forging processes which do not need succeeding finishing operations are desired. This desire is not fulfilled by the fact that the states of complete filling up of material into die cavity at a conventional closed die forging necessitates theoretically infinitive working pressure because fractional reduction in area becomes unity. Precision die forging processes are developed based on the concept of utilizing divided flow which always preserves relief portion of material flow at some unnecessary location of the contour, even when the complete filling up of material is attained at necessary contour portion, and thus prevents a steep increase in the working pressure at the stroke end. By these processes, gear-toothed parts (SIOC, SCM22 steels and A1100 AI) can be forged with relatively low working pressure and the accuracy of the products can be as precise as that of machined gears. Working principles of these processes are explained. 11 ref.--AA K. Kondo. Advanced Technology of Plasticity, Vol. 2 ]Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A. 8503-72-01og) 878-887, [in English].
52-0285
Analysis of Closed-Die Forging of Gear-Like Elements. An analysis of forging of gear-like elements has been carried out using the upperbound method. A constant frictional stress has been assumed on the contacting surfaces. The effect of various parameters, such as module, number of teeth, t/D ratio, etc., on the punch load has been studied. The expressions for punch pressure give the value of load at any instant during the tooth formation in the forging process. 13 ref.--AA O.P. Grover, and B.L. Juneja. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 888-893, [in English]. 52-0286
Warm Forging o f A u t o m o b i l e Small Gears. Warm forging of automobile small gears of SCM420 steel and suitable forging conditions, i.e. blank did., lubricant, preheating of die, forging temp., etc., have been determined. Of all die materials examined in a mass production test, die life of SKD 61 ion-nitrided is the best. The surface temp. of dies is estimated to be from 720 to 750~ during forging by experiment and calculation.--AA W. Takahashi, T. Fukuda, H. Hagita, S. Sunouchi, and K. Igaki. Advanced Technology of Plasticity, Vol. 2 [P[oc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 108, Japan, 1984, (Met.A., 8503-72-0109) 894-899, [in English]. 52-0287 Radial S t r e s s D i s t r i b u t i o n on the C o n t a i n e r Wall in Cold Backward Extrusion o f Steel. In the cold extrusion of low-carbon steel (C1121 Yugoslav steel), the tools make direct contact with the metal to be extruded. Those tools are exposed to high contact stresses which, in certain cases, may be limiting factors in applying this technology. The experimental research of the radial stress distribution on the container wall in cold backward extrusion of steel is reviewed. A special tooling operating on the principle of the pin load cell built in the container wall was designed. The intensity and distribution of the radial stress for four different extrusion ratios were determined. The distribution was estimated for various moments of the punch position, i.e. for the various bottom thicknesses of the can.--AA
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M. Plan(~ak, and V. Vujovi6. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 900~905, [in English].
52-0288
The Research on the D e f o r m a t i o n F o r c e o f Combined Extrusion. Starting from the analysis of the flow of metal, a kinematically admissible velocity field for axisymmetric combined extrusion in steady state was constructed and the upper bound solution of deformation force was derived. The value of the radius of the separating flowing point is given. The analytic results of deformation force have been compared to the experimental results on Pb billets. 17 ref. --AA X. Ruan, S. Li, S. Zhang, and G. Li. Advanced Technology of Plasticity, VoI. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-25 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 906-911, [in English]. 52-0289
Optimization o f Shrink Ring I n t e r f e r e n c e Configuration for Matalforming Die. The tensile stresses developed at the inner surface of a metalforming die are influenced by the form of the normal pressure distribution imposed on the die by the shrink ring. To maximize die life, it is necessary to optimize the shrink ring interference configuration. Numerical and experimental methods used for analyzing the stress distribution in the die insert and shrink ring are reviewed and results are presented for particular shrink ring configurations which are shown to reduce the stress concentration at the die cavity end the die/shrink ring interface. Application of the results of the analysis to commercial die design has resulted in significantly increased die life before failure.--AA J.B. Hawkyard, T. Hirai, T. Ishise, and T. Katyayama. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 850372-0109) 912-917, [in English].
52-0290 Upsetting o f Continuous Cast Steel f o r Closed-Die Forging. Upsetting can be used to improve the properties of cast material. Investigations were carried out to study the possibility of using as-cast billets or billets with low roiling reductions for closed-die forging. Upsetting between flat tools of carbon steel and low-alloy steel was studied at MEFOS, Luletz, Sweden. Upsetting followed by closed-die forging of a gear was studied at Wirabo Bruka AB, Virsbo, Sweden. Both the geometry of the block and the ratio of upsetting are important for the results. A higher block needs a higher ratio of upsetting. The results also indicate that it may be possible to use strand-cast billets as-cast for production of forgings where the center is punched out. For other forgings the tests show that small rolling reductions may be satisfactory.--AA M. Jarl. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 918-923, [in English]. 52-0291
Precision Forging Hollow Cylinders. Experiments with three designs of die-set, with completely closed cavities containing mandrels, for forging hollow billets are described. The designs differ in the manner of movement of their basic elements. Using plasticine testpieces, the manner in which the cavities in each design are filled is identified. Lead billets are used 1o establish relations between forging load/displacement and their dependency on initial billet geometry for each design of die. Forging loads are predicted, with engineering accuracy, using an established upper bound. The incorporation of the strain hardening characteristics of the Pb in the analysis produces greater accuracy than the assumption of constant flow stress, only at high loads. Forces required to eject forgings vary markedly with process variables and the mechanics of ejection. Lowest forces are required when the mandrel is extracted before the forging is pushed from the cavity.--AA C. Tuncer, and T.A. Dean. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 924-929, [in English]. 5 2 - 0 2 9 2 Modeling and Numerical Analysis o f Cross-Rolling and Profile Ring-Rolling Processes. For analyzing the three-dimensional unsteady flow which occurs in cross-rolling processes, a steady flow rolling model and a twodimensional analysis method are introduced. In the model, the actual unsteady flow is converted to the superposition of steady flows and the steady threedimensional flow is simulated by two-dimensional finite element method, using a stream function formulation with suitable modification of the value of the stream function at the surface in contact with the roll. The modeling and numerical analysis are verified by experimental observations and examples of the application of the method in practical cross-rolling and profile ring-rolling situations are given. --AA Y. Maekawa, T. Hirai, T. Katayama, and J.B. Hawkyard. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A_, 850372-0109) 930-935, [in English].
52-0293 Application Study on Cross-Roll Method for A x i s y m m e t r i c a l Stepped Shaft. The cross-rolling method, a forging method for producing axisymmetrical stepped shafts from a heated billet during one rotation of two rolls, is described. Application of this method to the production involves some technical problems to be examined: design of the roll dies, estimation of the rolling force acting on the rolling dies during forming and limitation of forming, etc. The application example to new forming process of two parts forming in one shot is reported. To design the dies, simplified expressions for the rolling force are assumed and, using these formulas, the method to decide the design parameter is proposed. 8 ref.--AA H. Tsukamoto, K. Morimoto, T. Juge, and K, Takahashi. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.]' Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A. 850372-0109) 936-941, [in English].
J. APPLIED METALWORKING
52-0294
Rotary F o r g i n g - - a New Approach. The concept and implementation of a two year SERC/industrially supported investigation into rotary forging at Nottingham are described. A comprehensive classification system identifying seven distinct rotary forging/rotary riveting machine head motions is proposed. Analysis of the various head motions is used to indicate the complex nature of the process. Implications of the work to industrial users of the process and researchers are suggested.--AA P.M. Standring. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minatoku, Tokyo 106, Japan, .1984, (Met.A., 8503-72-0109) 942-947, [in English]. 5 2 - 0 2 9 5 Analysis o f F l o w Through Conical Converging Dies--Update 1984. Experimental study of metal flow encounters inherent limitations in the absence of adequate theoretical support. Such support is provided in this presentation of a combined analytical and experimental approach to the study of drawing or extrusion through conical converging dies. Limit analysis is based on the principle of min. energy leading to approx, solutions which place upper and lower bounds on drawing or extrusion force as a function of the semicone angle of the die, reduction, friction and material properties, The analysis brackets the conceptual exact solution between these upper- and lower-bound solutions. Comparison of outcomes shows reasonably good agreement with the data of Wistreich's classic experimental study. Explicit criteria, in which friction is a predominant factor, are derived for fracture and other flow patterns. 29 ref.--AA B. Avitzur. Advanced Technology of Plasticity, Vol. 2 [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi. Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 948-960, [in English].
5 2 - 0 2 9 6 Mechanics of Plastic F l o w in Metalforming: General Solutions for a Class of Ductile Materials. A comprehensive insight into the mechanics of flow of material in metalforming processes is possible only if a sufficiently simple picture of the stress-rate of strain relations and of the boundary conditions of tool/wcrkpiece interface is accepted. Closed form solutions are presented to frictionless metalforming problems where the physical set-up shows a high degree of axial symmetry, such as in ring forming and wire drawing. The presentation is for a class of incompressible ductile bodies, defined on the basis of a quasilinear stress-rate of strain relation restricted to include just one material constant, K, with the dimension of stress. The novel element is that the solutions are first presented in general form and thereafter applied to specific yield criteria. 8 ref.--AA S.H Talbert. Advanced Technology of Plasticity, Vol. 2 [Prec. Conf,], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minatoku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 961-966, [in English].
volumetric strain rate. V-die forging of octagonal material was found to be the best in terms of effective strain at center zone, and of 100% consolidation at center of porous Cu with smaller amounts of reduction and effective strain.--AA S. One, M. Tanaka, H. Tsukada, and T. Iwadate. Advanced Technology of Plasticity, Vol. 2 [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1964, (Met.A. 8503-720109) 997-1002, [in English].
52-0301 Simulation of Throe-Dimensional D e f o r m a t i o n in Matalforming by the Rigid-Plastic Finite Element Method. To simulate three-dimensional deformation in metatforming processes, the rigid-plastic finite element method is applied with the use of isoparametric hexahedral efements with eight nodes. Side-pressing of pipe and upsetting of rectangular prism are chosen as examples of simulation. In the side-pressing process, the central region of the side surface of the pipe is compressed by flat parallel tools. The computed shapes of the workplace and working load in side-pressing and upsetting are found to be in good agreement with the experimental ones carried out on AI pipes and blocks. 11 ref.--AA K. Mori, K. Osakada, K. Nakadoi, and M. Fukuda. Advanced Technology of Plasticity, Vol. 2 [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-720109) 1009-1014, [in English],
52-0302 Numerical Simulation System for Plastic M o t a l f o r m i n g Process Based on a FEM Introducing Slide Between Elements. A rigidplastic finite element method in which the slippage between elements is taken into consideration has been newly formulated to solve the problem of singularity which exists in the analysis of forming processes where sharply edged or cornered tools are employed. Based on this finite element modeling, a simulation system for met ~ alforming processes has been developed. Solutions to problems of axial symmetry andl plane strain and certain three-dimensional problems of arbitrary profile are clarified by this system. Material characteristics, such as work hardening, strain rate dependence and their combination, are also covered. The accuracy of the simulation results is discussed through the comparison with slip line theory and experiments on foward extrusion of 2S-0 AI. 9 ref.--AA K. Sate, S, Tanaka, and F. Uchida. Advanced Technology of Plasticity, Vol. 2 [Prec. Conf,], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-25 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 10211026, [in English].
52-0303 Analysis of Block C o m p r e s s i o n With S i m p l i f i e d ThroeDimensional Elements. A simplified eight-node element was devised by taking
5 2 - 0 2 9 7 Application of UBET to N o n a x i s y m m e t r i c Forging. An analytical method based on UBET (upper bound elemental technique) was developed to simulate nonaxisymmetric deformation behaviors of works in various metalforming processes. It was applied to simulate nonaxisymmetric forging processes where various products with side-flushes were investigated. In those simulations, the details of deformation of the work which flows into the side-flush cavity of die were successfully analyzed. By this method, it has become possible to calculate the ultimate filling rate of the cavity of die, the ultimate share and dimension of product and others, which are very important factors for the optimum design of the die. The results of simulations have been compared with experimental measurements on eb and they show very good coincidence with each other. 7 ref.--AA M. Kiuchi, and A. Karato. Advanced Technology of Plasticity, Vol. 2 [Proc. ConL], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2 5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 967-972, iin English].
one layer of elements in the direction normal to the plane of symmetry and assuming that the element sides, which are initially normal to the plane, remain normal during deformation. Using the simplified element, the three-dimensional analysis was performed for block compression. Simulations of compression of rectangular blocks were performed for two geometries under two friction conditions for each geometry. Comparison of some of the computed results with experiments (2024 AI) showed excellent agreement. The technique was further extended to take into account the presence of a neutral zone, occurrence of folding and lifting and applied to the analysis of compression of a wedge-shaped block between two flat parallel dies. 9 ref.--AA J.-X. Sun, and S. Kobayashi. Advanced Technology of Plasticity, Vol. 2 [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 1027-1034, [in English].
52-0298 Plastic Flow in Deep Indentation During Open-Piercing o f T h i c k Circular B l o c k s o f Aluminum by Rigid Mandrel and Ring-Type Piercers. Some typical results are presented of an experimental investigation to ascertain the variation of specific working pressures and geometry changes with variation in depth of penetration in axisymmetric, incremental open-piercing of thick circular blocks of commercially pure AI by rigid solid mandrel and ring-type piercers. A number of same size specimens for each group with initial dia. to thickness ratios Do/H o = 1.5 and 2.25 were loaded quasistatically in a progressive manner to gradually increasing punch penetration depth stages. The observed changes in specimen geometry, the deformation modes and the variation in punch load--punch penetration characteristics suggest that, in deep penetration, the ductile material undergoes three or more distinct flow stages. 15 ref.--AA N.R. Chitkara, and U. Patel. Advanced Technology of Plasticity, Vol. 2 [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 5503-72-0109) 973-979, [in English].
52-0304 The Role of the Finite Element Method in Metalforming Technology. Recent developments on the application of the finite element meth-
5 2 - 0 2 9 9 The Physical Modeling of Plastic Working Processes. Physical process modeling (simulation of metal flow by using a soft model material instead of the real metal) has been developed into a very efficient and powerful tool. The most important papers describing the development and the different applications of physical modelling of plastic working processes are reviewed. Requirements which the model experiment must fulfill and how the experiment should be designed, depending on the objective of the experiment, are described. Selection of material for tool and workpieces and the necessary equipment are investigated. Various pitfalls which an inexperienced user of model experiments may face are described. 132 ref.--AA T. Wanheim, V. Maegaard, and J. Danckert. Advanced Technology of Plasticity, Vol. 2 [Proc. ConL], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A,, 8503-72-0109) 984-996, [in English]. 52-0300 Analysis on Distribution o f Deformation During Hot Forging. Some plane strain open die forging processes were evaluated by applying a matrix method on visioplasticity using Plasticine and sintered porous Cu as model materials. Friction conditions of the model materials were controlled to simulate hot forging of steel. Sintered Cu was useful to evaluate static pressure because it follows deformation mechanics of porous material and static pressure is proportional to
J. APPLIED METALWORKING
od, particularly the rigid-plastic approach, to the problems in two areas are presented. One is process simulation, the other preform design in metalforming. In process simulation the developments concerning the three-dimensional metal flow analysis are discussed and examples are shown for block compression (2024 AI) with three-dimensional elements and for spread analysis in flat tool forging using simplified elements. In the area of preform design, a unique application of the finite element method to the problem is introduced and illustrated by preform design in nosing. Preform design in rolling is shown as an application. 9 ref.--AA S. Kobayashi. Advanced Technology of Plasticity, Vol. 2 [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minatoku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 1035-1040, [in English].
52-030S
Finite Elements in Forming Processes. Flow formulation and its finite element approximations are discussed with application to industrial forming processes of metals and plastics (extrusion of commercial-purity AI). The viscous constitutive law is introduced and its relation to the conventional rate independent plasticity discussed. Numerical procedure is outlined without the algebraic detail. The importance of thermally coupled effects and its numerical implications are emphasized. A few illustrative examples are included to demonstrate the performance of present approach. Difficulties related to the imposition of boundary condition are pointed out in these computational exercises. 35 ref.--AA O.C. Zienkiewicz, S. Nakazawa, and J.P. Vilotte. Advanced Technology of Plasticity, Vol. 2 [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-720109) 1041-1050, [in English]. 52-0306 Finite Element Mesh Rezoning and Its A p p l i c a t i o n s to Metalforming Analysis. In many practical forming processes, deformation is usually large. Such large deformation and displacements cause FEM mesh distotted in such a degree that a new FEM mesh is necessary for further simulation. Rezoning procedure and interpolation methods suitable for rezoning in rigidviscoplastic FEM analysis are described. Three interpolation methods are proposed. These are the least square fit method, the area weighted average method and the hybrid method which combines the previous two methods. The three methods are described and evaluated in terms of their accuracies and convenience. Then FEM solutions of various metalforming processes are given including forging
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of 8620 steel gears and Ti-6242 alloy, to show applications of rezoning procedure. 11 ref.--AA S.I. Oh, J.P. Tang, and A. Badawy. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-25 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (MeLA., 8503-72-0109) 10511058, [in English].
52-0307 Research on the Deep D r a w i n g o f Re-Entrant C o n t o u r Shells. The deep drawing of L-shaped shells (304 and 430 steels) was investigated as an example of that of re-entrant contour shells. By employing a slip-line field method, optimum blank shapes for obtaining the L-shaped shell with uniform flange around the side wall were theoretically predicted and the plastic flow in the flange region was analyzed. The forming mechanism of the re-entrant wall on the basis of a simple kinematic model of material flow is discussed. Deep drawing tests performed on the optimum blanks showed that the actual deformation mode of particles in the flange agreed well with the theoretically predicted behavior by slip-line field method. The measured thickness strains in the re-entrant wall confirmed the calculated values.--AA T. Jimma, T. Kuwabara, and S.C. Choi. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-25 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8603-72-0109) 10911096, [in English]. 5 2 - 0 3 0 8 T h r e e - D i m e n s i o n a l Finite Element Prediction of Material Flow and Strain D i s t r i b u t i o n s in Rolled Rectangular Billets. A three-dimensional
Relationships between the strains, mechanical properties and microscopic structure of steel pipes which are rolled by pilot and production mills are discussed. Equivalent strain of a pipe defined by incremental strain theory is large enough to improve satisfactorily mechanical properties and microscopic structure of pipe which is made by the press roll piercing method of continuously cast bloom. The press roll piercing method is commercially applied to the mass production of hollow blooms directly from continuously cast square blooms. 10 ref.--AA S. Yoshiwara, and T. Kawanami. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1954, (Met.A., 6503-72-0109) 1266-1273, [in English].
52-0323
New DM Planetary Tube Cold Rolling M i l l - - E x p e r i m e n t s and Results. The DM rolling mill with planetary rolls which circle around the tube and which are supported on a back-up ring is discussed_ Owing to the drive both of the basket with rolls and of the back-up ring, twisting of the tube is avoided. As a result of cold rolling, tubes (carbon steel) with surface finish and accurate dimensions are obtained. The tubes may be used without machining for the production of cylinders, linings, etc. The actual rolling mill stand has a simple design, is cheap and is operated in a uniform motion. It has a low power consumption and does not cause noise.--AA W. Dobrucki, J. Mischke, and A. Pietrzykowski. Advanced Technology of Plasticity, Vol. 2 ]Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 6503-720109] 1274-1278, [in English].
finite element computer model has been developed for the simulation of metal deformation during rolling processes (rolling steel beams). The three-dimensional analysis is applied to the simulation of rolling rectangular billets between flat rolls. For a fixed roll dia., billet thickness and percent reduction, the effects of billet width ere studied with the model. Results are presented for predicted head-end and tail-end metal flow and steady-state bulge deformation within the rolled billet for several different billet widths. Distributions of strain components at various cross-sections of the billet are also presented to illustrate how the details of internal metal deformation can be studied with the three-dimensional model. 19 ref. --AA B.V. Kieter. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A. 8503-72-0109) t 116-1126, [in English].
ysis on material behavior, optimum roll profile and operating condition in rolling process of three-roll planetary mill (PSW) have been carried out using the plasticine model mill, generalized geometrical method and rigid plastic finite element method. It is made clear that the adoption of roll with curved smoothing zone remarkably reduces the spiral mark height and expands feasible region of rolling condition. Behavior of center porosity, twisting of material and the feature of top and crop losses are also clarified.--AA T. Tsuta et el. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minatoku, Tokyo 106, Japan, 1984, (Met.A, 8503-72o0109) 1279-1286, [in English].
52-0317
52-0325
Simulation of Wire Rolling in the Steady State, Transient S t a t e and I n f l u e n c e C o e f f i c i e n t . A new nonlinear simulation model for a wire and rod mill has been developed. The features of this model consist of calculating the interstand tension, height, width, temp., load and torque more accurately in the steady state and transient state and using influence coefficients. Simulation results are shown in comparison with measured values at model mill and wire mill. 9 ref.--AA Y. Noguchi, K. Aoyagi, T. Kawanami, M. Ataka, and K. Nakajima. Advanced Technology of Plasticity, Vol. 2 ]Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (MeLA., 6503-72-0109) 1212-1219, [in English].
52-O319 Effects of Roll Arrangements and Roll Sizes o n Shape C o n t r o l l a b i l i t y o f C l u s t e r Mills. A simulation model to estimate the shapes of rolled strips in a cluster mill is developed and confirmed by experimental tests. By using this model, the optimum conditions of actuators, such as the profile and the position of first intermediate rolls and the crown control of backing rolls, are determined to get a flat shape. It is clear that 12-high mills have higher shape controllability than 20-high mills with the same dia. work roll and that larger alia. work rolls bring simpler shape profiles into strips.--AA S. Hattori, A. Mizuta, M. Kitayama, and Y. Yamaguchi. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-6 Roppongi, Minato-ku, Tokyo 106, Japan, t984, (Met.A., 860372-0109) 1230-1235, [in English]. 52-0320
C h a r a c t e r i s t i c s o f Rolling in A s y m m e t r i c C l u s t e r Mill. The characteristics of rolling such as rolling force, rolling energy and shape controllability of asymmetric cluster mill have been investigated quantitatively and experimentally. The results show that an asymmetric cluster mill enables not only higher reduction rolling but also better shape control than a four-high mill and that an asymmetric cluster mill is suitable for high-reduction rolling of high-strength steel used for automotive bodies. 7 ref.--AA T. Kawanami et al. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-6 Roppongi, Minatoku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-01091 1236-1246, [in English].
52-O321 Theory o f P l a s t i c i t y on S e a m l e s s T u b e R o l l i n g and Its Application t o Field Operation. The rolling theories of seamless steel tubes and their applications to field operation are described. As examples of tube rolling processes, the rolling by a mandrel mill and by a stretch reducing mill is discussed. The rolling theories which have been developed are summarized. These theories were tried out on the field operations and they have been continuously used for designing groove geometries and roll revolution/minute set-up. They also contribute to the improvement of tube qualities and to the extension of the ranges of tube sizes. These theories are also useful for designing computer control systems which largely contribute to the economy of processes. 16 ref.--AA C. Hayaahi, and T. Yamada. Advanced Technology of Plasticity, VoL 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 6-2-5 Roppongi, Minato-ku, Tokyo tO6, Japan, 1984, (Met_A., 8503-72-0109) 1254-1265, [in English].
52-0322
E f f e c t o f R e d u c t i o n Ratio on the P r o p e r t i e s o f Seamless Pipe. Strains during rolling are analyzed by a newly developed electron beam marking method. An area of steel which is penetrated by an electron beam can be distinguished from the surrounding area by sulfur print or macroetching, although the deformation resistance of the area is not different from that of the surrounding area.
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5 2 - 0 3 2 4 Development of the Three-Roll Planetary M i l l - - E x p e r i m e n t a l and Analytical Studies o f Rolling Process. Experiments and theoretical anal-
Tool Design and Rectification of Inhomogeneity of Flow in
Rotary Tube E l o n g a t i o n D a Model Material Study. The efficiency of the Assel elongating process, related to the levels of redundant shearing strains, is investigated through the medium of a model material. The choice of a suitable concept of roll design is made on this basis and the problem of triangulation and geometry is considered. It is shown that modeling of a complex metalforming process by means of a wax material can provide sufficiently accurate evidence of the basic characteristics of flow to enable a clear assessment of forming conditions to be made. 8 ref.--AA T.Z. Blazynski, and R.S. Lee. Advanced Technology of Plasticity, VoL 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A.. 8503- 72-0109) 1287-1291, [in English].
52-0326 Lower-Upper-Bound Analysis o f the Ring-Rolling Process by Using Force Polygon Diagram end Dual V e l o c i t y Field. An important feature of the ring-rolling process is that the pressure roll of smaller dis. advances incrementally toward the rotating driven roll of larger dis. Thus the dual nature of the velocity field in the plastically deforming zone should be properly considered for better estimation of roll torque and pressing load. Pressing velocity and driven roll rotation are incorporated in constructing the hodogreph for upper-bound analysis. Two types of tangential velocity discontinuity patterns and related force polygon diagrams are compared with each other at the optimized values. The ratio of friction force and pressing load, or equivalent coefficient of friction (P'eq), is determined (for AI alloy) from the force polygon diagrams. It is shown that P.eq is related with the magnitude of pressure roll feed rate but not with the roll surface conditions. 12 ref.--AA J.S. Ryoo, D.Y. Yang, and W. Johnson. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-25 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 12921298, [in English]. 52-0330
Optimal Control System Design f o r Ring Rolling Processes. One of the important factors critical to the ring rolling process is the rolling load to be applied to the blank rings being rolled. The load has to be continuously varied, depending upon size and material property of the ring, and is closely related to the feed rate of the pressure roll. An optimal controller design method is proposed to control the pressure roll movement to track a desired feed rate profile during the rolling cycle. Dynamic responses of the pressure roll motion were simulated to examine tracking performance of both optimal and nonoptimal control systems. The simulation results show that the optimal control system yields much faster response and almost no tracking error except at an early stage of the rolling cycle. Effects of the integral controller gain on the tracking performance are discussed. 9 ref.--AA J.S. Yun, and H.S. Cho. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society tot Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109] 1322-1327, [in English].
5 2 - 0 3 4 5 New Aspects f o r the Mass Production o f Spur Gears by Cold Rolling. The cold rolling method of Ernst Grob, M~nnedorf, Switzerland, offers, on the base of its character, CNC-machines and tool production developments, new solutions for the mass-production of automotive gears by the chipless cold roiling process. Some sequence of operations and results are illustrated.--AA H. Krapfenbauer. IPE Int. Ind. Prod. Eng., 1984, 5, (3), 39-41, [in English]. ISSN 0343-334X.
J. APPLIED METALWORKING
52-0347
E f f e c t s o f Reduction on a Minimill Steel. Testing is done to assess the quality of small-section strand casters. An as-cast billet of AISI 8260 steel measuring 4 x 4 in. purchased from a minimill and forge reduced to various reduction rates is tested to determine its suitability for parts used in high stress environments. A rolled bar of ingot-cast 8260 was tested for comparison. Comparison is made for microcleanliness, mechanical properties and fatigue test data. It is concluded that tensile properties are little affected by the amount of reduction from cast billet, that impact properties reveal increasing thoroughness with increasing reduction, that fatigue resistance increases dramatically with increasing hot reduction and that forging reduction varies widely and may not produce the required property effects in forgings made from low reduction bar.--C.M.L.S. R.H. McCreery. MeL Prog., Dec. 1984, 126, (8), 29-31, [in English], ISSN 00260665.
52-0348 M e c h a n i c a l P r o p e r t i e s o f 20G2R Steel f o r Cold Formed Components. {Translation). See Met. A., 8412-52-2025, A,T. Bykadorov, V.E. Vinogradova, T.V. Komarova, and I.L. Kheifets. Steel USSR, May 1984, 14, (5), 236-238, [in English]. ISSN 0038-9218.
52-0349 M i c r o e t r u c t u r e Design o f Dual-Phase Steel With Proper Quality Balance. A scheme for designing microstructures of dual-phase products from viewpoints of aging and forming characteristics was established. The influence of microstructural factors on aging characteristics and typical formabilities such as stretchability (yield strength to tensile strength ratio), deep drawability (rvalue) and sheared edge ductility (hole expansion) is critically reviewed, Principles of microstructure design are proposed for typical property balance and several experimental results are given for examples, 22 ref.--AA K. Nakaoka. Scand. J. Metal/., 1984, 13, (5), 289-297, [in English], ISSN 03710459. 52-0350
On the Behavior o f Residual Organic Matter From Lubricating Oil on Steel Sheet Surfaces During the Annealing Process. Organic carbon stains on cold rolled steel sheet surfaces damage the surface cleanliness. The behavior of lubricating oil residue on steel sheet surfaces through thermal decomposition during the annealing process was investigated. The cold rolling lubricating oil left on the surface of "as-cold-toned steel sheet" still remains as decomposed residue, though in trace amount, and this residue primarily consists of fatty acids (ClsC18) and esters. With the annealing temp., the fatty acid does not change in molecular weight distribution but the esters change. At an annealing temp. of 300~ the mass numbers of the ester show the distribution scattering at ~ 440, whereas at 400 to 700~ they show the distribution at ~ 400. It was found, by field desorption mass spectrometer (FD-MS), that the higher the annealing temp., the larger the mass number tends to appear.--AA K. Tanikawa, and u Fujioka. Lubr. Eng., Dec. 1984, 40, (12), 715-718, [in English]. ISSN 0024-7154. 52-0351 Future C o n s i d e r a t i o n s f o r D&I Coolants and Rolling Mill Oils. The areas of concern to Al can manufacturers and their impact on lubricants for coilstock and can manufacturing are reviewed. The growing concern for cost, flavor impact, competition, environmental legislation and worker safety in today's workplace is examined. Each of the areas will make demands that the concerned suppliers will need to meet. The ability to respond to these needs will dictate the survival of a coolant vendor and may impact on the over-all economic status of the individual can companies.--AA S.B. Smith. Lubr. Eng., Dec. 1984, 40, (12), 725-728, [in English]. ISSN 0024-7154. 52-0352 H y d r o g e n P l a s t i c i z a t i o n o f T i t a n i u m A l l o y s During Hot Deformation. (Translation]. See Met. A., 8406-52-1025. B.A. Kolachev, and V.K. Nosov. Soy. J. Non-Ferrous Met., 1983, (5), 384-389, [in English]. ISSN 0038-5484. 52-0353 Hot F o r m a b i l i t y o f N b - - V M i c r o a l l o y e d Steels f o r Pipeline Fittings. The hot formability of two typical microalloyed steels for pipeline fittings has been evaluated by heat and thermomechanical treatments performed in the laboratory under carefully controlled conditions, simulating those actually adopted in the works. The results obtained on the corresponding microstructural variations show that, provided the strain is kept < 20%, deterioration in strength and toughness properties of the finished piece is only likely as a consequence of heating it to excessively high temp. (> 1000~ or of holding it for too long a time (e.g. 5 h) at relatively high temp. (> 98OoC).--AA G. Buzzichelli, M. Pontremoli, A. Pozzi, and G. Pastorino. Metal/. ltal., Mar. 1984, 76, (3), 117-123, [in English and Italian]. ISSN 0026-0843. 52-0357 The State o f Stress and Strain During Helical Rolling Without a Mandrel. (Translation). See Met. A., 8407-52-1145. Ya.S. Shvartsbart, and V.N. Zhuchin. Russ. Metal/., Sept.-Oct. 1983, (5), 67-79, [in English]. ISSN 0036-0295.
Combined Discharge o f Different C o m p o n e n t s o f Spherical 52-0360 Shape During Extrusion Through a Channel Into a Die. (Translation). See Met. A., 6407-52-1148. L.N. Moguchii. Russ. Metal/., Sept.-Oct. 1983, (5), 90-93, [in English]. ISSN 00360295. S2-0361 I n v e s t i g a t i o n o f S t a i n l e s s S t e e l Wire D u r i n g and A f t e r Electropiastic Drawing. {Translation). See Met. A., 8407-52-1149. G.N. Belozerskii et at. Russ. Metall., Sept.-Oct. 1983, (5), 197-200, [in English]. ISSN 0036-0295.
52-0362 Problems Involved in the Numerical A n a l y s i s o f Plastic Working Processes for New Materials. The present state of knowledge in finite-element analysis of plastic working is discussed. The two major models of viscoelastic and elastic/plastic strain-hardening are reviewed. Examples are given of the application of FEM to forging, extrusion and compaction, under isothermal conditions and also when adiabatic heating is included. The difficulties of
J. APPLIED METALWORKING
coupled thermomechsnical analyses are considered. The properties of some auperplastic and aerospace alloys (Me-base and austenitic stainless steels) and the newer ceramics are discussed in the context of bulk forming. It is concluded that although these present formidable problems for numerical analysis, finite-element methods are in principle able to deal with such materials, and ways in which they may do so are suggested. 58 ref.--AA G.W. Rowe. Advanced Technology of Plasticity, Vol. 1 [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo t06, Japan, 1984, (Met.A., 8503-72-0109) 27-38, [in English].
52-0363
Forging and Thermomechanical Treatment of ODS-Nickel-
Base Alloys. Oxide dispersion strengthened (ODS) Ni-base superalloys attract much attention because of their superior high-temp, strength compared with the Ni-base "y'-hardening alloys. These P/M materials need a very specific thermomechanical processing route for producing parts with right shape, structure and mechanical properties. The hot workability of MA-6000 is described as a function o1 temp., strain and strain rate. The relation between hot working parameters and subsequent recrystallization to get long elongated large grains was studied. Forging trials for blade shapes were conducted which resulted in the desired structure and mechanical properties. 13 ref.--AA G. Schroeder, H. Rydstad, R.F. Singer, and M. Nazmy. Advanced Technology of Plasticity, Vol. 1 [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 850372-0109) 39-44, [in English].
52-0364 A Model Study o f M e t a l f o r m i n g in the M u s h y S t a t e . A model study has been initiated to analytically obtain a yield criterion for alloys in their mushy state. A liquid pocket-matrix material system was selected to simulate alloys in their mushy state. Based on theoretical prediction of the response of that model to different states of stress, a yield criterion could be obtained. The yield surface was mathematically expressed in terms of flow stress of the matrix material and the solid fraction (by volume). The magnitude of hydrostatic tension beyond which a mushy alloy collapses due to instability has also been studied; an equation was derived expressing that limit of stability as a function of the volumetric solid fraction and the vapor pressure of the liquid phase at the forming temp. A comparison was also made between the range in which the present theory is valid. --AA S.D, El Wakil. Advanced Technology of Plasticity, Vol. 1 [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minatoku, Tokyo 106, Japan, 1984, (Met.A. 8503-72-0109) 45-49, [in English], 52-0365 Extrusion Behavior o f Semisolid Alloys and Its Improvement by Rbeocasting. The extrusion behavior of semisolid Pb-- 19% Sn alloys is studied with materials of conventionally solidified dendritic structure and rheocast nondendritic structure obtained through mechanical stirring at a constant temp. (7) between liquidus and solidus. A rheocast structure consists of approx, spherical primary particles, which volume fraction, size and spacing decrease as T increases, embedded in a mixture of fine dendrites and eutectic. Whereas the theecast alloy can be extruded in the semisolid state under low extrusion forces giving a perfectly continuous rod, the conventional alloy requires higher forces and produces a completely fragmented product. The influence of extrusion temp. on quality of extruded rods is discussed in terms of solid volume fraction and structure of the initial billet. 10 ref.--AA M.A. Taha, and N.A. EI-Mahallawy, Advanced Technology of Plasticity, Vol. 1 [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-25 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 50-54, [in English]. 52-0366 Tandem Multidrawing of Seam-Welded Metallic Tube Containing Optical Fiber. A combined process of seam-welding and tandem multidrawing for tube fabrication is presented. This unique process developed for housing optical fiber, is characterized by fine synchronization of every drawing speed not to introduce any harmful stress in the optical fiber and the introduction of the floating plug drawing to obtain smoother inner surface to enable the replacement of optical fibers. Utilizing this process, the first practical composite overhead ground wire with optical fibers--OPT-GW--has been produced and installed and this type of OPT-GW has been dominant for use as telecommunication networks, observation systems of related natural phenomena--thunder, snow accretion, etc., along overhead power transmission lines.--AA Y. Naganuma, and K. Abe. Advanced Technology of Plasticity, Vol. 1 [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 55-59, [in English].
52-03S7 An E x p e r i m e n t a l Study o f Superplaetic D e f o r m a t i o n Under Combined Stresses. A study of superplastic Sn--Pb alloy thin-walled tubes subjected to axial tension or compression and internal pressure is described. Yield locus of the superplastic material observes the Mises yield criterion. Because the superplastic material is sensitive to strain rate its yield locus expands out homogeneously with increasing strain rate. It is shown that the stress--strain relation of superplastic deformation observes the Levy--Mises theory under nonproportional loading conditions and corresponds to the total strain theory if the loading path does not deviate far from proportionalily.--AA Z.R. Wang, B.C. Zhu, and L.J. Liu. Advanced Technology of Plasticity, Vol. 1 [Prec. Conf.]. Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-O109) 60-65, [in English]. 52-0368 S u p e r p l a e t i c l t y in A l p h a - B e t a T i t a n i u m A l l o y s and D e f o r m a t i o n in Hot Dis Forging. An investigation was conducted to clarify the influences of metallurgical factors and process variables on high-temp, deformation behaviors of two a-/~ Ti alloys, T i - - 6 A I - - 4 V and T i - - 6 A I - - 2 S n - - 4 Z r - - 6 M o . The grain size effect is very strong for superplasticity of both alloys. The ot + # preforms with fine equiaxed o~structure show excellent superplasticity over wide deformation ranges, On the contrary, the • preforms exhibit poor ductility and minor temp. dependence of m value. Internal voids observed in T i - - 6 A I - - 4 V are
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77
largely dependent upon the grain size and temp., but no voids are observed in T i - 6 A I - - 2 S n - - 4 Z r - - 6 M o . Tensile properties of isothermally forged materials are also discussed in relation to process v a r i a b l e s . - - A A A. Hasegawa, T. Matsushita, and Y. Moriguchi. Advanced Technology of Plasticity, Vol. t [Prec. Cent], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 66-71, [in English].
52-0369 Apparatus for Testing Materials Under High Hydrostatic Pressure and High Deformation Speed and Some Experimental Results o f Z i n c . A testing apparatus in which some deformations, such as tension and blanking, can be given to metals at ambient temp. under hydrostatic pressures up to 700 MPa and with deformation speeds up to 1000 mm.s - 1 is described. Using this apparatus and another one, tensile tests of a high-purity polycrystalline Zn w e r e carried out in a wide range of deformation speeds. The increase of the brittleto-ductile transition pressure with increasing strain rate is discussed on the basis of rate dependency of fracture stress. 16 r e f . - - A A M. Ohmori, M. Itoch, F. Yoshida, and M. Inoue. Advanced Technology of Plasticity, Vol. 1 [Prec. Conf.J, Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 72-77, [in English].
52-0370
Dynamic Recovery During Deformation o f a Medium-Carbon
S t e e l . An SAE 1045 carbon steel was subjected to incremental plastic deformation by reversing the application of load, which was achieved by extruding and upsetting a solid cylinder alternately at atmospheric temp. and at low effective strain rates of ~ ~ 0.02 rain - I . It was found that this type of deformation, which resulted in zero net change of shape, induced lowered flow stresses but very little grain distortion. It is suggested that the deformation consisted of dislocation movement, which resulted in simultaneous strengthening and weakening. Some experiments made where a change of shape of the specimen occurred showed a somewhat smaller decrease in the flow stress but, at the same time, more grain distortion. It is concluded that dislocation strengthening and recovery are at work during deformation.--AA E.G. Thomsen, and A.E. Shabaik. Advanced Technology of Plasticity, Vol. 1 [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 84-69, [in English]. 52-0371 C o n s t i t u t i v e M o d e l i n g o f t h e i n e l a s t i c B e h a v i o r o f Austenitlc Steel. A set of constitutive relations is presented to describe the e l a s t i c - inelastic behavior of austenitic steel in the range of small strains and up to 600~ This model permits a description of the hardening behavior in the case of mechanical loading and hardening and softening in the case of thermal loading. The loading path may be either monotonous or cyclic. For this purpose, the well-known concepts of isotropic and kinematic hardening are connected within the framework of an internal variable theory. A number of suitably defined internal variables is introduced to describe the transition from isotropic to kinematic hardening behavior of the material. The model also allows for rate-dependence of the behavior when exceeding the yield limit. Therefore the concept of "overstresses" is introduced, where the (real) stresses during inelastic deformations are rate-dependent multiples of the (static) plastic stresses, thus both stresses coincide in the limit of vanishing velocities (static limit). 11 r e f . - - A A O.T. Bruhns. Advanced Technology of Plasticity, Vol. 1 [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minatoku, Tokyo 106, Japan, 1984, (Met.A. 8503-72-O109) 90-95, [in English].
52-0375 Some New Thoughts on the Mechanisms of Sliding and Sticking Friction in Metal Working Processes. A slipline field asperity deformation model is given 1o represent the mechanical interactions which occur between contacting surfaces sliding over each other under normal sliding conditions, i.e. where the real area of contact is much less than the apparent area of contact. This model effectively combines the adhesion and ploughing mechanisms, which are usually treated separately in friction theory, in a single model. Experimental results are presented in support of predictions made from the model. It is then shown how the model can be extended to the case where the real area of contact approaches, and in the limit equals, the apparent area of contact. Some consideration is given to the influence of material properties on the frictional process under, what are popularly termed, sticking conditions. 11 r e f . - - A A J,M. Chanen, and P.L.B. Oxley, Advanced Technology of Plasticity, Vol. 1 [Prec, Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109] 127-132, [in English]. 52-0376 T r i b o l o g y in M e t a l f o r m i n g P r o c e s s e s . Tribological problems in metalforming, above all the fundamental concepts regarding friction, testing methods and various measures obtainable from them to assess lubricity and antiweldability, and practical devices for lubrication improvement are reviewed. The ironing of carbon, high-strength and austenitic sleets and cold rolling of At are discussed. 35 r e f . - - AA N. Kawai, and K. Dohda, Advanced Technology of Plasticity, Vol. 1 [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 145-156, [in English].
52-0377 Tribological Attempt t o E s t i m a t e S e i z i n g A b i l i t y o f M e t a l Sheets. The method of seizing ability determination of AI, Cu and stainless steel sheets is presented. The test device modeling, drawing with changes of sheet thickness, test technique and criteria of estimation of seizing ability of sheets are described. The results of laboratory tests on the determination of the effect of drawing parameters (velocity, lubrication conditions) and certain factors, such as surface roughness, hardness of sheets and die material and the existence of oxide films on the sheet surface on the appearance of seizing are presented. The results of tests on the selection of lubricants and antiadhesive coatings on the sheet drawing tools are also described.--AA M. Gierzyfiska-Dolna, and E. Bociaga, Advanced Technology of Plasticity, Vol. 1 [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-
78
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5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (MeLA., 8503-72-0109) 157-161, [in English].
52-0378
A Method for Evaluating Tool Materials Against Seizure in
M e t a l f o r m l n g . A testing method of friction and seizure characteristics of tool material is proposed, A bar of tool material is rubbed with newly generated inner surface of a ring-shaped specimen under an arbitrary contact pressure. The frictional stress increases linearly with contact pressure and it deviates from Amonton's law when the pressure in kgf/mm 2 exceeds the value of Vickers hardness number of the specimen. Under a higher pressure it saturates. The coefficient of friction under low pressure has a close relation with the saturated frictional stress and with the degree of seizure. Some tool materials, with and without hardened or coated surfaces, are evaluated for some representative workpiece materials (carbon, austenitic, stainless and C r - - M o steels and AI- and Ti-base alloys).--AA K. Osakada, and F. Murayama. Advanced Technology of Plasticity, Vet. t [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1964, (Mef.A., 8503-72-0109) 168-173, [in English]. E f f e c t o f W o r k Hardening Property on Pick-Up B e h a v i o r o f Aluminum and Its Alloys. The effect of work hardening property of workpiece on 52-0379
its pick-up behavior has been investigated by ironing the annealed and the work hardened AI base alloys (1100, 3003 and 5052). The strip, 10 mm wide and 2 mm thick, is ironed between a long flat die and a cylindrical tool traveling perpendicular to its axis on the strip. When liquid paraffine is applied as the lubricant, many cracks are observed on the surface of the work hardened specimen; however, annealed specimen has no crack on the surface after ironing. None of the specimens has any cracks on the ironed surface when lithium stearate is added to liquid paraffins. Both decrease in work hardening exponent of the workpiece and worsening of the lubricity of the lubricant exert the same influence on the pick-up behavior of AI and its alloys.--AA T, Sakai, H. Sasaki, Y. Saito, and K, Kate, Advanced Technology of Plasticity, Vol. 1 [Prec. Conf.], Tokyo, Japan, 1964, Japan Society for Technology of Plasticity, 52-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 174179, [in English].
52-0380
Fundamental Mechanisms of Galling and Other Surface
D a m a g e C a u s e d by Sliding a n d / o r P l a s t i c D e f o r m a t i o n . The features and mechanisms of flaking and powdering of electrogalvanized and galvannealed steels have been studied to avoid the surface failures of pressed autobody panels. Various modes of plastic deformation were used as surface damage tests and the associated experimental techniques and scanning electron microscopy were applied. Flaking is a surface damage occurring on the sheet with a soft and ductile surface layer. It is closely connected with galling in mechanism, though some additional factors (macroscopic localization of contact across width direction, weak constraint of the sheet, long contact along the sliding direction) help the fragment to develop and to be removed from the tool as the sliding continues. Bending-unbending does not seem to play an essential role. Powdering is caused by microcracking of a brittle surface layer which cannot deform plastically 1o fulfill the required straining.--AA H. Ike. Advanced Technology of Plasticity, Vol. 1 [Prec. Conf,], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato ku, Tokyo 106, Japan, 1984, (Met.A,, 8503-72-0109) 180-185, [in English]. 52-0381 S t r e s s S t a t e and S u r f a c e R o u g h n e s s . Single-crystal behavior of polycrystals during plastic deformation would lead to disintegration of the matel'ial. Hence, more slip systems must be active. Taylor selected these active systems considering some energy criterion. However, in a free surface, the material can shear differently by moving out of the surface. The well-known effect of the grain size and the amount of deformation on the surface roughness can thus be explained. Since the deformation in polycrystals mostly happens in or near to the planes of max, shear stress the extent of deformation, and so the surface roughness, could also depend on the state of stress. This relation is investigated for different stress states. 10 r e f . - - A A J,H. Dautzenberg, and J.A.G. Kale. Advanced Technology of" Plasticity, Vol. 1 [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-25 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) f66-191, [in English].
52-0382 Tribological Approach to M a t e r i a l s P r o c e s s i n g . Materials processing usually involves a machine tool, processing tool, workpiece and lubricant or coolant. An integrated tribological approach to the whole system is described. Examples are given from both metal cutting and forming processes of AI sheet illustrating this approach, The results enable a better understanding of processes which cause improvements in productivity and workpiece quality. It is shown that tribological interactions of material processing affect the performance and reliability of critical components during their use. 9 r e f . - - A A K.C. Tripathi. Advanced Technology of Plasticity, Vol. 1 [Prec. Conf], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minatoku, Tokyo 106, Japan, 1984, (Met.A., 6503-72-0109) 192-199. [in English]. A Model for the S i m u l a t i o n o f Friction Between Dies and Workpiece. Based on the interaction of asperities and the upper bound ap52-0383
proach, a mathematical model for the simulation of friction between dies and workpiece is proposed. By optimizing the mathematical model with respect to three variables it was found that in addition to adhering, tearing and ploughing, the asperities of the workpiece can move in a wave-like fashion along the surface layer and also, under certain circumstances, these asperities might collapse. During the wave-like motion of the asperities, the friction coefficient depends on the geometry of asperities; however, the bonding strength between the asperities has no significant influence on the over-all coefficient of friction. The depth of the plastic deformation zone in the workpiece is also related to the geometry of asperities. The validity of the proposed model and some of the analytical results were verified by several model experiments performed on commercial-purity AI.--AA B, Avitzur, C.J. Van Tyne, Z.J. Luo, and C,R. Tang. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for TechnologY of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-720109) 200-207, [in English].
J. APPLIED METALWORKING
5 2 - 0 3 8 4 Mutual Relation of M e t a l P l a s t i c F l o w and Friction Phenomena on the S u r f a c e o f C o n t a c t o f t h e M e t a l With T o o l s . The main statements of the hypothesis of cohesional-sliding friclion are presented. According to this hypothesis the unit forces tangential to the surface of contact of the tool and metal depend on the distribution of displacements, on deformation and on the way the subsurface layers of the metal flow, To examine the correctness of the thesis presented, investigations based on tests of rolling flat specimens and upsetting parallelepipedal, cylindrical and ring specimens of AI, Cu, Pb and brass were carried out. During tests, the unit tangential and normal forces and the displacements on the surface and inside of the specimens were measured. The results prove the correctness of the t h e s i s . - - A A W. Dobrucki, and P. Sobkowiak. Advanced Technology of Plasticity, Vol. I [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 208-213, [in English],
52-0390 Fundamental Tribology in C o l d Sheet Roiling--Development o f Methods for Evaluating the L u b r i c i t y o f L u b r i c a n t . A study was conducted to investigate the lubricant behavior in cold sheet rolling of carbon steels to gain a better understanding of evaluation of the lubricity of lubricant. The relationship among methods by fundamental testing machines, simulation testing machines and rolling mills is discussed. It was found that the Iubricity of lubricant should be evaluated by methods which simulated the actual contact conditions in cold sheet rolling process and the contact conditions of the tool and the material in the testing machines should coincide with those between the rolls and the sheet. A new simulation testing machine was developed and a good correlation was established between the simulating test and the mill test. The new simulating test was effective for evaluation of the lubricity of lubricant. 18 r e f . - - A A A. Azushima, and Y. Kita. Advanced Technology of Plasticity, Vol. I [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 241-246, [in English].
52"-0385
52-0391
52-0386
Foil. High-speed rolling tests, up to 150 mlmin, and pendulum-type friction test are conducted to determine suitable lubricants for rolling of At sheets and toils. An oil film is introduced into roll bite with increases in viscosity of a base oil and rolling speed. The most preferable additive for AI rolling is alcohol. Under the condition where boundary friction exists partially, additives have an important role in reducing rolling pressure. On the other hand, rolling pressure does not depend on the additives under hydrodynamic lubrication, which is realized when oil film thickness reaches the surface roughness. In foil rolling, the lubricating condition is influenced remarkably by additive even though rolling speed is high because of the roll coating formation depending on additives to determine the lubricating condition. 10 ref. --AA K. Metsui, T. Matsushita, K. Takatsuka, and Y. Yamaguchi. Advanced Technology of Plasticity, Vol. 1 [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 247-252, [in English].
Wear, F r i c t i o n a n d L u b r i c a n t s in H o t F o r g i n g . Lubricants and die steels for hot forging have to fulfill different requirements, It is convenient, therefore, to analyze their properties by separate, simple technological testing methods. It was proved that the temp. of tool and workpiece and the reciprocal action between lubricant and die steels (X32CrMoV33) correlate with wear behavior. Characteristics--particle size, crystal size, microporous texture, hardness and purity--describe the properties of graphite powders. Calculation of temp. on the boundary layer and the resulting tensile strength and yield stress are used to predict wear behavior. Wear increases with toad and path of friction and decreases with the temp. of workpiece and hardness of the t o o l . - - A A E. Doege, and R. Schneider. Advanced Technology of Plasticity, Vol. 1 [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-8 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (MeLA., 8503-72-0109) 214-218, [in English].
Study on the Frictional Boundary Condition at the Edge o f T o o l / M a t e r i a l interface in Massive Forming. By using friction testing apparatus in which frictional sliding occurs, in one direction, at the die surface between edges, AI workpieces with various kinds of topography and roughnesses are forged at a slow speed for a paraffinic lubricant. Precise observations are made on the variations of the frictional coefficient and the collapse of asperities around edges during a process. The outward flow of the lubricants trapped in the interface is differently checked at the edges according to the mode of deformation or the singularity of deformation at the edge. The surface topography of the workpiece, which makes up isolated micropools of lubricant in the interface, has a significant influence on the effective decrease of the frictional force and the maintenance of the lubricant film, especially when the singularity is w e a k . - - A A H. Saiki, H. Nishitake, Y. Yoshioka, and T. Kumagai. Advanced Technology of Plasticity, Vol. 1 [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984. (Met.A., 8503-720109) 219-224, [in English]. 5 2 - 0 3 8 7 E v a l u a t i o n o f W e a r and G a l l i n g R e s i s t a n c e o f S u r f a c e Treated Die Steels. To improve the lives of forming dies, carbide and nitride coatings prepared by CVD and molten salt immersion are often employed. The tribological characteristics of these surtace-treated steels, mainly VC coated steels, by molten salt immersion, were investigated in several experiments simulating the metalforming process. The results indicate that the carbide and nitride coatings are remarkably effective in suppressing the galling tendency compared with other surface treatments. Because of this property, a VC-coated smooth punch could make cups with smooth inner surface by backward extrusion without lubricant. It was important to finish the surfaces of tools as smooth as possible to make the most of the properties of the coatings. 13 r e f . - - A A T. Arai, and Y. Tsuchiya. Advanced Technology of Plasticity, Vol. I [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 225-230, [in English].
52-0388
The T r i b o l o g y o f a S i m p l e H o t Forging Process: I n f l u e n c e o f L u b r i c a t i o n and N i t r i d i n g T r e a t m e n t . To be able to forecast the life of a forging die, CAD programs must take into account the main damage types. A CAD program has been designed which provides a good estimation of the wear by abrasion of flat dies without surface treatment. To study the influence of nitriding, a series of carbon steel cylinders (1 to 3000) has been upsetted between dry or lubricated nitrided flat dies with a mechanical press. Friction is reduced by nitriding and lubrication. Contrary to nonnitrided dies, the most severe damage arises from cracking of the surface by thermal fatigue and scale films stick to the dry die surface and reduce die surface heating, friction and cracking. Great metallurgical changes occur in nitrided layer and induce a decrease in its hardness which remains nevertheless high enough (> 800 HV) near the surface to avoid abrasion. --AA E. Felder, J.-F. Renaudin, and Y. There. Advanced Technology of Plasticity, Vol. 1 [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-25 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 231-234, [in English]. 5 2 - 0 3 8 9 A Method for E v a l u a t i n g Liquid L u b r i c a n t s Using Piezoelectric Sensor. Stress wave generated by metallic contact at die/wire interface during drawing of AI and Cu wires are detected by using a piezoelectric sensor. The del e t t e d signals are processed in the root mean square (RMS) voltage. Nrms is proposed which can be utilized for evaluating lubricant characteristics. In the proposed Nrms the influence of drawing speed on the RMS voltage is taken into account. Relationships are obtained between the reduced film thickness of lubricants h" and the Nrms. Relationships between the h" and the coefficient of friction or the fraction of metallic contact area are also obtained. Applicability of the Nrms is thus confirmed.--AA S. Masaki, and T. Tabata. Advanced Technology of Plasticity, Vol. I [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 238-240, [in English].
J. APPLIED METALWORKING
Evaluation of Lubricants for Rolling of Aluminum Sheet and
52-0392
Tool/Workpiece I n t e r f a c e S t r e s s e s in C o l d Forward E x t r u s i o n . Based upon a general theoretical model for friction valid at low and high normal pressures the normal and friction stress distribution along the t o o l / workpiece interface in cold forward extrusion is estimated. The influence of reduction, die angle, friction factor, strain hardening, prestrain and initial roughness of the specimen surface on stress distribution is calculated. The results are in good accordance with experiments on cold extrusion of AI alloy AI2S specimens. 8 ref. --AA N. Bay. Advanced Technology of Plasticity, Vol. I [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 259-266, [in English].
52-0393 Investigation Into Seizure Mechanism by Means of ExtrusionType F r i c t i o n T e s t i n g M a c h i n e . An extrusion-type friction testing machine has been designed for examining the seizure mechanism in cold metal deformation processes. This apparatus was devised to simulate the frictional surface accompanied with a remarkable surface expansion, a high contact pressure and a forced relative slip displacement and to measure directly contact pressure p and frictional shear stress ~f distributions on that surface. Using the frictional testing machine, a commercially pure AI has been tested as the work metal under some frictional conditions. Although seizure was initiated near the die exit in a dry frictional condition, the seizure initiation was suppressed in the inner region of the die where a contact pressure p was higher than the critical condition: p = 220 H~ (MPa). Here, Hmeans a punch stroke (mm). 9 r e f . - - A A T. Nakamura, A. Urata, and K. Kate, Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-25 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 267-272, [in English].
52-0394 Bulge Forming o f T h i n W a l l e d T u b e s by Micro-Computer Controlled Hydraulic Press. The development of an automatic test system for tubular materials under biaxial stresses by using a microcomputer is described. The system is used to study bulge forming of thin-walled tubes under internal pressure and axial force. By this newly developed equipment, any desired loading path can be applied to tubular materials. The experiment was carried out to examine deformation behavior and limit expansion of AI tubes for the linear and the nonlinear loading path. In linear loading path, it is found that limit expansion of tube increases as the stress ratio ~ (= meridional stress~circumferential stress) approaches zero, where the value of limit expansion reaches the max. The effects of loading path on limit expansion of tubes are similar to those of sheets. 10 ret. --AA K.-i. Manabe, K. Suzuki, S. Mori, and H. Nishimura. Advanced Technology of Plasticity, Vol. 1 [Prec. Conf.1, Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (MeLA., 8503-720109) 279-284, [in English], 52-0395 On the Flattening of Cross-Section of Circular Tubes in Uniform Bending. The influence of material characteristics, especially plastic anisotropy, on the flattening of cross-section in uniform plastic bending of circular Cu tubes is analyzed theoretically and the results are compared with experimental results. The flattening is analyzed by the energy principle based on the deformation theory and the Hill's theory of plastic anisotropy. The strain components are determined to minimize the functional which is defined as the scalar product of stress and strain. The flattening of cross-section increases as the strain hardening exponent is larger. It also increases as r0-value, which is defined in uniaxial longitudinal tension, is larger and as the r~-velue, which is defined in uniaxiaJ circumferential tension, is smaller. T h e s e t h e o r e t i c a l results c o i n c i d e well with t h e experimental results.--AA J. Endow, and T. Murota. Advanced Technology of Plasticity, Vol. I [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 285-290, [in English].
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Computer Simulation o f Cold Forming o f Tubes. The simulation of metalworking processes using an EA1500 Hybrid Computer is described. Differential equations describing the tube forming processes have been developed and converted into a form suitable for analog simulation. Machine equations are developed and scaled to suit the range of values likely to be encountered for all relevant parameters in the industrial situation. The simulation allows graphical output on a video terminal of the solution of metalworking problems and allows any parameter or parameters to be varied so that a comparison of the effects can be visualized or studied with accuracy and speed. 9 ref.--AA W. Thompson, and K. Denmeade. Advanced Technology of Plasticity, Vol. I [Proc. Conf.], Tokyo, Japan, t 984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 291-296, [in English].
52-0404 Application o f Powder Forging to Automotive Parts. Various problems regarding parts to be adopted, the scale of installation and processes which are adequate for the application of powder forging to automotive parts are clarified mainly from an economics point of view. Suitable powder forged parts are those which use plain carbon steel, particularly parts which are relatively large and complicated and which are not easily produced by a competing process. The single heating method, which is the best process for energy savings, should be adopted in heating preforms. How the problems are solved using connecting rods as a concrete example is described.--AA C. Tsumuki, K. Imahashi, and I. Nagare. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-25 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 339-346, [in English].
52-0397 Influence of Strain-Hardening Exponent on the Deformation of Thin-Walled Tube of Finite Length Subjected to Hydrostatic Internal Pressure. The bulge forming process of thin-walled tube of finite length subjected
5 2 - 0 4 0 5 Forging o f a H o l l o w Metal Powder Preform Disk. Industrial processing of metal powder preforme is currently arousing global interest as an economic method of producing components from metal powders. Considering the process of the forging of a hollow metal powder preform disk under axisymmetric conditions, the problems of pressure distribution at the die/workpiece interface and processing load have been analyzed. The correctness of the yield criterion and intertacial friction law used during the analysis have also been confirmed experimentally through the forging of Fe powder. The results are discussed critically to illustrate the interaction of various parameters involved and are presented graphically. 8 ref.--AA A.K. Jha, and S. Kumar. Advanced Technology of Plasticity, Vol. I [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 353-360, [in English].
to hydrostatic internal pressure is analyzed numerically by the strain incremental theory. The ends of the tube are closed and are restrained from radial motion but are free to translate axially. It is assumed that tube material is isotropic and rigidplastic and obeys the power law of strain hardening, aeq F~nq.The Levy--Mises stress--strain relations and Mises' yield condition are used. The solutions are obtained in terms of stress and strain distributions, relation between internal pressure and center radius of tube, max. internal pressure and critical expanding radius. The influence of strain-hardening exponent (n-value) on these deformation characteristics is discussed. 10 ref.--AA S. Fuchizawa. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minatoku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 297-302, [in English]. =
52-0398
Instability Phenomena in the Pure Bending of Shape Steels.
The lateral buckling or wrinkling formation in shape steel components and plates having symmetrical cross-sections made of elastic--plastic workhardening material subjected to pure bending is investigated theoretically. Hill's general theory of uniqueness and bifurcation in elastic--plastic solids and separation of variables and the finite element method are employed to obtain the bifurcation point and associated mode. The influence of the shape of the components and boundary conditions upon the bifurcation behavior is mainly investigated. Upon comparing the predicted and experimentally determined bifurcation point for AI plates a favorable correspondence is obtained. 13 ref.--AA A. Zghal, A. Shindo, and Y. Tomita. Advanced Technology of Plasticity, Vol. 1 [Prod. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-25 Roppongi, Minato-ku, Tokyo 105, Japan, 1984, (Met.A., 8503-72-0109) 303-308, [in English].
52.0399 A Successive U- and O-Bending f o r M a n u f a c t u r i n g LongLength Circular Tube. Attempts have been made to form a strip of carbon steel into a long length circular tube by an incremental forming technique, using specially designed U- and O-bending die sets mounted together in sequence in a conventional press, with usual intermittent feeding of the strip metal for every stroke of the press. The final circular shape is imparted to the flat strip by the action of incremental deformation, gradually leading initially to U-shape followed by a similar action of O-bending sequence to circular shape. The action of incremental deformation has been achieved by making a portion at the entrance of the bending punch and dies, inclined along the longitudinal direction, so that the strip entering the die set takes the final form gradually. At U-bending stage, camber and formation of edge waves appeared depending on the bending conditions. However, most of these defects were overcome by the subsequent incremental bending at Oforming stage by selecting a suitable condition and finally giving circular tubes of adequate dimension and shape accuracy.--AA H. Ogawa, K. Tamura, and T. Nakagawa. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 52-5 Roppongi, Minato-ku, Tokyo 108, Japan, 1984, (Met.A., 8503-72-0109) 309314, [in English].
52-0402
Microcomputer-Aided Analytic Method for VTR Images of
Two-Dimensional Plastic D e f o r m a t i o n . For analysis of two-dimensional plastic deformation of a coarse crystal AI sheet specimen under several forces, a new microcomputer-aided analytic method to monochromatic video images of plastic deformation of fine square grids, which have excellent contrast to the specimen and good deformability with the specimen, was developed, images on the specimen in testing are taken continuously with a CCTV camera having an object lens with suitable magnification and recorded into a video tape. Selected images are converted into digital data and written into a floppy disk, one after another, and an image made by binary data is transfered monochromatically on a colored, high discrimination display of a microcomputer. Cartesian coordinates of each cross-point after a new fining processing are read out and several deformation distribution and strain maps in various cases, shown by vectorial expression, are obtained on a display and printer.--AA N. Fujimori. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 327-332, [in English]. 52.0403 Measurement o f Dihedral Angle o f a Plate in Bending With an Image Sensing Camera, The noncontsct method combined by an image sensing camera and microcomputer is applied to the measurement of dihedral angle of a bent plate. The sectional view of the plate reflected by the camera is projected on the matrix array of the photodiodes, where it can be analyzed geometrically as an image pattern. The relation between the image pattern and error of the bending angle is investigated and the trials to decrease the errors are discussed. Experiment shows that the angle with little error can be measured by the image sensing camera with the linear array of photodiodes.--AA T. Sawada. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 333-338, [in English].
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52-0406 E f f e c t o f Hydrostatic Pressure on the D e f o r m a t i o n o f Sintered Metals. Plastic deformation behavior of sintered metals is studied using the upper bound theorem approach with a rigid perfectly plastic unit-cell model. An effective hydrostatic pressure necessary to cause volume change of voids and tensile flow stress of void materials after pressurized or under hydrostatic pressure are analyzed. The ductility of the void materials is also discussed on the basis of void growth mechanism. The analytical predictions of various behaviors are compared with experimental results of eintered Fe and Cu. 10 ref.--AA F. Yoshida, M. Ohmori, and M. Sawa. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-25 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 361-366, [in English]. Finite Element Analysis o f Tube Deformation Under Impulsive Internal Pressure. The elastic--plastic analysis of high-speed tube expansion
52-0407
is made to investigate the deformation processes of tube forming by a high-energy rate forming method. A formulation of the finite element method based on the large deformation theory is developed in combination with Newmark method of time integration scheme. The numerical solutions are obtained in terms of the profile and deformation path, velocity and acceleration, strain and strain distribution of the tube wall for the applied internal pressure. The analysis gives a clue to obtain an accurate solution for dynamic tube deformation and to predict a practical procedure for tube forming. 7 ref.--AA H. Suzuki, Y. Yokouchi, M. Murata, and H. Negishi. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-720109) 367-372, [in English]. 52-0408 Impulsive Forming o f Tube Ends by Electromagnetic Force. Tube ends of an AI alloy (A6063TD) are expanded electromagnetically. Free expanding is investigated with respect to high-speed deformation behavior, deformed shapes, strain distribution, an axial component of forming load, etc. Straight expanded cross-sections and sharply tapered angles are obtained by the free expanding with the use of a back-up ring. Die expanding is also studied using dies of O = 30, 60 end 90* to get desired shapes exactly. For short length I (I _< 20 mm) to be expanded, complete fitting to dies is obtained by choosing the appropriate charged energy. For the long I (I > 20 ram), an introduction of field shapers a~hieves good fitting and leads to the improvement of forming limit. 7 ref. --AA T. Sand, M. Takahaahi, Y. Murakoshi, and K. Matsuno. Advanced Technology of Plasticity, Vol. I [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 850372-0109) 373-378, [in English].
52-0409
New Processes for Explosive Metalforming of Sheet Parts in Batch Production, New results were obtained from fundamental studies of parameters and factors influencing explosive forming with amorphous energy conveying media in a closed mold. The knowledge of the stress and energy parameters involved and of means to influence them is important for controlling the explosive forming process and for properly designing production means. As a result, explosives could be utilized as an energy source for batch production. Applications include new and economical methods of forming automobile axles and conveyor screws for screw pumps. 7 ref.--AA A. Neubauer, H. Steinicke, K. Vinzens, and H. Schmicker. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 850372-0109) 379-384, [in English]. 52-0410 Forming Limit Criteria and F o r m a b i l i t y o f Aluminum Sheet in Explosive Forming. Investigations have been carried out in a laboratory-type explosive forming set-up using suitable grooved dies to stretch form AI blank in water medium. The concepts of drawing, stretch forming and forming index are presented for quantitative evaluation. Several criteria of formability of sheets are presented. Formability and forming index of fractured components increased with the increase in number of stages of explosions. The strains are presented in a triangular coordinate system. It is concluded that materials prosseasing poor forms-
J. APPLIED METALWORKING
bility can be satisfactorily deformed in multistage explosion with interstage annealing. 11 ref.--AA T. Behera, and S. Misra. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 385-390, [in English].
An Approach to the Theoretical Analysis in Rotary Forming Process of Cylindrical Rods. Rotary forming has been noted as a process of 52-0411
forming axisymmetrical profiles by a small force, it is necessary to analyze the deformation process theoretically to predict the working forces and the other information available in selecting working conditions for production. Many difficulties must be overcome. Therefore, the theoretical analyses of two fundamental deformation processes are proposed and it is clarified that these are available to analyze the complex deformation process in rotary forming. As examples, the calculated results are given on cross-rolling and an approach is also presented on the theoretical analysis of defects in the process. The features in rotary forging are described and a guide is given to the theoretical analysis of this process.--AA M Hayama, and K.-i. Kawai. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A. 8503-72-0109) 391-400, [in English].
52-0412
The Shear Spinning Technology of Tubes With High
Dimensional Precision. In conventional tube spinning technology the size of the finished tube is limited to a max. length of 4 m and a rain. outside dia. of 40 mm. A modified tube spinning technique and the equipment developed for it, which can produce tubes as long as 10 m and dia. as small as 10 ram, is described, This technology has been used to produce high precision tubes with a wall thickness as low as 0.3 mm in Inconel, Incoloy, stainless steel and Ti. Potential new applications of tube spinning have been suggested. A further advance in technology where it may be possible to replace a long mandrel with a short stationary plug is also suggested.--AA B.K. Agarwala. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minatoku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 401-409, [in English].
5 2 - 0 4 1 3 Shear Spinning Modeling. A theory based on the upper-bound theorem for pure shear spinning process is presented. A general review of previous theories is given, then the geometric pattern is described and the power and tangential force are estimated. The whole power is computed from the discontinuity of velocity between infinitesimal rigid elements of a rigid-plastic material. Assuming that the only cause of energy dissipation is the tangential component of force, it is possible to estimate its value. The axial and radial components are estimated from geometric considerations and the experimental results are contrasted with the theory, g ref.--AA P.R de Francisco, and A.M.S. Pdrez. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-25 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 410-415, [in English]. 52-O414 Forming of Corrugated Diaphragms by Rolling Steel Balls. Some theoretical and experimental investigations on forming of metallic corrugated diaphragms are discussed. Both the blank and die are fixed to the end of the main spindle of a drilling machine, on the other hand, the punch with several steel balls are set under them. When the revolving blank moves down and touches the punch, the steel balls are rotated and the blanks are formed with the normal and tangential forces. The experimental results show that this method can make the corrugated diaphragms under very small forces. This effect is atttributable to the small contact area between ball and blank and receives the combined forces. --AA H. Furukawa, I. Kasamatsu, and I. Hirata. Advanced Technology of Plasticity, Vol. I [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 52-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 416421, [in English]. 52.0415 The D e v e l o p m e n t of Longitudinal Strain in Cold Roll Forming and Its Influence on Product Straightness, One of the main criteria of selecting roll pass schedule in cold roll forming is to obtain a straight product using rain. number of rolls. An investigation into the development of strains during cold roll forming of symmetrical channel selections from mild steel is described. The instantaneous strain histories have been obtained using bonded strain gages for various stages of channel forming. The significance of the initial and final bend angles has been demonstrated and the guide rules for selecting optimum roll pass schedules have been discussed. A logical flow chart has been suggested for the selection of rolls. 10 ref.--AA D. Bhattacharyya, and P.D. Smith. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-25 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A. 8503-72-0109) 422-427, [in English], Roll Forming o f U-Shaped Ribs by a New Roller Die Forming Process. A roll-forming process, roller die forming, was developed. In general a conventional roll-forming process for large*sectioned material entails such problems as high investment cost, generation of scratches and end deformation on cutting. To solve these problems, small-dia, rolls which were set on die plates along the shapes were used and the cause of the end deformation on cutting low-carbon steel was analyzed by experiments and a new installation to prevent the end deformation was invented.--AA Y. Mihara, K. Suzuki, and I. Yamanobe. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-25 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 428-433, [in English].
of the required motions and other functions such as automatic tool changing in a flexible machine tool including also the control of peripheral equipment is a prerequisite for the realization of FMPS and FMPC for plastic working. Various examples of already existing FMPS and FMPC are demonstrated. They also represent "pure" systems for either steel sheet metal shaping by shearing processes or bulk forming processes as "mixed" systems for shearing and forming of sheet components. A system provided with laser is also included. 8 ref.--AA K. Lange. Advanced Technology of Plasticity, V o L t [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (MeLA., 8503-72-0109) 434-445, [in English].
52-O418
FMS in Metal Stamping. A situation in which metal stamping, the most effective mass production technology to date, has stood face to face with the problem of adapting to the "small lot production", a forerunning situation of FMS realization, is presented, The development of the flexible manufacturing cells which permit the realization of FMS and views and open points of the total FMS and the importance and position of the dies in FMS are discussed.--AA M. Iwamatsu. Advanced Technology of Plasticity, VoL 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi. Minatoku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 446-448, [in English].
52-0419
Metalforming Machinery Developed in the National Project o f FMSC. An R&D project of an integrated flexible manufacturing system complex (FMSC) including a metalforming subsystem is underway, Four prototype forming machines (automatic open die forging machine, multiram precision forging machine, disk-ring roiling machine, hot isostatic pressing machine) were developed together with forming techniques. An example is given of HIPing an Fe alloy. The project is now in the final stage and the evaluation of the machines and conceptual designing of an integrated system are being carried out.--AA C, Soda, T. Sano, and K. Matsuno. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-25 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 449-460, [in English]. 52-0420
F l e x i b l e Rolling o f Bar and Rod in Small-Order Lots. Many bar and rod mills have a wide product mix which implies frequent stoppages for the rebuilding for a new size or profile. A flexible rolling technique is described where stoppages are almost eliminated as the change for a new product is made in a very short time. The rolling mill can therefore also work on-line with a continuous caster to save energy. Rolling at a low temp., warm rolling, is very suitable and will help to accomplish direct roning.--AA P,O. Strandell. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minatoku, Tokyo 106, Japan, 1984, (Met.A. 8503-72-0109) 461-465, [in English].
52-0421 Transfer Lines for MulUstep Sheet-Metal S t a m p i n g With industrial Robots. The major trends of developing robotic multistep sheet-metal stamping are considered. The most effective field of industrial robots application is creating easily readjusted complexes for two-, three- and four-step sheet-metal stamping with carried away dies.--AA Y. Semenov, S. Scorodumov, and M. Kryuchkov. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-720109) 465-470, [in English]. 52.0422
Contribution to Automatic Selection of Processes Application
to Axisymmetric Formed Parts. Two principal notions very important to production, the process and the product, are discussed. A methodology that allows for the determination on a technical level of the best adapted process for a given product is presented. To increase the application field of forming, welding processes are also taken into account. 7 ref.--AA J. Triouleyre. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minatoku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 471-476, [in English].
5 2 . 0 4 2 3 Precise Forming With a Multiaction Press, A closed type multiaction hydraulic forging press was made to solve the following problems: the improvement of yield, the omission of after-working process, the improvement of the working environment, the reduction of vibrations and noises, etc. As a result of investigating the influence of the subram stroke and the subram pressure upon the configuration of a C r - - M o - - V steer forging about the journal, it is clear that the cause of the incorrect configuration is the time lag between the upper and the lower subram motion within the term from the start of changing speed until the end of pressing. And if the time lag is < 0.01 s, the configuration becomes correct and total forming force becomes min. which can be estimated with a combination of stress analysis on basic deformation patterns.--AA Y. Taura, H. Yoshimura, and J. Shimazaki. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 52-5 Roppongi, Minato-ku, Tokyo t06, Japan, 1984, (MeLA., 8503-72-0109) 477482, [in English].
52-O416
52-O417 Flexible Manufacturing Systems for Plastic Working. The flexibility of metalforming processes depends on the type of workpiece shape generation and the tool adaptability with respect to the workpiece. The numerical control
J. APPLIED METALWORKING
52-0424 Forming a Three-Dimensional Surface With a Triple-RowPress. Shell plates in the stem and stern form a complicated three-dimensional curved surface. Bending work of these plates still depends, in most cases, on thermoplastic working, to automate the bending work of steel plates and to make cold working possible for the rationalization of operations, the improvement of working environment and prevention of deterioration of the products by heating, a triplerow-press was made consisting of three rows of punches (30 pieces) capable of creating any bending form by the numerical control of punch strokes on the basis of the results of analysis of bending forms. As the result of practical tests, it was confirmed that the press can satisfy the initial object.--AA Y. Iwasaki, H. Shita, and Y. Taura. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-6 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 483-468, [in English].
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81
52-0425 The Application o f C A D / C A E / C A M From the V i e w p o i n t o f Plastic Working Technology. Many computer-aided activities in technology are now in use. Concerning metalforming, commonly used abbreviations, future tasks and a task distribution for further research are explained, The process of metalforruing and a model for planning and simulation of the metslforming process by a computer system are described.--AA R. Kopp, and G. Arfmann. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (MeLA., 8503-72-0109) 489-497, [in English]. 5 2 - 0 4 2 6 C A D w C A M and Spinning. A spinning system with adaptative command, which avoids the use of a highly qualified operator, is presented. This system is the base of a new machine structure adapted to automatic production. To increase the application field of the system, software takes account of the different elements that have to be included in the elaboration of a more general processing, which is the case to obtain polygeometric products. 10 ref.--AA J. Triouleyre. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minatoku, Tokyo 106, Japan, 1984, (MeLA., 8503-72-0109) 498-502, [in English]. 52-O427 I n t e g r a t e d C A D / C A M S y s t e m f o r Roils, Tools and Steel Products. Along with computer-aided measurement (CAM) and data acquisition and control system (DACS) of rolling process, CAD/CAM has been applied for roll design which had been considered a confined art rather than scientific engineering design since its start in 1728 when J. Payne was granted a British patent which referred to rolling various shapes with grooved rolls. A "systems approach" to computerize such an art-like genre of engineering design through modeling of metal deformation by process analysis and extensive use of coordinate measuring machines (CMM) to measure the cross-section of semi- and finished shapes is discussed. A 2-D interactive graphic system was developed to be run under the TSS multiuser environment and communication feature, packet switching network, is provided so that various types of engineering analysis and remote service are available. 7 ref.--AA H. Kozono. Advanced Technology of Plasticity, Vot. 1 [Proc. Conf.}, Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 503-507, [in English]. 52-0428 A Computer-Aided Design S y s t e m f o r Cold Roll Forming. The design of the successive shapes of the rolls and the determination of the number of roll passes necessary to form a given section are discussed. The shape factor expressing the degree of roll forming severity is newly defined and it is known that the number of roll passes reported in catalog No. 265 of Hitachi Metals, Ltd., was closely related to the shape factor. The following equation was derived from the formulation of empirical designs: cos 8 i = I + i t - - c o s 8o) {i2(2i--3N)/N3)--Si is the bend angle of the i-th stand, 8o is the finish bend angle and Nis the number of the total stands. Applying this method of roll design, the roll flowers could be computed and graphically represented for forming of a sash and a track frame. --AA H. Ona, T. Jimma, and H. Kozono. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, t 984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 506-513, [in
English]. 52-0429 N e w D e v e l o p m e n t s in CAD f o r Roll Forming. Recent improvementa to an interactive computer-aided design system for roll forming, CADROF, is described. Springback allowance, bending energy and longitudinal strain distribution during forming are included. Examples are given of the various graphics oplions produced by CADROF and of how they may be interpreted and used to assist in making design decisions. The possible variations of the final product shape as changes are introduced to the strip material properties and/or roll forming conditions are shown. The identifications of overworked areas from the bending energy diagrams and overstretched areas from the strain distribution diagrams are illustrated.--AA W.Y.D. Yuen, and C.H. Ellen. Advanced Technology of Plasticity, VoL 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 514-519, [in English]. 52-0430 Computer-Aided Design and M a n u f a c t u r e o f a Fine-Blanking T o o l , The HJC system used for fine-blanking tool design and manufacture is described. The system, which is divided into five parts, consists of 12 modules, each of which can be used independently. In consideration of complicated shapes of fine-blanked parts, the wireframe method end a digitizer are adopted to input shapes of piece parts. Encoding work is very simple. The shape model generated automatically is suitable to CAD of press tools. The changeable standardized die cores, which are designed and manufactured by the system, can be located in three different general die sets.--AA J. Xiao etal. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minatoku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 526-530, [in English]. 52-0431 C A D / C A M of Tooling and Process for Plastic Working. During the last decade, computer aided design, engineering and manufacturing (CAD/ CAE t CAM) are being increasingly used in the metalforming industry. The practical application of CAD/CAE/CAM has the potential of cost reduction, quality improvement and reducing the dependence on skilled tool and die makers. The hardware and software requirements for CAD/CAE/CAM and selected applications on extrusion dies for AI solid shapes, rolling of airfoil, rod and other simple sections, design of blocker and finisher dies in closed die forging, forging of Ti spiral bevel gears and metal flow simulation via FEM are discussed. The future trends and requirements for cost-effective application of CADICAEICAM in metalforming are discussed. 32 ref.--AA T. Allan, and S.I. Oh. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf], Tokyo, Japan, t984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 531-544, [in English].
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52-0432 Application o f CAD System to Hot Forging. The role of CAD (computer-aided design) in die forging is quite important as a means for saving material, extending die life, improving forged products and capability of DNC die sinking and shortening design time. Osaka Steel Works of Sumitomo Metals has been involved in CAD/CAM development since 1980 to apply it to practical use for hot forging by empirical data including a few experimental works. Examples are given of its use on automobile crankshafts and tool joints for oil fields. The integrated CAD/CAM system of the future is discussed.--AA R. Gotoh, M. Nishimura, and M. Nishiguchi. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 545-550, [in English]. 52-0433 C o m p u t e r - A i d e d P r o c e s s D e s i g n for Cold Forging Operations. Some developments in computer-aided procedures for cold forging process and die design are described. The system is based upon a simple classification of cold forged parts. Design rules for sequences are formulated from processing limitations for the various operations. Geometric description of the finish forged part by means of simple volumetric elements enables appropriate forging sequences to be determined automatically, together with details of the corresponding dies. 10 ref.--AA T.P. Davison, and W.A. Knight. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Mineto-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 551-556, [in English]. 52-0434 Computer-Aided Design o f E x t r u s i o n Tooling. An interactive computer program is developed to design the die and tooling for forward extrusion
of structural shapes. Five types of die profiles, including flat-faced, conical, curved profiles based on strain and strain rate concepts and their combination, are available to suit various product geometries and materials. The optimal die geometry is designed according to the upper-bound analysis such that the extrusion load is rain. The tool assembly for extrusion subpress is designed interactively with the aid of a geometric solid modeling software, PADL-t. A blares curve-fitting program is also developed to generate the curved die profile into NC data. The developed interactive program has been implemented on a CAD system. 17 ref.--AA R.S. Lee. Advanced Technology of Plasticity, VoL 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 557-562, [in English]. 52-0435 Forging and Preform Design Using UBET. The upper bound elemental technique is used to simulate the bulk flow characteristics in closed die axisymmetric forging processes. The technique is performed in an incremental manner, internal flow inside the cavity is predicted using a velocity field that minimizes the rate of energy consumption. Application of the technique includes an assessment of the formation of flash and of the degree of filling in a double deep cavity using billets with various aspect ratios. A new approach for preform design using 'UBET' is introduced which analyzes the process in reverse, starting with the required final forging shape. 8 ref.--AA F.H. Osman, A.N. Bramley, and M.I. Ghobrial. Advanced Technology of Plasticity, VoL 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato~ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 563-568, [in English]. 52-0436 Use o f Elemental Upper Bound Technique in CAD. The CAD system, elaborated in the Institute of Mechanical Technology and Materials Science of the Budapest Technical University, uses the UBET with easy formalization of the boundary conditions. The tool's geometry, the preliminary shape of the workpiece and the material properties must be given interactively. The parameters which are varied for the direct minimization of functional describing the increment of total potential energy will be determined by the system automatically. The momentary shape and the forming load are determined. To reduce the computation time the CAD system utilizes such elements of engineering which are normally used in artificial intelligence studies. 7 ref.--AA L. Cser, and G. Ziaja. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (MeLA., 8503-72-0109) 569-573, [in English]. 52-0437 Numerical Method f o r Plastic Working Processes and Die Design. Cold forming is widely used for the mass production of small parts to reduce production costs and save material. It has, however, some disadvantages, such as a short tool life, possible inaccuracy of geometry and initiation of cracks. To support efficient production techniques and die design, a finite element method is employed. The flexible adaptability of the FEM allows the forming processes, with complicated configuration and well-defined boundary conditions, to be calculated stepwise to obtain the material flow and contact stresses. To reduce the computational time, there are many simplifications such as a rigid-plastic model, linear elements, single-point integration, a structural solution procedure for contact problem, etc. Numerical examples, such as die forging of 1015 steel and the backward extrusion of En2E steel in cold forming are illustrated. 9 ref.--AA N.L. Dung, and O. Mahrenholtz. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 574-579, [in English]. 52-0436 Pressure Peak in Bending and Unbending Process. Existence of two peaks required for the uniform contact of sheet metal with bending roll is pointed out. A peak is derived from the discussion on the reason why the current stress system could not give constant moment to any part of a specimen. Pressure variation along the contact arc is investigated for AI, carbon and austenitic stainless steels using the roll with a pressure sensor, to verify such consideration. A pressure peak at both the entrance point and the exit point of contact arc is undoubtedly observed. Strain distributions also support the new stress system, especially by the evidence of constant strain between two peaks. It is shown that the
J. APPLIED METALWORKING
starting point and ending point of constant strain region are almost the same location as o1 the first peak and the second peak, respectively.--AA K. Hanaki, and K, Kato. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 581-586, [in English].
A. Melander, and E. Schedin. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1964, (Met.A, 8503-72-0109) 635-639, [in English].
52-0439
U n i a x i a l Tension and Hemispherical Punch Stretching. Swift's diffuse necking criterion for the strain hardening materials (a = F(n) is extended to the sheet metals showing the strain rate dependency in addition t o the strain hardening (~ = K~m(n). The analytical prediction emphasizes the significance of the rate of change of the strain rate during stretching and assesses the role of m value together with n value and the strain rate path. Tensile test and rigid hemispherical punch stretching for some nonferrous metals (AI a n d Zn) were carried out at room and elevated temp. It was clarified that the instability limit could be increased by higher value of the strain rate p a t h , - - A A H. Ohsawa, S, Yamazaki, and H. Nishimura. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (MeLA., 8503-72-0109) 640-645, [in English].
New Results in the Theory of Tension Leveling. The develop-
ment of tension leveling has been largely empirical, but, as the range and quantity of strip being leveled are increasing rapidly it is important that new designs can be assessed analytically. One o1~the outstanding problems in this area is the prediction of the bend radius when strip does not conform to rolls. A method for the solution of this problem is presented and approx, expressions are developed and shown to be a c c u r a t e . - - A A N.E. Thompson. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minatoku, Tokyo 106, Japan, 1984, (Met, A, 8503-72-0109) 587-592, [in English].
52-0440
C a l c u l a t i o n o f S p r i n g b a c k o f S h e e t M e t a l B e n d s . The purpose of this work is to provide a complete computer program for the accurate calculation of springback of bent sheet metal in which the bending and the springback processes are modeled in detail. True stress--strain curves from tensile tests with necking provide a base for calculation of stress distribution and bending moment. in combination with detailed considerations of tool geometry and friction change forces, bent sheet length and springback are calculated" The program can be used in C A D / C A M environment. The possibilities of simplification of the bending model are discussed and wide experimental support to the accuracy of the theoretical calculations is given. Experiments are carried out on heavy, high-strength steel plates in air bending t o o l s . - - A A O. Andreen, and R. Crafoord. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A. 8503-72-0109) 593-598, [in English].
52-O441
Stamping and Springback o f P l a t e B e t w e e n C y l i n d r i c a l Dies. Experiments on Cu, brass and carbon steel strips that are plastically formed between cylindrical dies are used to relate the final deformed shape to the die curvature and punch pressure. The final curvature produced by constant radius dies is not uniform since plastic deformation involves the history of curvature during the forming process. Elastic and rigid-plastic analyses which follow the history of strip deformation through the sequence of deformation modes that occur as the die closes have been used to calculate the press force and to understand measurements of the distribution of final curvature.--AA T.X. Yu, W.J. Stronge, and W. Johnson. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-25 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 599-604, [in English]. 52-0442 Theoretical I n v e s t i g a t i o n of Buckling Behavior of Axisymmetric E l a s t i c - - P l a s t i c Membrane Shells Subjected t o Axisymmetric Forming. Investigations directed toward the prediction of the nonaxisymmetric buckling frequently seen during forming processes such as deepdrawing, nosing and sinking process of axisymmetric thin shells have been carried out by means of Hill's bifurcation theory in conjunction with the finite element approximation. The effect of various factors such as the shell dimensions, die geometries, material parameters, including the average r-value on the buckling onset, has been numerically clarified. 16 r e f . - - A A A. Fatnassi, Y. Tomita, and A. Shindo. Advanced Technology of Plasticity, Vol. 1 [Proc. ConL], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-25 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 611-616, [in English].
52.0443
S h e e t M e t a l F o r m i n g L i m i t s Under Complex Strain P a t h s U s i n g S h e a r I n s t a b i l i t y C r i t e r i o n . Shear instability criterion has been applied by Bressan and Williams for predicting the onset of local necking in sheet metal forming and for predicting forming limits under constant strain-ratio paths, The shear instability criterion has been used for predicting the forming limits under twostage strain paths. It is observed that the forming limit predicted by using this criterion, when plotted on an equivalent strain limit diagram, appears as a horizontal line for a particular final-stage strain path. The uppermost limit is achieved when the second stage is equibiaxial and the lowest limit is achieved when the second stage is plain-strain. The upper limit signifies the max. strain limits which can be achieved if strain-path is favorably controlled and the lower limit signifies the min. strain limits which can be achieved irrespective of the strain path followed. Using the same criterion, the effect of material parameters such as strain hardening exponent (n), normal anisotropy (R) and modified Hill yield criterion exponent (m) on the upper and lower limits are analyzed. 14 r e f , - - A A U.S. Rao, and R.C. Chaturvedi. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A. 8503-72-0109) 629-634, [in English]. 52-0444 On the Forming L i m i t in S h e e t M e t a l F o r m i n g . A number of properties characterize the formability of metal sheet. Two central aspects are the distribution of strains during forming and the ultimate formability. The latter is usually described by the forming limit diagram (FLD), How different material parameters influence the strain distribution during stretch forming and the FLD is discussed, The forming limit is studied both for straight strain paths and for composite strain paths with more than one straight segment, A model for the FLD is formulated which considers the development of a sharp neck. The neck is assumed to originate from a heterogeneous distribution of inclusions and martensite islands in the sheet. The rate of growth of the sharp neck is controlled by the work hardening ability, the strain rate sensitivity, plastic anisotropy and void growth at inclusions and martensite in the material. The theory describes the FLD well for positive minor strains, both for straight and complex strain p a t h s , - - A A
J. APPLIED METALWORKING
52-0445
The Role of Strain Hardening and Strain Rate Sensitivity in
52-0446 L i m i t S t r a i n s in Sheet Metal Stretching When the Principal Axis of Stress Does Not Coincide With the Anisotropic Axis. The limit strain equations in sheet metal stretching, when the principal axis of stress does not coincide with the axis of anisotropy, are quite general. The three sets of equations deduced on the assumption that the principal axis of stress coincides with the axis of anisotropy for calculating limit strains in anisotropic, aeolotropic and isotropic sheet metal stretching are special solutions of the general equations. The direction of extreme value of the major limit strain perpendicular to the thickness in mild steel sheet stretching, is discussed and the experimental results in punch stretching are given. The experiments show that the failure of mild steels is a common occurrence in the directions of lowest r value but it is relatively insensitive to n values in every direction. 9 r e f . - - A A J. Kuihua. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A. 8503-72-0109) 646-650, [in English]. 52-0447 M e t a l l u r g i c a l Factors Affecting the F o r m a b i l i t y o f R o l l e d Z i n c P o l y c r y s t a l S h e e t s . The influence of some metallurgical parameters such as grain size and microstructure on the formability of rolled Zn polycrystals is analyzed by Erichsen and tension tests. Grain sizes ranging from 25 to 45 p.m seemed to have no influence on the formability while Fe and Pb impurities reduced it drastically. Some x-ray diffraction tests were carried out which demonstrated that rolling schedule exerts a great influence on the final crystallographic orientation, even when the same total final reduction is obtained with different total p a s s e s . - - A A H, Balmori-Ramfrez, V. L6pez-Hirata, and Y. Mitani. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A. 8503-720109) 651-653, [in English].
52-0448 A Numerical A n a l y s i s o f Experimental Errors in the Hydrostatic Bulging Test. The hydrostatic bulge test is becoming a routine method for determining hardening laws in balanced biaxial tension. In this test, the strains are nonhomogeneous and strain rates can vary with time. Hence, experimental errors in the calculated hardening law can occur as a result of finite instrument size, Methods to predict the magnitudes of these errors are reviewed, A finite element procedure is used which is based on an "incremental-deformation" theory of rigid plasticity, including rate sensitivity. Errors in the calculated s t r e s s - - s t r a i n curve resulting from using a bulging apparatus without strain rate control are evaluated. For typical sheet metals, they are rather small. In contrast, large errors can occur if the sizes of the measuring instruments are too large. By using a spherometer which is larger than the extensometer, experimental errors can be significantly reduced. 8 r e f . - - A A M.L. Wenner. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minatoku, Tokyo 106, Japan, 1984, (Met.A. 8503-72-0109) 654-659, [in English].
52-0449 Computer-Aided Analysis of Sheet Material Forming Processes. A computer software system that is capable of determining the formabUity of sheet metal parts at the design stage is made of several modules. One of the modules contains a finite element analysis method which is based on the deformation theory of plasticity. Although the computed results are in agreement with the general trends indicated by forming experiments, the analytical method has a limitation in that it can treat only the single-stage forming process. To extend the analytical capabilities from the single- to multiple-stage forming processes, the flow theory of plasticity is incorporated while applying the rate of potential energy in the updated Lagrangian form. Revised mathematical approaches and their implications are outlined. 8 r e f . - - A A K. Chung, and D. Lee. Advanced Technology of Plasticity, Vol, 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A. 8503-72-0109) 660-665, [in English].
52-0450
A N u m e r i c a l A n a l y s i s o f B u l g i n g and Punch Stretching o f C i r c u l a r Disks Based on Kirchhoff Plate Theory. The updated Lagrangiantype finite element method for analyzing the bulging and punch stretching of e l a s t i c - - p l a s t i c circular disks is formulated based on Kirchhoff plate theory. It accounts for the large strain, bending and thickness change and embodies the J2 flow law and J2 deformation theory. In case of the punch stretching of circular disks, Coulomb friction condition between the material and the punch surface is assumed, it is revealed by the numerical analysis of the free bulging and the hemispherical punch stretching of disks how the thickness and the boundary 6ondition influence the strain distribution, especially where the local neck is generated. 12 ref.--AA E. Nakamachi, and R. Sowerby. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Rop-
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pongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 666-671, [in English].
52-0451
E l a a t l c ~ P l a s t l c Stress Analysis of U-Bend Process of Sheet Metal. Elastic--plastic incremental finite element calculation has been carried out to analyze plane strain sheet metal bending process. The method is formulated based on the finite elastic--plastic deformation theory in rate form. Sufficiently accurate stress distributions and deformed geometries of sheet metals have been obtained through the whole bending process and if has been made clear that the stress distribution is not as simple as ordinary elementary solution, especially near the contacting region to the tool. The springback angle and the residual stress distribution after unloading have also been xedab 520185 calculated for a mild steel and two HS steels.--AA A. Makinouchi. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minatoku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 672-677, [in English]. 52-0452 Analysis o f Deep D r a w i n g o f N o n a x i s y m m e t r i c Cup by the Finite Element Method. To determine the reasonable shape and size of a blank for deep drawing of the nonaxisymmetric cup with the fiat head punch, an analytical technique using the finite element method is proposed. In the analysis, at any stage of the drawing process, the drawn hollow shell is divided into three regions, the flange, the side wall and the bottom, and the stiffness matrices derived from divergence theorem ere calculated in each region. The nodal forces and the nodal velocities ere converged with iteration method under condition that nodal forces of one region have 1o equate to those of another region and nodal velocities are continuous on the boundary curves. The predictions were obtained in terms of the drawing force-punch stroke, the ear shape of deep-drawn cup, the effective height of drawn cup and the drawing height distribution of the product. These theoretical predictions agree with the experments carried out for the fa|se elliptical and the square hollow shells with brass sheet metal. 8 ref.--AA H. Iseki, and T. Murota. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-O109) 678-684, [in English]. 52-0453 A s s e s s m e n t o f Material Formability. Different formability criteria encountered in different forming operations ere considered. Most important kinds of material tests are also discussed-- simulative tests, test detecting the material proneness to the specific limiting phenomenon, tests for determining basic material features and standardized material tests which enable the set of material parameters to be determined. It is suggested to describe the formability by means of the reliability ratio Fkl being a function of the material parameters, forming conditions end geometric parameters of the process. 11 ref.--AA Z. Merciniak. Advanced Technology of Plasticity, VoL 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minatoku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 685-694, ]in English].
52-0454 A New Plastic C o n s t i t u t i v e Equation and Its Applications to Forming Limit Problems o f Metal Sheets. A new (elesto-)plestic constitutive equation with vertex effect is applied to prediction of the forming limit strains of metal sheets subjected to various nonproportional loading without unloading and to proportional loading after another proportional loading, with or without unloading. It is demonstrated that the constitutive equation proposed is very effective, that appropriately curved strain-paths give very larger limiting strains than the corresponding straight paths do, that abrupt change in stress- or strain-path veyr often induce a catastrophic breakage at the instant of the path-change and that very useful secondary FLD's (forming limit diagrams) of prestrained sheets can be drawn. The localized bifurcation (necking) due to St0ren and Rice is adopted as the breakage condition of At and steel thin sheets. 11 ref.--AA M. Gotoh. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 695-700, [in English]. 52-0455 C o n s t i t u t i v e Relations and Forming Limit Criteria. The effect of the shape of the yield locus on the limit strains in sheet metal forming is reviewed. Experimental results are presented for the expanding yield loci of 70/30 brass, commercial-purity AI and AI-killed steel. The yield loci based on uniaxial tension, uniaxial compression, plane strain compression and balanced biaxiai tension are obtained on the basis of equal amounts of plastic work. It is concluded that the yield loci for the steel expand isotropically but that for the brass and AI the expansion is anisotropic. For steel Hill's new parameter, m, is found to be constant, whereas for brass and AI the value of m increases with increasing plastic strain. 20 ref.--AA A. Mohammed-All, and P.B. Mellor. Advanced Technology of Plasticity, VoL 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-25 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 701-706, [in English]. 52-0456 D e v e l o p m e n t of C o n s t i t u t i v e Equations f o r Sheet Forming Analysis. A range of techniques have been applied to understanding the largestrain plastic behavior of sheet alloys. These techniques are both experimental and analytical, and include various kinds of tensile testing, plane-strain testing, hybrid strain-path tests, finite element modeling and strain localization analysis. The experimental data generated has produced a more detailed and accurate understanding of the constitutive equations which govern the flow and failure of sheet alloys during forming operations. The resultant constitutive equations are reviewed and the implications for analysis of sheet forming operations are discussed. Special attention is paid to sheet steels, AI alloys, Zn and brass. 16 ref.--AA R.H. Wagoner. Advanced Technology o1 Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minatoku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 707-711, [in English].
52-0457
Prediction o f Limit Strains in Biaxial Stretching o f Sheets Using M a r c i n i a k ' s Approach. Following Marciniak's approach of assuming an initial inhomogeneity, an analysis was developed to predict the forming limit curve
84
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in biaxial stretching of sheets. This analysis takes into account the material anisotropy, strain and strain-rate-dependent flow behavior of the sheet material and the orientation of the inhomogeneity. Based on the analysis, e computer program is developed to predict the FLC for any sheet material of given flow properties. Theoretical results are given which show the influence of strain hardening, strain rate sensitivity, anisotropy, initial inhomogeneity size and fracture strain on the forming limit curve. 9 ref.--AA G.D. Lahoti, V. Nagpal, and T. Altan. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-25 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 712-718, [in English]. 52-0458 A T h e o r e t i c a l A p p r o a c h to the D e v e l o p m e n t o f Forming Limit Criteria in Plastic Working Processes. A forming-limit criterion for plasticworking processes is developed from the plastic limit-load or internal-necking mechanism of ductile fracture. A closed-form expression for the total strain to ductile fracture is obtained as a function of the microvoid nucleation strain, the microvoid volume fraction and the terminal mean-normal stress level. The expression is then modified for use in practical plastic-working processes. 10 ref.--AA P.F. Thomason. Advanced Technology of Plasticity, Voi. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minatoku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 719-722, [in English]. 52-0459 Use of New Yield Criteria in Determining the E f f e c t o f Strain Path on Forming Limit Diagrams. To determine the effect of strain path on forming limit diagrams (PLD), three of the nonquadratic yield criteria for a material with in-plane isotropy proposed by Hill were used. By using these criteria, the experimentally determined FLD, for Armco Fe, Cu, AI and steel at different strain paths were transformed to FLD on stress coordinates. Calculations were made for 1.5, 1.8 and 2.0 values of exponent m in the yield criteria. On the basis of good agreement between the experimentally determined and the calculated values of strain at the point of instability, the best yield criterion and value of m were found. 26 ref.--AA J. Gronostejski. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minatoku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 723-728, [in English].
52-0460
Trends in Forming Technology for Car Body in Japan. Press forming technology for mild and high-strength steel eutobody parts plays the most important role in the final stage of both body development and production design, and in the first stage of the actual production process. For the former, this technology is marked by the use of software, while in the latter, hardware plays the dominant role. There are many kinds of autobody models produced in Japan in numbers varying from large to small. The press forming technology has been changing so as to shorten the lead time preceding actual autobody production and to reduce costs and further improve quality. This technology now employs increasingly sophisticated software in the computer-aided systems used for body development and production preparation. In the production line, it relies on new hardware, such as large transfer presses, to form panels of large dimension. To bring about these and other such changes in press forming technology it is necessary to establish a system for evaluating forming severity. Towards this end, cooperative research is being actively carried out.--AA K. Yoshida. Advanced Technology of Plasticity, Vol. 1 [Proc, Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met, A, 8503-72-0109) 729-734, [in English]. 52-0461 Control o f Side Wall Curl in Draw-Bending of High-Strength Steel Sheets. One of the typicel troubles observed in applying high-strength steel sheets to sutobody structural members with hat-shaped cross-section is side wall curl which appears along side walls from a bottom to a top (or a flange) and deflects walls outward. It was found that side wall curl was eliminated by choosing a die profile radius about twice as large as sheet thickness under the optimum die clearance. A rather small die profile radius was advantageous for producing the reverse bending against bending at the die profile. This reverse bending contributed to reducing side wall curl by removing the residual bending moment in side walls which had been subjected to bending at the die profile. The other interesting observation was that the dual-phase steel had a larger tendency to the outward side wall cur~ than the precipitation hardening steel with similar tensile strength. This difference is also discussed. 9 ref.--AA Y. Hayashi, and M. Takagi. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 723-728, [in English]. 5 2 - 0 4 6 2 Modeling o f Sheet Metal Forming. The use of steels o1 increasing strength and decreasing thickness is associated with different forming problems such as spring-back, surface deflections, low forming limit. There is therefore a need for accurate optimization of the use of these materials through careful modeling of sheet metal forming. Different approaches to spring-back, surface deflection and necking that allow the determination of the influence of separate constitutive parameters are presented and an application to the evaluation of the discrepancy allowed on these parameters is presented. 12 ref.--AA J.M. Jalinier et al. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minatoku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 741-746, [in English]. 5 2 - 0 4 6 3 E f f e c t s o f Material P r o p e r t i e s on Surface D e f l e c t i o n Behavior Due to Elastic R e c o v e r y in Press Forming. One of the important factors which determine the forming limit in press forming of large-sized panels is a surface deflection due to elastic recovery. The essential factor which affects the surface deflection is the nonuniform distribution of stresses during forming, which induces elastic buckling or springback after unloading. The effects of mechanical properties of carbon and high-strength steel sheets on the surface deflection due to elastic recovery are investigated by a simulative test (Yoshida buckling test) and a square shell model forming. The most influential property of steel sheets is yield
J. APPLIED METALWORKING
strength. Sheet thickness, r value and n" value are also influential on the initiation of surface deflection. To control the geometrical surface defects more precisely, it is necessary to understand quantitatively the equivalent relation between material properties and forming conditions. 7 ref.--AA K. Yoshida, H. Hayashi, M. Usuda, T. Amaike, and H. Komorida. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 747-752, [in English]. 52-0464 A Study o n Pure Stretch Forming. The pure stretch forming of sheet metals by hemispherical punch is analyzed semiempiricany. The incremental numerical analysis is performed by using Woo's general method, adopting Hill's new yield function for anisotropic materials. The coefficient of friction at the punch/sheet interface is assumed to be a variable during the forming process, In the numerical process, the coefficient of friction at each sheet element is calculated from the equilibrium equation and iterated to give a pole thickness which is close to the experimental value. Soft commercial-purity AI and rimmed steel sheets are selected for model problems and the results are compared with those of experiment. 14 ref.--AA D.W. Kim, and N.S. Kim. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 753-758, [in English]. 52-0465 A Sheet Metal Forming Process Employing the Viscoplastic Substance as a Pressure-Carrying Medium. A method for sheet metal forming which employs a viscoplastic material and does not require any punch and blankholder is proposed. To clarify its applicability, an impact compression test for nonmetallic materials (i.e. clay, plasticine, silicone polymer and rubber) which have various viscous/elastic/plastic properties has been performed using a drop hammer apparatus, and the contact pressure on the specimen/platen interface was examined. From the laboratory experiments, it is concluded that the proposed process is advantageous for manufacturing small parts. Various applications are presented, including the blanking and piercing and stretch forming of AI1050 and AIIN30 alloy. 7 ref.--AA Y. Kurosaki, and I. Fujishiro. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1964, (Met.A, 8503-72-0109) 759-764, [in English]. 5 2 - 0 4 6 6 Forming Limit Curves f o r Aluminum, Copper and Their Alloys. The forming limit curves (FLC) of various sheet materials were determined and the effect of strain path on the curves were investigated. The test materials used are AI, Cu, brass and AI--Mn alloy 0.8 mm thick. The forming limit curves were determined using three different deformation methods--hydraulic bulging, punch stretching and uniaxial tensile stretching. Two types of two-stage strain paths-combination of uniaxial tensile deformation and biaxial tensile deformation--were adopted to test the effect of strain path. Copper and brass had better formability than AI on the whole range of FLC. The FLC of Cu was similar to that of brass. However, the FLC of AI was lower than that of AI--Mn alloy. Two-stage strain paths brought about higher limit strains than the case of single-stage strain path in all sheet materials used. 8 ref.--AA S. Kohara, M. Katsuta, K. Aoki, and K. Suzuki. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 765-768, [in English]. 5 2 - 0 4 6 7 An Analysis o f Combined Loading During Forging. An approach to evaluating the efficiency of combined loading schemes is proposed whereby the methods of plastic analysis are applied to the integral rather than local parameters of the forging process. This approach is examined for the case of forging involving torsion and shifting of the hammer head, with Pb used as a model material. The efficiency of a combined loading scheme depends on a significant reduction in the applied force which is largely determined by the ratio of the velocities of the principal and auxiliary motions of the deforming body. 8 ref.--V.L. V.M. Segal, and D.A. Pavlik. Izv. Akad. Nauk SSSR, Met., 1954, (5), 95-98, [in Russian}. ISSN 0568-5303. 5 2 - 0 4 6 8 The E f f e c t o f the Initial Structure on the T e x t u r e o f Extruded Bars o f Titanium Alloys. With reference to experimental results for pseudo-= (OT4 and VT20) and = + /3 (VT3-f) Ti alloys, it is shown that the initial structure has no effect on the type of texture formed during the hot extrusion of bars. The only difference between the extruded bars is the intensity of individual components, which is higher in bars produced from alloys with a fine structure. The formation of a multicomponent texture in VT20 and VT3-t is associated with the effect of deformation and recrystallization processes and also with phase transformations during cooling. In OT4, however, the formation of the texture is largely due to the deformation of the ~ phase. The formation of a strong (OO01) axial component in VT20 and VT3-1 alloys results in improved strength characteristics. 10 ref.--V.L. S. Grebenkin, A.M. Dekun, A.S. Shishmakov, and R.A. Adamesku. Izv. Akad. Nauk SSSR. Met., 1984, (5), 133-138, [in Russian]. ISSN 0568-5303.
520470
Selecting Steels for Body Structures. The selection of highstrength steels for the press working of automotive body panels is reviewed. Designing of automotive body components in high-strength steels is shown to involve more than substituting one type of steel for another and reducing metal thickness in accordance with the gain in tensile strength. The engineer should familiarize himself with such basic metallurgical features as the Fe--C diagram, the resulting formability characteristics and the practical limitations of certain steel production processes. Consideration is given to scrap control, bake hardening, box annealing, temper rolling and strain aging. Cost comparisons are given for t t steel types used by U.K. automobile makers, including mild steels, HSLA steels, dual-phase steels, rephos and bake-hardenable rephos steels.--D.O.N. M. Jacobson. Automot. Eng. (UK), Oct.-Nov. 1984, 9, (5), 46-47, 50-54, [in English]. ISSN 0307-6490.
J. APPLIED METALWORKING
52-0472
Material D e f o r m a t i o n in the Piercing Process. In the plastic deformation of metals a distinction is made between the deformation required for the change in the shape of the machined workpiece and the so-called redundant deformation. It is attributable to the irregularity of the material flow along the deformation zone and does not affect the change in the workpiece shape. Model investigations and theoretical considerations of the deformation curve of the piercing process on M63 brass specimen in a three-roll inclined rolling stand indicate ways of minimizing the redundant deformation. Possibilities exist if the mandrel projection feed is reduced via the narrowing, roll speed, dia. and length of the mandrel head, angle of inclination of the roll and the rolling pressure in the narrowing increased. 14 ref.--AA Z. Polek, and W. Kubinski. Strips, Sheets, Tubes, Sept. 1984, t, 5-9, [in English].
52-0473
E f f e c t o f the Material in the Shaping o f T u b e s . Not much is known about the effects of the material properties on the deformation behavior during necking down and flaring of tubes. In flaring the max. interpressure Pmax i8 affected not only by the tube length but also by the work hardening exponent n. This work hardening exponent also affects the deformation limit, the axial force and distribution of the strain. In contrast to the strain distribution the stress distribution is only slightly dependent on the plastic anisotropy r. The effect on n on tube formability was investigated for AI, Cu and brass. 15 ref.--AA K.-i. Manabe, and H Mishimura. Strips, Sheets, Tubes, Sept. 1984, 1, 10-13, [in English].
52-0474 C o n t r o l l a b l e P a r a m e t e r s in the Rolling of Aluminum Foils. As the composition of the lubricant and its viscosity change during the rolling of At foils, the coefficient friction and thus the final thickness should vary. However, the investigation did not confirm that fluctuations in the lubricant composition affected the final thickness. By contrast, variations in the initial thickness of the strip and plastic resistance have a significant effect. One problem in the construction of a process model for the rolling is the determination of the coefficient of friction.--AA Strips, Sheets, Tubes, Sept. 1984, 1, 14-15, [in English]. 52-0475
D e f o r m a t i o n E f f i c i e n c y in the Deep Drawing of High-Grade Steel. In first-operation deep drawing the ratio of ideal plastic deformation work to the total drawing work is defined as the deformation efficiency. While the ideal deformation work can be calculated by the plasticity theory the drawing can only be determined experimentally. The plasticity theories of H. Tresca and R.v. Mises give different values for the deformation efficiency. The difference is related to the material of the circular blank (Cr steel and Ni--Cr steel). It is also found that the degree of deformation efficiency is appreciably affected by the punch dia. and the die radius. The relationship to the blank holder force is, however, slight. 9 ref. --AA D. Bauer, and F.-J. Lenze. Strips, Sheets, Tubes, Sept. 1984, 1,22-24, [in English]. 52-0476 A u t o m a t i c Punching Machine Cuts, Shapes and A s s e m b l e s Sheet-Metal Parts. Sheet-metal working can often be rationalized by process combinations. The aim is to take control of the part only once during production. For example, punching operations can be linked to other production processes and finally also integrated in automatic punching machines. Combined punching, shaping and assembly not only rationalizes the actual production, but in the final analysis also leads to notable improvements in quality.--AA K. Schekulin. Strips, Sheets, Tubes, Sept. 1984, 1, 25-27, [in English].
52-0477 Shaping Heavy Plate With Vertical Bending Presses, For the forming of heavy gage, high-tensile steel plate, there is a trend away from using bending machines with three or four rolls towards computer-controlled vertical bending presses. Although this technique does not provide an absolutely round closure, this disadvantage, compared with a plate-round-bending machine, can be minimized by a sufficiently large number of bending points. On the other hand, the vertical bending press offers a large number of advantages. The computer control makes very tight tolerances possible and inherent springing is not present with vertical bending. Due to the absence of longitudinal elongation, the closure can be welded immediately after rounding.--AA W. Klein. Strips, Sheets, Tubes, Sept. 1984, t, 16-19, [in English]. 52-0478 The F o r m a b i l i t y o f Hot Rolled Aluminum-Killed S h e e t Steels. The cold formability of a series of new nonaging high-ductility hot rolled AI-killed steels, including 08YuA, 10YuA, 15YuA and 20YuA, was studied. Mechanical tests and chemical analyses of the steels made it possible to determine standard steel properties and chemical composition required for high formability. A continuous process was then developed for producing high-ductility steel sheets for automotive components. The variability of the steel properties does not exceed 4% for the same heat; the steels are characterized by high structural uniformity and have lower amounts of free cementite and larger ferrite grains than other steels used for cold forming.--V.L. V.B. Nosov, V.G. Meleshko, V.I. Limanyuk, V.I. Pustovalov, and V.G. Ivanchenko. Avtom. Prom-st., July 1984, (7), 29-30, [in Russian]. ISSN 0005-2337. 52-0479 An O v e r v i e w o f Forging T e c h n o l o g y . Two aspects of forging technology are discussed in detail: conversion from machining to closed die forging in the manufacture of spiral bevel gears and a change from ingot cast to strand cast steel in forging center linkages for autos. The conversions are the payoff of CAD/CAM program at Battelle Columbus Laboratories and Eaton Corp. Lower material cost and betler surface quality are benefits. The work cell at McWilliams Forge, consisting of a 35 000 Ib Erie Press Steam hammer, a Salem/Brosius rotary hearth furnace, an Erie 1200 ton hydraulic press and an Erie manipulator (The Equalizer), is also considered.--C.M.L.S. H.E. Chandler. Met. Prog., Dec. 1984, 126, (8), 19-21, [in English]. ISSN 00260665. 52-0480
Multiple-Pass Rolling S e c t i o n Billets From C o n t i n u o u s l y C a s t Slabs. (Translation). See Met. A., 8412-52-2020. Yu.D. Makarov, BN. Polyakov, and P.B. Sokolov. Steel USSR, May 1984, 14, (5), 227-229, [in English]. ISSN 0038-9218.
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52-0481
Temperature Rise in Lubricant in Inlet Zone in Wire Drawing.
An attempt is made to measure temp. rise in the lubricant in inlet zone in wiredrawing of Cu. The temp. appears to start to rise far before the entry point; this obviously suggests that the temp. rise is due not only to heat generation by shear in the lubricant itself but also to heat transfer between the lubricant and the die and between the lubricant and the workpiece. An attempt is also made to analyze the temp. rise by taking account of the heat generation and heat transfer. It is thus possible to make temp. rise curves similar to the experimentally derived ones; this is not possible by the conventional analysis where the heat generation clue to shear only is considered. 7 r e f . - - A A S. Shima, Y. Tozaki, N. Yamamoto, and M. Oyane. Advanced Technology of Plasticity, Vol. 1 [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-720 1 0 9 ) 253-256, [in English].
52-0482 Research on Precision Die Forging U t i l i z i n g D i v i d e d Flow. IV.--Influence of Restricting a Centripetal Flow. In the proposed precision die forging utilizing divided flow, the filling up of materials into the die corner can be made more effective by suppressing an increase of the centripetal flow rate and by promoting an increase of the centrifugal one. In this research, the following is confirmed. When both the step height of a die and the size of the relief-hole diameter are chosen suitably, the working pressure required for a complete filling up becomes lower than that in the process utilizing the relief-hole principle without decreasing the product height. This suggests that a suitable restriction of the centripetal flow will be effective to improve the tool-life and save the material. The two step forging method proposed in the third report is found to be a preferable one in the case of this flow r e s t r i c t i o n . - - A A K. Ohga, K. Kondo, and T. Jitsunari. Bull. Jpn. Soc. Mech. Eng., Aug. 1983, 26, (218), 1434-1441, [in English]. ISSN 0021-3764.
52-0483 I n f l u e n c e o f t h e Drawing Angle on t h e M e c h a n i c a l Properties o f S o m e S t e e l s . Rods of LH15, St5 and A11 steels, 22 mm in diameter, were drawn with drawing angles of 11~ ', 12o30', 15~ ', 17~ ' and 20o05 , on a commercial machine at 0.65 m / s e c with a force of 300 kN to reduce the diameter to 20.9 mm. Subsequently hardness, 0.2% proof stress, tensile strength, failure strength, total and uniform elongations and reduction in area were determined. The variation of hardness across the section and internal stresses in the surface layer are considered. 9 ref.--A.W. J. Luksza, and J. Pis. Hutnik (Katowice), 1984, 51, (1), 3-7, [in Polish]. ISSN O0195669. 52-0484
Manufacture of Enlarged T u b e s in V T Z ] R o l l i n g Mill P l a n t s ] C h o m u t o v . An account is given of basic principles of the theory of enlarging tubes and details are presented of technology for enlarging steel tubes 530 mm in alia. and 7 mm in wall thickness from semiproducts 329 mm in dia. and 11.5 mm in wall thickness. Shortcomings of the process are indicated and ways for improving the quality of the enlarged tubes are shown. 7 ref.--L.G. M. TomeS,. HutmT< (Prague), June 1984, 34, (6), 216-219, [in Czech]. ISSN 00188077. 52-0485 E x p e r i e n c e W i t h a N e w G r o o v i n g P a t t e r n on Rolls o f t h e B l o o m i n g Mill II a t T Z VRSR [ T f i n e c Iron and Steel Works]. Details are given of the development of both the grooving of rolls and the technology of rolling blooms on the 1150 blooming mill at the Ti=inec iron and Steel Works, Czechoslovakia. Compared to grooving used earlier, the new grooving is characterized by widening of the first and the second grooves. Experimental rolling showed that this grooving as well as pass schedules were of e satisfactory standard, ensuring the required conditions for manufacture of slabs 1050 mm wide and enabling highquality rolling of sheet billets to be a c h i e v e d . - - L . G . T. Walach, and K. Skuta. HutmT< (Prague), June 1984, 34, (6), 219-223, [in Czech]. ISSN O018-8077.
52-0486
Choosing a W i r e D r a w i n g B e n c h - - D e t e r m i n a t i o n of the N u m b e r o f D r a u g h t s . The dependence of the number of draughts of a wire drawing bench on the total draught is analysed and a comparison is made between constant and degressive draught sequence spacing. Several conclusions are reached on choosing a wire drawing bench and the number of draughts.--L.G. J. Ba~a. HutnB< (Prague), June 1984, 34, (6), 224*228, [in Czech]. ISSN 00188077. 52-0487 T h e D e v e l o p m e n t o f a Method for C a l c u l a t i o n o f Varying P l a s t i c F l o w . The process of forming with elongation of axisymmetric metallic shells of fixed contours is analysed using a method developed for calculation of varying plastic flow in Euler coordinates. Sheet metal parameters, tool geometry, and magnitude and sign of contact friction are considered and the results of calcu= lations experimentally v e r i f i e d - - L . G . T.A. Bobrova. Izv. V.U.Z. Mashinostr., Apr. 1984, (4), 102-105, [in Russian]. ISSN 0536-1044. 52-0488 T h e S t r e s s S t a t e o f D i e s D u r i n g I n d i r e c t E x t r u s i o n . The stress state of an axisymmetric cylindrical die subjected to loading characteristic of indirect extrusion was investigated, taking into consideration friction between the in sert and the sleeve. The results obtained showed considerable non-uniformity in the distribution of circumferential and axial stresses along the height of the insert. Reduction of circumferential compressive prestresses in the insert at the faces of the die reached 45% and led to the formation of high tensile stresses under the ac lion of the working load. In the distribution of axial stresses sharp changes were found near the boundaries of the zones to which the working pressure was applied; the tensile axial stresses could initiate circumferential cracks in the inserts of the dies.--L.G. A.G. Ovchinnikov, and A.A. $imbirskii. Izv. V.U.Z. Mashinostr., Apt. 1984, (4), 114 118, [in Russian]. ISSN 0536-1044.
52-0489
Analysis o f t h e S t r e s s S t a t e D u r i n g U p s e t t i n g o f a R e c t a n g u l a r S t r i p . A theoretical study is made of the stress state in a rectangu-
86
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lar strip of rigid--plastic material during upsetting under plane-strain conditions. The length of the slip zone, lines of contact stresses, and the mean pressure necessary for upsetting are analyzed, and it is claimed that the theoretical results obtained agree well with experimental data published in the literature.--L.G. G.L. Baranov. Izv. V.U.Z. Mashinostr., May 1984, (5), 3-7, [in Russian]. ISSN 05361044. 52-0490 C l o s e d Die F o r g i n g o f S u p e r p l a s t i c Z n - - 2 2 A I A l l o y . Closed die forging of water quenched superplastic and furnace cooled non-superplastic Z n - 22AI alloys was made in axi-symmetric conditions to investigate the effects of superplasticity on the working force and material flow. The results are as follows. (1) The working force of the quenched material was 1 / 3 - 1 / 5 of that of the furnace cooled materials, but there was no marked difference between the material flow behaviour of the materials. Surfaces of worked pieces were smoother in the quenched materials than in the furnace cooled materials. (2) In axial flow typeforging, the working force for the movable container type die was t / 3 of that for the fixed type die in both materials. (3) The working force in centrifugal flow type forging was lowest in both the materials, when a forging technique was adopted by which nearly perfect centrifugal flows of materials were produced, t0 r e f . - - A A H. Takei, T. Oshita, and T. Hatayama. J. Jpn. Inst. Met., July 1984, 48, (7), 742747, [in Japanese]. ISSN 0021-4876. Forming Behaviour of Aluminium AI99.5F10 and Copper-Zinc-Alloy C u Z n 3 7 F 3 9 D u r i n g F i r s t S t a g e D r a w i n g . By the aid of uniaxial 52-O491
tensile tests both, the work hardening of material and the vertical plastic anisotropy ratio with the deviations of the average vertical plastic anisotropy ratio and the plane anisotropy have been investigated. Standardized tension specimens, according to DIN 50114, were cut from rolled sheet at 0, 45 ~ and 90 ~ to the rolling direction. The measurements contain the following results: the work hardening of material is to a first approximation independent of the rolling direction. The work hardening of material aluminium AI99.5FlO, can be described by a power function. In the case of CuZn37F39 this is only possible with some restrictions. The r-values prove to be constant only above a fixed value of the Iogarithmical strain. Moreover the r-value is dependent upon which angle to the direction of rolling the tension specimen is cut. The drawing tests showed, that satisfactory drawing results can only be obtained with certain blank-holder loads and with certain lubricants. Often the drawing tests with aluminium produced tool cold welding, which damaged the tool and the surface of the workplace. However the brass sheets could be drawn without any difficulties. 14 r e f . - - A A H. Salam. Metal/, June 1983, 37, (6), 597-601, [in German]. ISSN 0026-0746.
52-0492 Niobium B e a r i n g F e r r i t e - - B a i n i t e High Strength Hot-Rolled S h e e t S t e e l With I m p r o v e d F o r m a b i l i t y . ( T r a n s l a t i o n ) . See Met. A., 830252-0274. M. Sudo, S. Hashimoto, and S. Kambe. Trans. Iron Steeliest. Jpn., Apr. 1983, 23, (4), 303-311, [in English]. ISSN 0021-1583. 52-0493
Analysis o f F l a t n e s s o f H o t R o l l e d S t e e l S t r i p A f t e r C o o l i n g . ( T r a n s l a t i o n ) . See Met. A., 8212-52-1805. H. Yoshida, T. Sasaki, T. Tanaka, and Y. Hirose. Trans. Iron Steel Inst. Jpn., Mar. 1984, 24, (3), 212-220, [in English]. ISSN 0021-1583. 52-0494
C h a r a c t e r i s t i c s o f S h a p e C o n t r o l in an A s y m m e t r i c C l u s t e r Mill. An asymmetric cluster mill has been developed modifying an existing fourhigh mill to attain higher reduction than either a four-high mill or a six-high mill. The upper part of the mill is of six-cluster roll structure with a small work roll, two intermediate rolls and three backup rolls. The lower part is of two-roll structure with a large work roll and a backup roll. Furthermore, this mill has a crown-bender and an intermediate roll-bender to control strip shape over a wide range from edge waving to center buckling or from center-edge buckling to quarter buckling. It is considered that the asymmetric cluster mill will show excellent shape controllability to reduce shape faults, especially quarter buckling which occurs in the wide strip rolled by a four-high mill. 16 r e f . - - A A T. Kawanami, S. Omori, K. Oya, K. Morimoto, and H. Yamamoto. Trans. Iron Steel Inst. Jpn., Mar. 1984, 24, (3), 221-227, [in English]. ISSN 0021-1583.
52-0498
S i m u l a t i o n o f Horizontal 2-Stand Rolling by P l a s t i c i n e . ( T r a n s l a t i o n ) . See Met. A., 8203-52-0384. K. Chijiiwa, Y. Hatamura, N. Hasegawa, and Y. Tanabe. Trans. Iron Steellnst. Jpn., Apr. 1984, 24, (4), 292-300, [in English]. ISSN 0021-1583.
52-0501
New Rotary Metalworking Processes D e v e l o p e d in P o l a n d . During the last fifteen years some new rotary metalworking processes have been invented or developed in Poland. These include ( t ) Hot rolling of twist drills on the WS automatic machines, (2) Rocking die method, (3) Transverse bar rolling and forming inner profiles by WPMR method, (4) Cold transverse rolling of splines and gears by WPM method, (5) Combined pressing and rolling, (6) Radial extrusion of gears. Lately, new interesting results have been obtained, both in the study of the processes and improvement applied to machine designs. Information about the methods, the designs of machines and the range of their applications is provided. Work on the development of these methods were carried out by the Metalforming Institute in Poznafi, The Research and Development Centre PLASOMET in Warsaw and The Warsaw Technical University. 8 r e f . - - A A Z. Marciniak, and Z. Kopacz. 2nd International Conference on Rotary Metalworking Processes [Prec. Conf.]. Stratford upon Avon, England, 6-8 Oct. 1982, IFS (Publications), 35-39 High Street, Kempston, Bedford MK42 7BT, England, 1982, (Met.A. 8503-72-0142) 1-7, [in English]. 52-0502
Cross Roll Method for the Production o f A x i - s y m m e t r i c a l S t e p p e d S h a f t . The cross rolling method is a kind of forging method for producing one or more axi-symmetrical stepped shafts, during one rotation of the rolls, from a heated billet inserted between two rolls rotating in the same direction. This method has the following merits: (1) noiseless and vibrationless operation, (2) compact in size and high productivity, (3) automated facility. The following items of this method are reported, (1) basic properties of the cross rolling method, (2)
J. APPLIED METALWORKING
basic ideas concerning the design of the roll dies, (3) examples of the rolled parts. 7 ref.--AA H. Tsukamoto, K. Morimoto, and T, Juge. 2nd International Conference on Rotary Metalworking Processes [Proc. Conf.], Stratford upon Avon, England, 6-8 Oct. 1982, IFS (Publications), 35-39 High Street, Kempston, Bedford MK42 7BT, England, 1982, (Met.A., 8503-72-0142) 9-20, [in English].
52-0503
Development o f S k e w R o l l i n g Forming Process in China. A history of the development of the skew rolling process in China is given. This is followed by a description of some of the products manufactured by this process. --AA Z.-H. Hu. 2nd International Conference on Rotary Metalworking Processes [Proc. Conf.], Stratford upon Avon, England, 6-8 Oct. t 982, IFS (Publications), 35-39 High Street, Kempston, Bedford MK42 7BT, England, 1982, (Met.A., 8503-72-0142) 2126, [in English]. 52-0504 M e t h o d o f D e t e r m i n i n g t h e Rolling Radius o f W o r k p l a c e for Cross Wedge Rolling. In general, it is difficult to measure directly the rolling radius of the workpiece for cross wedge rolling. An indirect method was adopted to define the rolling radius of the workpiece. It may be simply related as follows: first. a formula for calculating the rolling radius of the workpiece is obtained by geometry; second, let the angular displacement of roller and workpiece measured in experiment be substituted into the formula, hence the numerical value of the rolling radius of the workpiece can be calculated.--AA C.-f. Zhu. 2nd International Conference on Rotary Metalworking Processes [Proc. Conf.], Stratford upon Avon, England, 6-8 Oct. 1982, IFS (Publications), 35-39 High Street, Kempston, Bedford MK42 7BT, England, 1982, (Met.A, 8503-72-0142) 2732, [in English].
52-0505 Development of High Speed and High Precision Hot Roll Forming Process for H e l i c a l G e a r s . In the high speed hot roll forming process, developed by Toyota, for precise involute helical gears, the teeth are generated between two rotating gear-shaped roller dies by use of circular bulk blank with the periphery induction heated. The outside dia. and face width of the gears are also precisely formed in the process. The hot roll formed gears have the dimensional accuracies of JIS No. 5 quality class and can be finished only by conventional shaving without any further machining operation. Automobile transmission gears can be successfully roll formed by this process at the speed of 15-30 seconds per piece.--AA A. Danno, and T. Tanaka. 2nd International Conference on Rotary Metalworking Processes [Proc. Conf.], Stratford upon Avon, England, 6-8 Oct. 1982, IFS (Publications), 35-39 High Street, Kempston, Bedford MK42 7BT, England, 1982, (Met.A, 8503-72-0142) 33-42, [in English]. 52-0506 R e s e a r c h in t h e Field o f P r o d u c t i o n o f Ribbed Tubes. The types of ribbed tubes that are rolled are discussed and their uses, such a s for heat exchangers, are described. The technological problems considered to be o1 greatest importance are assessed. These include (i) the proper choice of the initial dimensions of the tube, (it) the determination of the stress--strain conditions of the process and their relation to the characteristics of the tube metal, (iii) the rolling forces. A description of a practical rolling mill and the tools used is provided.--A.M. J. Bazan, S. Nowak, A. Pasierb, J. Richert, and K. Swiatkowski. 2nd International Conference on Rotary Metalworking Processes [Proc. Conf.], Stratford upon Avon, England, 6-8 Oct. 1982, IFS (Publications), 35-39 High Street, Kempston, Bedford MK42 7BT, England, 1982, (Met.A., 8503-72-0142) 43-58, ]in English].
52-0507
Deformation B e h a v i o u r in S i m u l t a n e o u s Backward Extrusion--Upsetting b y R o t a r y F o r g i n g . Simultaneous backward extrusion--upsetting has been carried out by rotary forging and conventional forging. Three materials have been used, commercial purity aluminium, oxygen free copper and 0.35% C steel. The two processes have been compared in relation to workpiece dimensions. A method of determining the initial blank dimensions is de: scribed and this method is useful for the forming of a component with a complex geometry. The backward extrusion length increases with increasing height reduction. No great difference in backward extrusion behaviour can be observed for the three materials. The relative backward extrusion length increases as the aspect ratio increases. In the same aspect ratio, the effects of the working processes and the draft per oscillation on the relative backward extrusion length are extremely small. The upset profile is affected markedly by the draft per oscillation. In both processes, the relationship between the relative extrusion rate, Ah/AH, and the ratio of the remaining height to the equivalent diameter, H/Den, is effective in aiding the analysis o1 the deformation behaviour. The relative backward extrusion length, h/d, aids the determination of the optimum initial blank dimensions. These results will enable the blank dimensions to be determined so as to avoid costly waste of material.--AA T. Nakane, M. Kobayashi, and K. Nakamura. 2nd International Conference on Ro tary Metalworking Processes [Proc. Conf.], Stratford upon Avon, England, 6-8 Oci. 1982, IFS (Publications), 35-39 High Street, Kempston, Bedford MK42 7BT, England, 1982, (Met.A, 8503-72-0142) 59-71, [in English].
5 2 - 0 5 0 8 Rotary Forging o f a C o m p o n e n t With a N o n - C i r c u l a r F l a n g e - C o n t r o l of Forging Force and Energy D i s s i p a t i o n . Experiments on the forging of a component with a rectangular flange and circular hub (tail shaft flange), using lead as the test material are discussed, Force measurements are taken throughout the process and observations made on die filling. It is shown that forging force can be controlled in the final stage of forming by suitably proportioning the die base nose over which forward extrusion takes place. The max. force is halved, as compared with an equivalent operation with no provision for forward extrusion. The effect of die closure rate on force is investigated and a simple analytical treatment is developed for plastic work and temp. rise in the workpiece. It appears that the temp. increase can be appreciable in the final stage of forming. --AA J.B. Hawkyard, and G. Moussa. 2nd International Conference on Rotary Metalworking Processes [Proc. Conf.], Stratford upon Avon, England, 6-8 Oct. 1982, IFS
J. APPLIED METALWORKING
(Publications), 35-39 High Street, Kempston, Bedford MK42 7BT, England, 1982,
(MeLA., 8503-72-0142) 73-80, [in English]. 52-0509 Some Basic Problems o f R o t a r y Forging and Its Applications. Rotary forging machines, rotary forging technology and the deformation theory of the rotary forging are discussed and some applications are introduced. Several rotary forging machines from 36 kN to 4 MN have been designed and manufactured in the People's Republic of China. More than 100 000 forgings have been produced. Among them the forgings of large gears with dia. 380 ram, of the semiaxia and of the cutter blade are typical. A model of a thin workpiece was loaded during rotary forging and the deformation produced was measured and analysed. 8 ref. --AA X. Pet, D. Zhou, and Z. Wang. 2nd International Conference on Rotary Metalworking Processes [Proc. Conf.], Stratford upon Avon, England, 6-8 Oct. 1982, IFS (Publications), 35-39 High Street, Kempston, Bedford MK42 7BT, England, 1982, (Met.A. 8503-72-0142) 81-90, [in English].
5 2 - O 5 1 0 A S t u d y o f R o t a r y F o r g i n g . An experimental study of the deformation undergone has been made during rotary forging of cylinders and rings. It is indicated that an increase in the radial dimension of workpieces in the deformation zone is likely. The distribution of pressure in this zone has been measured, which can explain the centre cracking of workpieces while rotary-forging thin discs and measures are proposed to prevent it. The required tangential force to anchor the lower die has also measured.--AA X. Pet, D. Zhou, and Z. Wang. 2nd International Conference on Rotary Metalworking Processes [Proc. Conf.], Stratford upon Avon, England, 6-8 Oct. 1982, IFS (Publications), 35-39 High Street, Kempaton, Bedford MK42 7BT, England, 1982, (MeLA., 8503-72-0142) 91-100, [in English]. Numerically Controlled Orbital Forging: F e a s i b i l i t y o f High Precision. Orbital forging is a unique metalforming process that requires forces 52-0511
much smaller than conventional forging. Because of this it has the potential of producing high precision parts. It is also amenable to the application of numerical (NC) and adaptive (AC) controls. A model of the orbital forging process is presented that gives an estimate of the part accuracy as a function of material, part design, and machine characteristics. The model shows good agreement with experiments conducted. The concept of employing NC and AC has been explored and indentified as a viable approach to improve the precision and optimize the operation of the orbital forging process, 34 r e f . - - A A J. Carleone, C.C. Pet, and M. Mueller. 2nd International Conference on Rotary Metalworking Processes [Proc. Conf.], Stratford upon Avon, England, 6-8 Oct. 1982, IFS (Publications), 35-39 High Street, Kempston, Bedford MK42 7BT, England, 1982, (Met.A., 8503-72-0142) 101-112, [in English]. 52-O512 T h e R o t a r y F o r g i n g o f P o w d e r M e t a l l u r g y Preforms Using a C o n f i g u r a t e d U p p e r Die T e c h n i q u e . The rotary forging of powdered metals is discussed and certain applications and techniques which may offer considerable industrial attractions are suggested. The concept and design of a novel floating die arrangement capable of forming high integrity parts is described. The cold forging of sintered annular preforms using configurated oscillating dies is reported. The production of fully formed and densified components approximating to spiral bevel gears is discussed. 9 r e f . - - A A E.R. Leheup, J.R Moon, and P.M. Standring, 2nd International Conference on Rotary Metalworking Processes [Proc. Conf.], Stratford upon Avon, England, 5-8 Oct. 1982, IFS (Publications), 35-39 High Street, Kempston, Bedford MK42 7BT, England, 1982, (MeLA., 8503-72-0142) 113-123, [in English]. 52-0513 S i m u l a t i o n o f the R o t a r y F o r g i n g o f Ring S h a p e d B i l l e t s With P l a s t i c i n e . Model material technique is used to determine the final dimensions and forces in the rotary forging of steel ring shaped billets at room temp. The real billets are made of 1045, 52100 and 316 steels; the simulated billets are prepared in stone plasticine. The real tooling is machined from a T1 steet; the tooling for simulation is moulded in a vinyl acetate and ethylene copolymer. Upsetting of the rings was achieved both on a 1.6 MN hydraulic rotary press and on 0.1 MN experimental apparatus. The dimensions of the forged billets and forging forces are compared. Very good correlations are obtained which demonstrate that a model material technique is efficient in that new process. 12 r e f . - - A A J. Pudin, and Y. Ravalard. 2nd International Conference on Rotary Metalworking Processes [Proc. Conf.], Stratford upon Avon, England, 6-8 Oct. 1982, IFS (Publications), 35-39 High Street, Kempston, Bedford MK42 7BT, England, 1982, (Met.A., 8503-72-0142) 125-135, [in English]. 52-0514 C r i t e r i o n o f C e n t r e T h i n n i n g in R o t a r y F o r g i n g o f C i r c u l a r Plate. By means of the measurement of distribution of deformation and the analysis of the characteristics of deformation, this paper attempts to determine why centre thinning is produced and give the hypothesis of the condition for centre thinning. The results of simulated experiments show that centre thinning is affected by various technological parameters, On basis of which and through the management of experimental data the experimental criterion of centre thinning is obtained. And the verification of the criterion is also worked out. In the measurement of distribution of strain in rotary forging of the circular plate the "moire" method is used. And in the management of data, statistics and computer technology are applied.--AA Q. Lu, Z. Lui, and J. Wet. 2nd International Conference on Rotary Metalworking Processes [Proc. Conf.], Stratford upon Avon, England, 6-8 Oct. 1982, IFS (Publics* tions), 35-39 High Street, Kempston, Bedford MK42 7BT, England, 1982, (Met.A. 8503-72-0142) 137-148, [in English].
The Development of Cold Roll Forming Technology at The Machine Tool Industry Research Association. Since 1974, The Machine Tool 52-0516
Industry Research Association has been using computer-aided methods for the design and manufacture of rolls for cold roll forming on behalf of a number of companies, The use of the methods developed at MTIRA to aid the roll designer in selecting a suitable forming sequence and then processing this information to manufacture a set of rolls is explained. 7 r e f . - - A A P.K. Eyres. 2nd International Conference on Rotary Metalworking Processes [Proc. Conf.], Stratford upon Avon, England, 6-8 Oct. 1982, IFS (Publications), 35-
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39 High Street, Kempston, Bedford MK42 7BT, England, 1982, (Met.A., 8503-720142) 165-174, [in English]. 52-O517 D e v e l o p m e n t s in C o m p u t e r - A i d e d D e s i g n f o r Roll F o r m i n g . A computer-aided design program has been developed to assist the user in the design of the forming sequence and sssociated'toolage for almost any proposed roll formed profile. Aids to the designer include the flower diagram and material flow plots, planned and actual turning angles, and other design options. The philosophy behind such a development is discussed, as is work in progress to provide further aids to the user, in predicting the characteristics of the product as a function of the feed material and roll former. Examples are given of the various options available in the computer-aided design package. 8 r e f . - - A A C.H. Ellen, and W.Y.D. Yuen. 2rid International Conference on Rotary Metalworking Processes [Proc. Conf,], Stratford upon Avon, England, 6-8 Oct. 1982, IFS (Publications), 35-39 High Street, Kempston, Bedford MK42 7BT, England, 1982, (Met.A., 8503-72-0142) 175-186, [in English]. 52-O518 I n f l u e n c e o f Forming Technology on Product D e s i g n . Manufacturing cost and profitability of product lines, can be greatly influenced by frequently disregarded factors such as tolerances, method of dimensioning, starting size of material, availability of right equipment, tooling, etc. The effects are shown of specified bending radii, width of unstiffened sections between bending lines, stiffener ribs, angles to be formed, and location of holes, notches related to bend lines. The influence of material and coating specifications on forming technology and other practical aspects to be considered at design stage are also described.--AA G.T. Halmos. 2nd International Conference on Rotary Metalworking Processes [Proc. Conf.], Stratford upon Avon, England, 6-8 Oct. 1982, IFS (Publications), 3539 High Street, Kempston, Bedford MK42 7BT, England, 1982, (Met.A., 8503-720142) 187-212, [in English]. 52-0519 O v e r a l l S t u d y o n R o l l Forming Process o f S q u a r e and R e c t a n g u l a r P i p e s . Effects of process variables and pass-schedule were experimentally investigated on deformation behaviour of each part of pipe, shape and dimension of formed product, limit condition for occurrence of defects and forming toad in roll-forming process through which original circular pipes were continuously made into square a n d / o r rectangular pipes. Moreover, the optimal forming conditions were investigated to attain the required accuracy of products and the required productivity. The main results were as follows; (1) The deformation path of each part of original pipe and its characteristic were systematically clarified. (2) Relationship between longitudinal elongation and cross-sectional reduction was quantitatively made clear. (3) The change of wall thickness distribution in the cross-section of pipe at each step of forming process was quantitatively clarified. (4) Effects of pass-schedule on the corner radius of square a n d / o r rectangular cross-section of the product were quantitatively clarified and attainability of the min. corner radius was investigated. (5) The formula to calculate forming load, that is roll-separating force, necessary to get the required product was developed. (6) The method to design the optimal pass-schedule with minimum numbers of rollstands was p r o p o s e d . - - A A M. Kiuchi. 2nd International Conference on Rotary Metalworking Processes [Proc. Conf.], Stratford upon Avon, England, 6-8 Oct, 1982, IFS (Publications), 35-39 High Street, Kempston, Bedford MK42 7BT, England, 1982, (Met.A. 8503-72-0142) 213-225, [in English]. 52-0520 C o l d Roll F o r m i n g o f Strip and Sheet M a t e r i a l s . I I . - - R e s i d u a l S t r e s s in C o l d Roll F o r m e d S e c t i o n s - - I t s C a u s e a n d E f f e c t on Product D e s i g n . The effect of cold roll forming on the basic material is considered, The results of physical tests on the parent strip and on the section profiles are considered in detail with particular emphasis on the e f f e c t on steels of varying properties. The results of tensile tests taken on the full section profiles are given and comparisons made with the average increase in hardness and the increase in the yield stress of the basic material and the final section profile shape. Reference is made to the basis of the design of structural sections in the U.S.A., Canada and in Europe. This part of the paper concludes with an analysis of the tests and calculations.--AA E. Griffin, 2nd International Conference on Rotary Metalworking Processes [Proc. Conf.], Stratford upon Avon, England, 6-8 Oct. 1982, IFS (Publications), 35-39 High Street, Kempston, Bedford MK42 7BT, England, 1982, (MeLA., 8503-72-0142) 227-246, [in English]. T h e E f f e c t o f R e l a t i v e Angle Between Work and Roller Axes on Forces and M a t e r i a l C h a r a c t e r i s t i c s in F l o w T u r n i n g o f A l u m i n i u m 52-0521
C o n e s . A previous paper by the authors in the proceedings of ROMP 1979 discussed the effect of mandrel cone angle, roller diameter, and form radius, mandrel speed and tool feed on the forces during flow turning of aluminium. This paper extends that work to include the relative angle between the work and roller axes for various tool feed per revolution values, Results include the axial, radial and tangential components of force exerted at the workpiece/forming roller interface during deformation and hardness and tensile strength of the final component material. The results are discussed and where appropriate compared with theoretical predictions, tO r e f . - - A A K.S. Lee, and C.F. Noble. 2nd International Conference on Rotary Metalworking Processes [Proc. Conf.], Stratford upon Avon, England, 6-8 Oct. 1982, IFS (Publications), 35-39 High Street, Kempston, Bedford MK42 7BT, England, 1982, (Met.A., 8503-72-0142) 265-275, [in English]. 52-0522 On t h e S p i n n a b i l i t y o f S t e e l S h e e t s . The influence of metallurgical and mechanical properties of mild steel sheets on the overall spinnability is investigated using four typical spinning experiments. Cleanness and grain size can be marked as the dominant factors that avoid fracture and raise the forming limit strain in spinning. Furthermore two problems related to failure in shape in spinning, the effect of planar anisotropy of sheet on earing and the influence of steel sheets strength on wrinkling are pointed out and analysed. And what kinds of sheet properties are profitable is wholly compared between spinning and press forming.--AA
88
VOL. 4, NO. 1, JULY 1985
T. Satoh, and S. Yanagimoto. 2nd International Conference on Rotary Metalworking Processes [Proc. Conf.], Stratford upon Avon, England, 6-8 Oct. 1982, IFS (Publications), 35-39 High Street, Kempston, Bedford MK42 7BT, England, 1982, (Met.A. 8503-72-0142) 277-286. [in English]. 52-0523 Some Aspects o f I n t e r n a l S h e a r F o r g i n g to Produce Large, I n t e r n a l l y R i b b e d A l u m i n u m A l l o y T u b e s . Large diameter, thin-walled, 2014 aluminum alloy tubes having uniform external profile and integral internal stiffeners were produced by the internal shear forging process. In this process, a cylindrical ring-shaped workpiece was positioned inside a rotating die and reduced in wall thickness by an internal roller fed axially across the workpiece. Roller selection and feed direction were adjusted suitably to produce circumferential internal stiffeners while maintaining the outer diameter of the tube constant. Structural defects observed and resolved include surface folds, laminations, cracks, buckling, and buildup. Solution heat-treatment was interjected into the mechanical working cycle both to eliminate having to solutionalize the finished, thin-walled tube to examine the beneficial effect, if any, on mechanical properties, For 2014 aluminum alloy, it was found that the yield and ultimate tensile strengths could be increased 20% over T6 levels by cold working the artificially aged material, but only at the expense of ductility, 9 r e f . - - A A S. Rajagopal, and S. Kalpakjian. 2nd International Conference on Rotary Metalworking Processes [Proc. Conf.], Stratford upon Avon, England, 6-8 Oct. 1982, IFS (Publications), 35-39 High Street, Kempston, Bedford MK42 7BT, England, 1982, (Met.A., 8503-72-0142) 287-298, [in English]. 52-0524 P r o f i l e Ring R o l l i n g - - R e c e n t R e s u l t s . At first, the past and the future of ring rolling are highlighted by mentioning the first installation and by describing the main features of a research-machine in operation at the Technical University Aachen, Germany. Current ring technique is represented by the discussion of a computerized control and aspects of reliability and availability. Questions of profiled ring rolling are considered by case histories in flange rolling, rolling of superalloys and some other special profiles. Relevant plant layouts and production results round off the presentation.--AA H.-J, Marczinski. 2nd International Conference on Rotary Metalworking Processes [Proc. Conf,], Stratford upon Avon, England, 6-8 Oct. 1982, IFS (Publications), 3539 High Street, Kempston, Bedford MK42 7BT, England, 1982, (Met.A. 8503-720142) 317-328, [in English]. 52-0525 A n a l y s i s for Predicting Process Parameters in C r o s s Rolling Mills. A new method of analysis has been established to predict the roll force, roll torque, axial plug load, guide shoe load and other process parameters of cross rolling mills. Under this analytical method, cross rolling is assumed to be a repetition every half rotation and analyzed basically by the slab method. The guide shoe resistance is assumed as forward and backward compression. However, for axial feed efficiency and circumferential feed efficiency experimental formulae are used. This new analytical method is used on a Mannesmann piercer, elongator and rotary expander. The effect of a variety of rolling conditions upon process parameters of cross rolling is then calculated. These results agree well with observed values. 12 r e f . - - A A S. Mizunuma, M. Kawaharada, and S. Yanagimoto. 2rid International Conference on Rotary Metalworking Processes [Proc. Conf.], Stratford upon Avon, England, 6-8 Oct. 1982, IFS (Publications), 35-39 High Street, Kempston, Bedford MK42 7BT, England, 1982, (Met.A., 8503-72-0142) 329-340, [in English].
Deformation Behavior and Fin Pass F o r m i n g C o n d i t i o n s in the 26-Inch Cage Forming ERW Pipe Mill. Behavior of steel sheet deformation (as 52-0527
expressed in strain history, projection trace and forming flowers) and forming load at fin pass rolls have been investigated in the 26 in. cage forming ERW pipe mill. Also, effect of downhill height and fin pass forming condition on edge wave has been experimentally studied using a 100 mm dia. model mill. The results are as follows: (1) In contrast to conventional grooved roll forming like breakdown roll forming, a gentle and smooth transition in the surface strain is observed in the cage forming zone. (2) A fairly large compressive and then tensile strain directly before No.1 fin pass roll can be remarkably reduced by introducingthe edge restraining roll between final cage and No.1 fin pass roll. (3) Optimum forming condition for preventing edge wave can be obtained by giving a fairly high reduction ratio at No. 1 fin pass roll under 0.8 to 1.0 x O.D. downhill height and 0.8 to 1.1% fin pass total reduction. (4) The forming load, which depends strongly on the strength and wall-thickness of sheet, can be expressed by the summation of forces which are necessary for the circumferential reduction and the bending of sheet. 23 r e f . - - A A T. Toyooka et al. 2nd International Conference on Rotary Metalworking Processes [Proc. Conf.], Stratford upon Avon, England, 6-8 Oct. 1982, IFS (Publications), 3539 High Street, Kempston, Bedford MK42 7BT, England, 1982, (MeLA., 8503-720142) 353-364, [in English]. 52-0528 D e f o r m a t i o n S t u d i e s in Blank Preparation for Ring Rolling. The piercing phase in producing a ring blank has been studied from three aspects. Firstly, the changes in workpiece shape have been studied quantitatively with respect to critical dimensions using pure lead cylinders of various height/diameter (Ho/Do) ratios. Secondly, the internal flow of material during piercing has been studied qualitatively using a recrystallisation and etch technique on aluminium specimens and by piercing and sectioning transversely laminated plasticine specimens. Finally, a number of analytical techniques have been introduced, based upon both empirical results and totally theoretical considerations. The object of this analysis was to provide simple mathematical models or equations for the prediction of workpiece shape for bulk and Iocalised deformation. 18 r e f . - - A A E, Appleton, and M.J. Pavier. 2nd International Conference on Rotary Metalworking Processes [Proc. Conf.], Stratford upon Avon, England, 6-8 Oct. 1982, IFS (Publications), 35-39 High Street, Kempston, Bedford MK42 7BT, England, 1982, (Met, A., 8503-72-0142) 365-384, [in English]. 52-0529 Commercial Wedge Rolling in the U n i t e d States. Manufacturing volumes in the United States are high, and able to justify the development work and the capital investment required to convert many engineering components to the wedge rolling method of manufacture. This is particularly suitable for producing
J. APPLIED METALWORKING
stepped shafts and forging preforms, and cost saving figures for two such applications are given. Process details are also given for parts rolled experimentally for Ford and General Motors, and for other large volume commercial components. Although it is confidently expected that wedge rolling will eventually replace the slower and more wasteful methods currently used on such parts, it is disappointing that progress is not faster. This is attributed, at least in part, to a reluctance towards backing new ideas in manufacturing not originating in the United States. --AA K. Belmont. 2rid International Conference on Rotary Metalworking Processes [Proc. Conf.], Stratford upon Avon, England, 6-8 Oct. 1982, IFS (Publications), 3539 High Street, Kempston, Bedford MK42 7BT, England, 1982, (Met.A, 8503-720142) 385-397, [in English].
Transverse Hot R o l l i n g o f F o r g i n g P r e f o r m s for Bicycle Cranks. The transverse hot rolling process was used until recently as part of a 52-0530
linked production line for forging bicycle pedal cranks, which have a heavy boss at one end. A headed preform was rolled from 0.4% carbon steel bar stock and then press-forged in a single blow, giving a material utilisation of 88%. One of the problems with this route is that the ideal temperature for rolling is lower than the temperature required to give a satisfactory life of the forging tools. A practical solution had to be found avoiding the use of a reheat stage which would also have been expensive. This paper describes the experience gained during a three year development period on hired equipment of Czechoslovak origin followed by five years of production running on equipment bought to UK specifications. It also deals with problems of reliability associated with the specialised nature of the equipment and with the process itself, and highlights the particular difficulty of making repeat rolling tools of consistent p e r f o r m a n c e . - - A A V.K. Mehan. 2nd International Conference on Rotary Metalworking Processes [Proc. Conf.], Stratford upon Avon, England, 6-8 Oct. 1982, IFS (Publications), 3539 High Street, Kempston, Bedford MK42 7BT, England, 1982, (Met.A., 8503-720142) 399-408, [in English]. 52-0537 P r o d u c t i o n o f M e t a l l i c A r t i c l e s . A method is disclosed of superplastically deforming a blank of a metallic alloy such as aluminium which: (1) has a composition suitable for superplastic deformation; (2) has a grain structure suitable for superplastic deformation; and (3) contains less than that percentage of a constituent known to inhibit grain coarsening after recrystallisation which is necessary for such inhibition. The method comprises raising the blank to a forming temperature d e f o r m i n g t h e blank at a first strain rate to induce dynamic recrystallisation and continuing to deform the blank at a second strain rate lower than the first rate. W.S. Miller, R. Grimes, and Alcan International Ltd. 14 Nov. 1984, Patent no. GB2139536A (UK), 30 Mar. 1984. 52-0539 Forming Process for M e t a l Rail B l a n k . A process for forming a rail blank in a universal stand, starting with an initial section of rectangular crosssection comprises a first series of passes for cutting into the web forming portion by means of horizontal rolls accompanied by reduction of the head by means of one of the vertical rolls, and a second series of passes for simultaneously reducing the head flank forming portions by the horizontal rolls and the base forming portions by one of the vertical rolls of the universal stand, the other vertical roll remaining non-active. J. Michaux, and Sacilor SA. 31 Oct. 1984, Patent no. GB2138725A (UK), 21 Mar. 1984. 52-0540 P r o d u c i n g H o l l o w A l u m i n u m E x t r u d a t e . A process for producing a hollow aluminum extrudate for use in a vacuum, for example, as a particle accelerating pipe, comprises the steps of hermetically closing the forward open end of a hollow shaped material immediately after extrusion, subsequently extruding a predetermined length of shaped material, and cutting off the predetermined length of extruded material. The latter cut end is hermetically closed at the same time, and the closed ends are then cut off. During extrusion, the inner surface of the hollow portion of the shaped material is substaintialty held out of contact with the atmosphere to inhibit a hydrous o x i d e on the inner surface, while permitting formation of a compact oxide film theron. H. Ishimaru, S. Nishizaki, and Shows Aluminium. 28 Nov. 1984, Patent no. GB2140340A (UK), 24 May 1983. 52-0541 Pressing Contoured S h a p e s . Sheet material such as sheet metal and, especially, sheets of composite material such as aromatic polymer composites, for instance carbon fibre reinforced polyetheretherketone, is formed into contoured shapes having high configurational accuracy and finish on both surfaces by pressing such sheet material between a rigid contoured tool and a complementarily contoured semirigrid diagphragm thrust against the sheet material and the tool by fluid pressure in a manner to cause the sheet material to conform to the tool configuration and to experience substantially isostatic pressure. The diaphragm is superplastically formed to the desired configuration from a material selected from Zn, AI, Ti or its alloys, stainless steel or Ni alloys. A. Green, and TKR International Ltd. 21 Nov. 1984, Patent no. GB2139934A (UK), 16 May 1983. 52.0542 P r e s e n t Opinions on the Hot F o r m a b i l i t y o f S t e e l s A f f e c t e d by S t r a i n Rate. ( T r a n s l a t i o n : BlSl 2 3 0 9 4 ) . See Met. A., 8404-52-0629. M. Strakos. Hutn. Listy, Dec. 1983, 38, (12), 853-857, [in English]. ISSN 00188069. 52-0543 Theoretical Method for Calculating the Maximum Reduction o f S h e e t R o l l i n g B e t w e e n Rolls o f U n e q u a l D i a m e t e r s . ( T r a n s l a t i o n : BISI 2 1 8 0 0 ) . See Met. A., 8201-52-0009. T. Wang. Iron Steel (China), June 1981, 16, (6), 31-35, [in English]. 52-0545 E f f e c t o f H o t - W o r k i n g P a r a m e t e r s on Microstructure and P r o p e r t i e s o f 1 6 M n S t e e l P l a t e . ( T r a n s l a t i o n : BISI 2 2 7 4 1 ) . See Met. A., 8402-52-0187. S. Li. Iron Steel (China), July 1983, 18, (7), 34-40, [in English].
J. APPLIED METALWORKING
52-0547 Low Viscosity Alloyed Oil for Drawing (Translation: BISI 2 3 1 2 1 ) . See Met. A., 8412-52-2031.
Micro-Wire,
A.P. KozIovtsev et al. Sta/', June 1984, (6), 64-66, [in English]. ISSN 0038-920X.
52-0549 TTR Diagrams (Time--Temperature--Reaction) for Thermomechanical Treatments of Steels. II.--Controlled Hot-Rolling and Intercritical Annealing of a Cold-Rolled HSLA Steel and a Maraging S t e e l . Cf. Kishida and Hornbogen, ibid., p 21. The microstructures of t w o steels were investigated after thermomechanicat treatments, which started either by hotrolling austenite or cold-rolling martensite. Wedge specimens were used to explore a wide variety of amounts of deformation. Emphasis w a s put on heat treatments in the ((x + 3')-field to produce coarse two-phase structures (dual-phase, duplex). More than 4 0 % plastic deformation (p = 0.51) w a s required to form equiaxed fine grained stuctures. In the maraging steel one of the components of the duplex structure was prone to considerable precipitation hardening when additionally heat treated. A two-phase structure did not start to form from sustenite even after annealing for 100 h at 700~ Tentative TTR diagrams have been developed for both materials and both types of thermomechanical treatment. They should allow microstructures which are formed by certain thermomechanical treatments to be predicted. 15 r e f . - - A A E. Hornbogen, and K. Kishida. Arch. EisenhOttenwes., Feb. 1984, 55, (2), 63-68, [in English]. ISSN 0003-8982. 52-0550 I n v e s t i g a t i o n o f D i r e c t C o o l i n g in D r a w i n g S t e e l W i r e . Direct water cooling of wire, employed immediately after drawing, only improves the mechanical properties if it is used in the last few draws of a multiple drawing machine, where the wire enters the die at high temp. Rapid quenching of the wire prevents deterioration of the mechanical properties which are comparable to those drawn at ambient temp. This is achieved if the temp. increase due to drawing is lowered by cooling by at least 50%, and is possible only if there is a minimum length of cooling tube to hinder the formation of a stable steam jacket. Effective cooling of wire occurs in the area of convective heat transfer. The range of bubble boiling is marked by three- or four-fold increase of the heat transfer coefficient. This region has to be avoided because increase of the temp. by only a f e w degrees centigrade leads to a stable steam jacket. In this case the only way to eliminate ineffective heat transfer is to decrease the wire speed. When using the system of direct wire cooling the lubricant must be an insoluble drawing soap that can prevent bad friction conditions in the following draws. Soluble lubricants are dissolved completely by the cooling water. 7 r e f . - - A A O. Pawelski, and R. Keuper. Arch. Eisenhdttenwes., Feb. 1984, 55, (2), 57-62, [in English]. ISSN 0003-8962. 52-0553 O v e r h e a t i n g of Low-Alloy S t e e l s . When low-alloy steels are reh e a t e d to high t e m p e r a t u r e s f o r forging, a d e t e r i o r a t i o n in t h e a m b i e n t temperature mechanical properties after a full heat treatment may be observed. This is linked with the appearance of intergranular facets on the fracture surface. The phenomenon has been described as overheating, and an extensive literature has developed describing experimental studies of the mechanical-property and microstructural changes induced in low-alloy N i - - C r - - M o steels. This literature is reviewed, emphasis being placed upon the property changes, methods of detecting overheating, and the theories that have been advanced to account for the observed effects. The important role played by non-metallic inclusions, particularly sulphides, is described. The methods of preventing overheating through control of steel composition, particularly in relation to sulphur and manganese, are described. Finally, an assessment is made of the methods that have been recommended for the r e c l a m a t i o n of steels which may have been i n a d v e r t e n t l y overheated during forging. 118 r e f . - - A A G.E. Hale, and J. Nutting. Int. Met. Rev., 1984, 29, (4), 273-298, [in English]. ISSN 0308-4590. 52-0555 O u t l i n e o f 4400 Ton Press and M a n u f a c t u r e o f L a r g e Forged S t e e l S h e l l R i n g s . A unique 4400 ton hydraulic press has been installed in Mizushima Works in order to provide larger shell rings and wider forged plates. The new press based on Kawasaki Steel's original idea forges the shell rings with the outside diameter up to 8.5 m. By using new equipment and large hollow ingots up to 320 ton, forged shell rings have been made available for the reactor pressure vessels of nuclear power plants and oil refinery plants. Experimentally manufactured shell rings showed uniform chemical composition and mechanical properties, thus suggesting their suitability for application in pressure v e s s e l s . - - A A M. Takada et al. Kawasaki Steel Tech. Rep., Mar. 1983, (7), 16-26, [in English]. ISSN 0388-9475. 52-0556 M e t h o d s o f C o l d R o l l i n g Oil E v a l u a t i o n in T e r m s o f H e a t S t r e a k R e s i s t a n c e and Strip S u r f a c e C l e a n i n g P r o p e r t y , T o g e t h e r W i t h Their Applications. Methods of evaluating heat streak resistance and sheet surface cleaning properties of cold rolling oil were established. The lubricity was evaluated by scoring limit load using the modified Timken tester and four-ball tester, Surface cleaning properties were quantitatively evaluated by the quantity of carbon on the surface of the test piece after annealing. Through these methods, it was possible to develop a high lubricity rolling oil with a performance to increase rolling speed by 10-20% and to decrease oil consumption by 15% compared with the conventional rolling oil. The new surface cleaning rolling oil has a good surface cleaning property and a lubricity that can be used in rolling steel sheet of 0.4 mm thickness. 9 r e f . - - A A K. Nakagawa et al. Kawasaki Steel Tech. Re/)., Mar. 1983, (7), 55-67, [in English]. ISSN 0388-9475. 52-0554 R i f l e d ERW B o i l e r T u b i n g . The development of rifled electric resistance welded boiler tubing began with the search for a method of rifle forming, passed the stages of clarifying the forming mechanism and developing e manufacturing device and ended with the development of the quality control technology for mass production. In parallel with this development process, studies of the tensile properties at elevated temperature and workabiliy of the rifled tubing were conducted, and the effect of spiral ribs on the deformation and breakage of the tube as well as its creep rupture strength were clarified.--AA N. Ando et al. Nippon Steel Tech. Rep., Dec. 1983, (22), 121-131, [in English]. ISSN 0300-306X.
VOL. 4, NO. 1, JULY 1985
89
52-0570
An Investigation of F e D S I Alloys in Compression Test Under
S p e c i a l Aspects of Ordering Effects. The plastic properties of F e - - l . 4 to 5.7% Si polycrystals and of F e - - 5 . 7 % Si single crystals have been investigated in compression tests under the influence of ordering heat treatment and deformation temperature. The results are mainly discusse d with respect to the rolling behaviour of these alloys. The rollability in the range of low Si contents depends mainly on solid solution hardening. In the range of higher Si contents the impediment of Frank--Read sources due to ordering effects is most important. 27 ref. --AA A.R. Biichner, and H.D. Kemnitz. Z. Metallkd., June 1984, 75, (6), 423-431, [in English]. ISSN 0044-3093.
52-0571 Influence o f V a r i o u s R o l l i n g C o n d i t i o n s and F i n e Surface Structure on the Deep-Drawing Behaviour of Aluminium Sheet. Various processing difficulties arise in the deep-drawing of AI sheet. The present investigation determines the microsurface characteristics and lubrication conditions that promise optimum processing conditions. Tests showed that for the alloys considered, a temper-pass reduction of 6 to 7% was particularly effective in producing a suitable micro-surface structure. A microsurface production in this way at the final stage with AIMg4 and AIMg0.4Si 1.2 sheet resulted in an improvement of the deepdrawing properties (differential force) by 10%, An unexpectedly large improvement of approximately 35% in the deep-drawing properties was obtained with both alloys when, after producing the microsurface in question, additional heat treatment was carried out. This improvement was given by a microsurface of suitable, nondirectional structure, with an amount of lubricant unusually small by today's standards. The transferability of the results obtained on an experimental press to fullscale dies with representative quantities was tested. Here for example, the proportion of rejects in the production of tailgate interior panels (folds, necking, tears), amounting to approximately 40%, could be cut back almost to 0%. [English version is in Aluminium English, 60, (10), E651-E657]. 8 r e f , - - A A F. Fischer, R. Pfleger, H. Drecker, and F. Braun. Aluminium, Oct. 1984, 60, (10), 745-751, [in German]., [in English]. ISSN 0002-6689.
52-0572
Practical Aspects of the P o r t e v i n D L e Chatelier E f f e c t . ~ l l . A
review is presented on how stretcher-strain markings of type-b are developed on the surface of metal alloy sheets when forming manipulations are carried out under conditions which favour the Portevin--LeChatelier effect. These strain markings are bands of highly localized deformation. Apart from impairing the smooth appearance of the surface, such markings are the starting points for shear fractures. The ductility is reduced. The second part of this work (Part h Aluminium English, 1984, 60, (9), E601) deals with ductility and fracture behaviour and the question of how to avoid stretcher-strain markings. The simple w a y to prevent type-b stretcher-strain markings is to avoid the conditions that cause them. Substitutional alloys are especially at risk, particularly those of aluminium, since the range of existence of the strongest Portevin-LeChtelier effect lies between room temp. and 60~ thus at cold rolling temp. [English version is in Aluminium English, 60, (10), E646-E650]. 58 r e f . - - A A E. Pink, and A. Grinberg. Aluminium, Oct, 1984, 60, (10), 764-768, [in German]., [in English]. ISSN 0002-6689.
52-0573
Aluminium in Sheet-Metal Working. Data presented in three groups of lectures at the 17 May 1984 D0sseldorf special conference on the title topic is summarised and covers various recent DFB-sponsored research projects. Thus, AI semifinished products are now available for formed sheet parts, and are now being standardized. The principles and practical application of forming by drawing and bending are being studied, mainly with reference to the automobile industry. In the field of wear protection, fluids for AI sheet processing must be of high separation power, polarity, capillarity and cooling capacity, and must also be easily removable. Resistance pressure-welding of 0.5-3.5 mm AI sheet, with shorter weld times, requires relatively high welding currents. On projection welding the low mechanical rigidity of the projections and the mechanical and dynamic characteristics of the machines also present problems. Spot welding tests on alloys AIMg5w and AIMgO.4Sil.2ka show that a higher tensile shear strength and a larger spot dia. are obtained when the joint components are pretreated. [English version is in AIuminium English, 60, (10), E676-E678],--R,H. Aluminium, 1984, 60, (10), 772-774, [in German]., [in English]. ISSN 0002-6689. 52-0577
Specify Forming for Precision. Monniot Reports the interest and activities of the Science Research Council (SRC) in researches to advance precision metal-forming techniques, such as precision forging, casting, squeezecasting, and powder metallurgy, eliminating all machining operations except for light finishing. Sansome discusses the direct drawing of wire, rod, tube, and bar, and Pearce defines superplasticity and describes its exploitation in the precision forming of, for instance, the superplastic 2004 A I - - C u - - Z r alloy to produce parts more complex than could be obtained by traditional sheet-forming methods, and in hobbing for the accurate production of deep cavities and faithful replication of fine detail. An SRC publication on previous casting is reviewed.--J.R. J. Monniot, H. Sansome, and R. Pearce. Engineering (London), Oct. 1984, 224, (9), 738-741, [in English]. tSSN 0013-7782. 52-0592
Synthetic Diamond Dies and Their Impact on the Industry. The development of better die materials and the introduction of synthetic diamond dies together with the availabilty of continuously cast and rolled rod has produced a great impact on the non-ferrous wire drawing industry both in production efficiency and die cost reductions. No article on dies would be complete without referring to the development of die materials and changes necessitated in the servicing of dies, particularly since the early 19th century. The main types of dies in use during this period were the steel plate dies usually in the form of a single tapered hole or multiple tapered hotes of reducing diameters on the one plate. In the latter part of the century, chilled iron dies were used for multi-die heavy wire drawing machines and diamonds, once successful drilling techniques were found for fine wires.--AA J.A. McLennan. Wire Ind., Aug. 1984, 51, (608), 572-574, 578, [in English}. ISSN 0043-601 t. 52-0593
Machining Processes Replaced by Cold Formers. Cold forming is a relatively new but already highly developed technology. Forming on a cold for-
90
VOL. 4, NO. 1, JULY 1985
mer has already been proven the technology in the mass production of fasteners. The mainstay of bolt and nut production has been the two- or three-stage cold header. Now further sophistication of cold forming technology has brought it to the multi-stage level, Complicated parts which used to be machined by single-purpose machines can now be produced directly from coiled wire of considerably reduced size and weight, These days one machine can include six or seven stages, including cut-off processes. The modern multi-stage cold former can boast many advantages, including material saving and high speed production.--AA Wire Ind., Sept. 1984, 61, (609), 630-631, [in English]. ISSN 0043-6011.
52-0594
The Mechanical Descaling of High-Carbon Steel Wire Rod. Mechanical descaling is well established for Iow-C rods but not for high-C. Tests have been carried out to study mechanical descaling of 0.7% C wire rod 3-5.5 mm. die, A descaler was designed to bend the rod in two planes generating a 6.5% strain in the outer skin. Tests were carried out to compare residual scale with original scale and the effect on die life was also assessed, together with the drawing temp. achieved at the die. Results compared well with those on pickled and coated rod and it was found that equivalent die life could be achieved by reducing drawing speed from 7.2 to 5.3 m/s.--P.C.K. H.J. Bockenhoff. Wire Ind., Sept. 1984, 51, (609), 632-637, [in English]. ISSN 0043-6011. 52-0595 S t a i n l e s s S t e e l W i r e s f o r S p r i n g s . ( T r a n s l a t i o n : BlSl 23323). See Met. A., 8404-52-0721. M. Robelet, and P. Armangaud. Aciers Spdc., May 1983, (62), 15-19, [in English]. ISSN 0373-0689.
52-0596 Criteria Governing t h e S e l e c t i o n o f A S u i t a b l e S e a m l e s s Tubemaking Process. ( T r a n s l a t i o n : BSlS 2 0 1 6 9 ) . See MeL A., 8203-520264. G. Pfeiffer. B~nder-Bleche-Rohre, Aug. 1981, 22, (8), 191-193, [in English]. ISSN 0005-3848.
52-0597 Development o f a P r a c t i c e f o r C o n t i n u o u s C a s t i n g and Processing o f As-Cast Blooms for Production of High-Alloy S e a m l e s s T u b e s . ( T r a n s l a t i o n : BlSl 2 3 0 7 1 ) . See Met. A., 8304-52-0455. P. Machner, and J. Stiebellehner. Berg HOttenm#nn. Monatsh., Sept. 1982, 127, (9), 358-363, [in English]. ISSN 0005-8912.
52-0598 I m p r o v e m e n t in t h e Q u a l i t y Of R o l l e d Pipes by M e a n s o f Applying New Grooving to Roils in t h e P l a n i s h i n g Mill. (Translation: BlSl 23092). See Met. A., 8404-52-0569. J. Kotrbaty, and J. Bar. Hutn. Listy, Nov. 1983, 38, (11), 779-782, [in English]. ISSN 0018-8069.
53
Machining
53-0505 High-Speed L a s e r M a c h i n i n g o f S m a l l - D i a m e t e r H o l e s in Printed C i r c u i t S u b s t r a t e s . ( T r a n s l a t i o n : V R / 2 4 6 8 / 8 4 ) . F,I, Zhuk, O.S, Lysogorov, and N.I. Chetverikov. Fiz. Khim. Obrab. Mater., 1983, 17, (3), Pp 5, [in English]. ISSN 0015-3214.
53-0506 A Data-Dependent Systems Approach to Optimal Microcomputer Control Illustrated by EDM. A new approach to microcomputer control of manufacturing processes is proposed and illustrated by application to optimal control of electrodischarge machining (EDM) of D2 tool steel. Based on a recently developed methodology called Data. Dependent Systems (DDS), it is capable of providing off-line modeling and analysis under working conditions to suggest the best possible strategy for the existing design, an on-line optimal control algorithm, adaptable fine-tuning of the controller to enhance its effectiveness, and finally, design improvements aimed at further increase in productivity and quality. All these features are illustrated by means of DDS models for pulse current and voltage in EDM. 13 r e f . - - A A S.M. Pandit, and W.H. Wittig. J. Eng. Ind. (Trans. ASME), May 1984, 106, (2), 137142, [in English]. ISSN 0022-0817.
53-0507
Tool Fracture Probability Under S t e a d y S t a t e C u t t i n g C o n d i t i o n s . Tool fracture probability for 6 wt.% Co/WC tools turning AISI 4340 steel (HB = 235 kg/mm 2) at 200 fpm was found to be small at the beginning of a cut or during steady state cutting at feeds up to 0.100 ipr (2.54 mm/rev). Steady state fracture probability was found to be high only when cutting with severe chatter at feeds of 0.100 ipr (2.64 mm/rev) or higher. Tool fracture probabilities were determined by finite element analysis for elastic tool stresses, an intensified max. tensile stress fracture criterion associated with circular defects and Weibull plot giving percent failed vs. fracture stress in uniaxial compression. 12 ref.--AA W.S. Sampath, Y.M. Lee, and M.C. Shaw. J. Eng. Ind. (Trans. ASME), May 1984, 106, (2), 161-167, [in English]. ISSN 0022-0817. 53-0508
Tool Fracture Probability of Cutting Tools Under Different
Exiting C o n d i t i o n s . A large number (150) tungsten carbide (6 wt.%) cutting edges were used to make single cuts in AISI 4340 steel (HB = 235 kg/mm 2) at a cutting speed of 200 fpm (61 m/min) and a variety of feeds and entrance and exit angles of workplace taper. A map shows types of brittle tool fracture occurring at exit for a wide range of feeds and exit angles. Fractures were of two types: those due to very sudden unloading of the tool at exit and those due to metal adhering strongly to the tool face following a cut. Reasons for the two types of exit failure are discussed. 7 ref.--AA Y.M. Lee, W.S. Sampath, and M.C. Shaw. J. Eng. Ind. (Trans. ASME), May 1984, 106, (2), 168-170, [in English]. ISSN 0022-0817.
J. APPLIED METALWORKING
53-0509
Quantitative Expressions for Some Aspects of Surface
53-0517
Recent Advances in Oesigning Free-Cutting Engineering
Integrity of Electrodischarge Machined Components. An on-line adaptive control of the electrical discharge machining (EDM) process needs proper quantitative relationships between output parameters and input variables of the process. An attempt to develop mathematically simple expressions for the depth of cracks, the depth of damaged layer and the depth of martensitic layer in terms of pulse duration and current is presented. The transient temp. distribution developed is used in obtaining thermal stress expressions. The hypothesis that the cracks are the consequence of thermal stresses exceeding the fracture level leads to the expression for the depth of occurrence of cracks. The estimation of the thickness of martensitic layer is based on the phase transformation temp. isothermal obtained from the temp. distribution. A simple expression for the depth of the damaged layer is also obtained using the experimental conclusions reported in the literature. Regression equations suitable for the on-line adaptive control of the EDM process are developed. The theoretical estimates are compared with the experimental measurements using D2 steel. 41 r e t . - - A A K.P. Rajurkar, and S.M. Pandit. J. Eng. Ind. (Trans. ASME), May 1984, 106, (2), 171-177, [in English]. ISSN 0022-0817.
Steels. (Pamphlet). The specially deoxidized free-cutting steel, to which Nb is added for refining the austenite grain size, forms the protective layer on tool surface and exhibits excellent machinability during machining by carbide tools. The steel has been commercially available and used in the automotive industry. The steel made by the addition of 0.06% sulfur and 0.01% Ca to the medium-carbon steel showed excellent machinability when worked by carbide or high-speed steel tools and demonstrated Charpy impact properties equal to those of steel of ordinary S content. When the steel was brought to a n e x t r e m e l y low S content, incidence of voids on the machined surface decreased since the MnS content of the steel decreased. The steel with low S and alumina content shows good machinability provided proper machining conditions are selected. 19 r e f . - - A A T. Akasawa, T. Imam, S. Katayame, and S. Ohtani. Metals/Materials Technology Series [Prec. Conf.], Los Angeles, Calif. U.S.A., 19-22 Mar. 1984, American Society for Metals, Metals Park, Ohio 44073, U.S.A., 1984, Paper No. 8407-003, Pp 8, [in English].
53-051 1
oped a HardTurning process using ceramic cutting tools. The process results in significantly improved dimensional and microfinish capabilities, facility cost reduction, tool cost reduction, maintenance simplification and the elimination of grinding wheel dust and coolant.--J.H.B. A.J. LeMire. Cutting Tool Eng., Nov.-Dec. 1983, 35, (11-12), 6-6, [in English]. ISSN 0011-4189.
M 7 7 4 Machine Chip Recycling. The program and the efforts to develop a method by which machine turnings of DU--O.75 Ti could be recycled are discussed--conversion of machine chips to UF4; coreduction of chips in UF4/Mg reaction vessels; inductoslag remelting; vacuum induction remelting; electron beam remelting. Indications are that the electron-beam method has the greatest potential in that it has the capability of decreasing impurity levels during the melt cycle. However, EB involves a high capital investment and has some technical uncertainties which could only be answered in large-scale production. Vacuum induction remelting is also a potentially viable recovery method; however, it cannot reduce impurity levels. Indeed, it will contribute to progressively higher carbon levels as generations of material are reclaimed. A specification for an electronbeam vacuum melting and casting furnace is included.--NTIS M J . Walz, C.E Latham-Brown, W. Sharpe, and Nuclear Metals Inc. AD-A134736, 31 Aug. 1983, Pp 126, [in English].
53-0512
E l e c t r o e r o s i v e Machining Method and Apparatus With
Discrete Metallic Electrode Bodies. A method of electroerosively machining an electrically conductive workpiece to form a cavity therein, comprises axially juxtaposing an elongate, open-ended tubular casing of a heat resistant material to define an electroerosion machining site in the region of the workpiece proximal to the open-ended portion of the casing, the casing having discrete metallic bodies packed in such a manner that they are arranged in a mutually contacting relationship at least in a longitudinal direction of the casing, each individually capable of constituting an electroerosion electrode; feeding a machining fluid into the machining site; feeding the discrete metallic bodies in the casing to discharge them successively into the machining region; passing an electroerosion machining current through the site between the workpiece and the discrete metallic bodies; and relatively displacing the heat resistant casing and the workpiece three dimensionally. K. Inoue, and Inoue Japax Research Inc. Off. Gaz., 29 Nov. 1983, Patent no. US4417962 (USA), 15 May 1980. ISSN 0360-5132. 53-0513 E n h a n c e d A l u m i n u m E t c h a n t , A process of chem-milling AI and AI alloys comprises adding in increments up to 70 g/I of sodium nitrate to a chemmilling composition which contains sodium hydroxide and continuing the chemmilling until the concentration of dissolved AI in the solution is ~ 120 g/l. W.E. Lindner, E. Malakelis, and McDonnell Douglas Corp. Off. Gaz., 29 Nov. 1983, Patent no. US4417949 (USA), 7 Sept. 1982. ISSN 0360-5132. P r o c e s s f o r M a k i n g a M o d i f i e d S i l i c o n A l u m i n u m Oxynitride Based Composite Cutting Tool. A process for obtaining an abrasion resistant cutting tool having a hard refractory material distributed in a homogeneous matrix containing a modified silicon aluminum oxynitride comprises: mixing from ~ 2090 vol.% silicon nitride, ~ 5-60 vol.% aluminum oxide, ~ 20-25 vol.% of a modifier to form a mixture; reacting at ~ 1400-1800~ for ~ 1-8 h in a nonoxidizing atmosphere to form a reacted mixture; comminuting a blend comprising from 40-95 vol.% of the reacted mixture and from ~ 5-60vo1.% of a hard refractory material to form a composite blend; and densitying the composite blend to form a homogeneous matrix having a dispersed phase of a hard refractory material throughout the matrix. S.-T. Buljan, V.K. Satin, and GTE Laboratories Inc, 20 Dec. 1983, Patent no. US4421528 (USA), 20 May 1982. 53-0514
53-0515 Alumina-Coated Composite Silicon Nitride Cutting Tools. A coated composite ceramic cutting tool is comprised of composite silicon nitride substrate body having at least one adherent coating layer consisting essentially of particles of a hard refractory material uniformly distributed in a matrix consisting of a first phase of silicon nitride and a refractory second phase comprising silicon nitride and an effective amount of a densification aid selected from the group consisting of yttrium oxide, hafnium oxide, lanthanide rare earth oxides and mixtures thereof; the adherent coating layer consisted essentially of aluminum oxide. V.K. Sarin, S.-T. Buljan, C. D'Angelo, and GTE Laboratories Inc. Off. Gaz., 20 Dec. 1983, Patent no. US4421525 (USA), 20 May 1982. ISSN 0360-5132. 53-O516 A l u m i n a - C o a t e d C o m p o s i t e S i l i c o n A l u m i n u m Oxynitride C u t t i n g T o o l s , A coated abrasion resistant composite ceramic cutting tool is comprised of a substrate body and at least one adherent alumina coating layer; the substrate body consisting essentially of a particulate material selected from the group consisting of the refractory metal carbides, nitrides, carbonitrides and mixtures thereof uniformly distributed in a matrix comprising a modified silicon aluminum oxynitride, the particulate material comprising from ~ 5-60 vol.% of the cutting tool and having an average particle size of between ~ 0.5-20 #m; the modified silicon aluminum oxynitride having a modifier selected from the group consisting of the oxides of Si, yttrium, Mg, Hf, Zr, beryllium, the lanthanides and combinations thereof. V.K. Sarin, S.-T. Buljan, and GTE Laboratories Inc. Off. Gaz., 3 Jan. 1984, Patent no. US4424068 (USA), 20 May 1982. ISSN 0360-5132.
J. APPLIED METALWORKING
53-0518 HardTurning With Ceramic Tools Replaces Grinding a t Automotive Plants. Kasper Machine Co., Madison Heights, Mich., has devel-
53-0519 Laser Manufacturing of Medical Devices. Lasers are currently being used for the fabrication of a variety of medical devices. Processes incorporating laser devices include heat treatment, cutting, welding and drilling. A lasercut Ti wire mesh pad for knee prosthesis is replacing bone cement. Microsurgical instruments fabricated from 303 stainless steel have benefited from the introduction of laser welding. Nozzles, with openings < 0.030 in. dia., can be fabricated from difficult-to-machine materials by laser drilling. 8 ref.--G.P.K. P. Hartung, and J.T. Feeley. Lasers Appl., June 1984, 3, (6), 105-108, [in English]. ISSN 0733-303X.
53-0520 Plasma Arc Interfaced With Robot Readily Cuts Gates and Risers. The use of a robot equipped with a plasma arc cutting device to remove gates and risers from gray iron castings is reported by the University of Rhode Island. By controlling the gas flow, standoff, rate of cut and current, it was found possible to limit the depth of heat penetration to 2-5 mils. Surface quality was acceptable, and machinability, which could suffer from the presence of a white iron zone, was not affected.--G.P.K. J.G. Sylvia. Ironcaster, May-June 1984, 16-17, [in English]. ISSN 0362-0425.
53-0521 Design, Development and Application of Modern M i l l i n g Machines and Machining Centers. The current tendency in machine tool engineering is determined by the automation potential offered by microprocessor technology. Because of this new technology, changes in the number and type of people employed in metalworking firms are expected. Topics addressed include slideway construction, measuring systems, design features for machining centers, flexible manufacturing cells and monitoring systems for automatic production facilities. --J.H.B. W. Babel. FWPJ., Mar. 1984, 24, (3), 7-8, 10, 14, [in English]. ISSN 0015-9026.
53-0522 Increasing Slitting Line Productivity With the Proper S l i t t e r Tooling System. Selection of tooling for max. productivity in a slitter tool system is discussed. A schematic of a typical arrangement of a slitter tooling system is presented. Factors to be considered in selection include selecting knives (toughness, wear resistance, keenness, heat resistance, shock resistance, composition of steels) and determining the type of materials to be slit (steels and AI), max. and min. thicknesses and tensile strength of materials to be slit, type and speed of the slitting machine, size of the knives, temp. of the material to be slit, and the material from which the knives should be manufactured (tool steels, superalloy or WC). Other considerations include costs, the importance of the spacer, rubber vs. steel strip rings, disks and nuts and making slitter tools that last Ionger.--C.M.L.S. Fabricator, May-June 1984, 14, (4), 12-13, [in English]. ISSN 0192-8066.
53-0523
Dual-Phase Steels Show Improved Machinability. Automotive components previously produced by casting or forging and machining can now be stamped and machined of dual-phase steels depending on part configuration and machining conditions for the material used. Comparisons were made for SAE 1010, SAE 980X and two dual-phase steel compositions.--J.H.B. C. Kim, M.S. Rashid, and W.J. Rifle. Automot. Eng., May 1984, 92, (5), 53-58, [in English]. ISSN 0098-2571.
Thermal Fundamentals o f C a l c u l a t i n g the Power of the Plasmatron in Plasma-Assisted Machining. (Translation: V R / 2 5 2 3 / 8 4 ) .
53-0525
L.A. Reznikov. Fiz. Khim. Obrab. Mater., 1983, 17, (5), Pp 4, [in English]. ISSP'
0015-3214.
53-0526
The Ledge Cutting Tool insert. (Pamphlet). The salient features of a simple, wear-tolerant cemented carbide tool are described. Results are presented for high-speed machining (3-5 times the conventional speeds) of Ti alloys ( T i - - 6 A I - - 4 V , T i - - 6 A I - - 2 S n - - 4 Z r - - 2 M o ) in turning and face milling. This tool, termed the ledge cutting tool, has a thin (0.015 to 0.050 in.) ledge which overhangs a small distance (0.015 to 0.060 in.) equal to the depth of cut desired. Such a design permits only a limited amount of flank wear (determined by the thickness of the ledge) but continues to perform for a long period of time as a result of wearback of the ledge. Under optimum conditions, the wear-back occurs predominantly by microchipping. Because of geometric restrictions, the ledge tool is applicable only to straight cuts in turning, facing and boring, and to face milling and some peripheral milling. In turning, cutting time of Ti alloys can be as long as ~ 30 min or more and metal removal of ~ 60 in. 3 can be achieved on a single edge. Wear-
VOL. 4, NO. 1, JULY 1985
91
back rates in face milling are ~ 2-3 times higher than in straight turning. The higher rates are attributed to the interrupted nature of cutting in milling. Use of a grade of cemented carbide (e.g. Carboloy Grade 820) which is too tough or has too thick a ledge for a given application leads to excessive forces which can cause gross chipping of the ledge (rapid wear) a n d / o r excessive deflection of the cutting tool with reduced depth of cut. Selection of a proper grade of carbide (e.g. Carboloy grades 999, 895, 883) for a given application results in uniform, low wear-back caused by microchipping. 10 r e f . - - A A R. Komanduri, and M. Lee. General Electric Co., Schenectady, N.Y. 12345, U.S.A., 1984, Rep. No. 84CRDt 15, Pp 18, [in English].
53-0542 A S i m p l e Microcomputer Aided NC [Numerical Control] Tape Generating System by Digitizing the Drawing Directly. The system was developed for two-dimensional contour milling and comprises programs for drawinginput, cutter compensation, tool-path simulation, and NC-tape output. The drawing information is inputted to a digitalizer by means of a stylus and is stored in a microcomputer in the form of contour data for use in each of the processes. The system construction is schematically illustrated and results obtained are presented and discussed.-- J.R. A. Takeuchi, and S. Shimizu. Bull. Jpn. Soc. Precis. Eng., Dec. 1983, 17, (4), 287288, [in English]. ISSN 0582-4206.
53-O531
5 3 - 0 5 4 8 An Anode Film-Type Mechanical Cutting-Off Machine. Details are given of the EPAA-6 anode-film/mechanical machine designed in Poland for cutting-off all kinds of electrical-conducting materials on a one-off or batchoperation basis. The technique is a combination of electrochemical solubilization, electromachining, and mechanical working, and comprises a corrosion-inhibitive electrolyte pumped in a closed circuit to the cutting zone, electrically fed by a rotating electrode tool accurately cutting 1.2-1.25 mm gaps in 60-120 mm dia. workpieces up to 6000 mm long. Individual working phases and dependencies of the output and the surface roughness on voltage and current density relationships in cutting different-hardness steels are illustrated.--J.R. E. Pajak. Pol. Tech. Rev., 1983, (6), 3-5, [in English]. ISSN 0032-3012.
Grinding o f S p i r a l B e v e l G e a r s . Machine cut spiral bevel gears are lapped after hardening to keep down their noise level. In recent times CBN grinding wheels have been employed for grinding such gears, which, however, prove costly and do not, as a rule, allow the user to modify the tooth profile. A process for grinding spiral bevel gears with conventional abrasives is described. This process not only achieves the high accuracy required but is also cost effective. --AA D. Wiener. IPE Int. Ind. Prod. Eng., 1984, 8, (1), 52-57, [in English]. ISSN 0343334X. 53-0532 Frequency Analysis of Surfaces Machined Using Different Lubricants. Surface roughness analysis as a means of investigating lubricant action in cutting is discussed. An experimental setup involving a high-resolution signal analyzer has been used to obtain power spectrum characteristics and conventional surface roughness parameters of surfaces machined using pure AI, electrolytic Cu, low-carbon steel and austenitic stainless steel work materials and various cutting fluids. Across the lay, conventional roughness parameters are dominated by the feed marks and discrimination between different lubricating conditions is difficult. Frequency analysis, on the other hand, permits the feed component to be isolated, making it possible to ascertain the effect of lubrication at other wavelengths. The lubricating action is even more pronounced when measurements are performed in the machining direction, though a larger scatter among the results is experienced. The averaged power spectrum ratios of surface roughness measured in the direction of cutting are used to describe the lubricating action. --AA L. De Chiffre. ABLE Trans., July 1984, 27, (3), 220-226, [in English]. ISSN 05698197.
53-0538 Analyses of Thermal Deformation of Workpiece in Honing Process. II.--Temperature Distribution, Honing Force, and Expansion Pressure of Honing S t o n e . Previous analyses by Y. and I. of the thermal deformation ibid., 173 are extended to consideration of honing-force (F) and stone expansion-pressure (Pro) parameters in relation to the temp. distribution in the cylindrical carbon-steel workpieces. The quasi-isothermal nature of the deformation is confirmed, and quantification of the relationship between it and the mean temp. increase shows that the latter can be accurately utilized in residual-energy estimations. Decrease of F in dry hoeing is shown to depend on decreases in the net Pm and in the depth of cut owing to increase of the stone/workpiece interface area, while in wet honing the F decrease is dependent on the cut-depth decrease owing to grazing. In selecting the Pm the frictional loss in the head should be considered, in addition to the spring force.--J.R. K. Yokoyama, and R. Ichimiya. Bull. Jpn. Soc. Precis. Eng., Dec. 1983, 17, (4), 247-252, [in English]. ISSN 0582-4206.
53-0539 Loading on Wheel Surface in Precision Traverse Grinding. A monitor developed for detecting the metal particles of work material loaded on a grinding-wheel surface is fastened to the front face of the wheel head, and comprises an eddy-current sensor probe at the end of an arm reciprocated along the width of the rotating wheel by a reversing motor. The output voltage indicates the sum of the flat area of metal particles under given p r o b e / w h e e l gap conditions. Results for cylindrical-traverse grinding of a C r - - M o steel with a WA40OK9V wheel are presented and discussed.--J.R. T. Sure, T. Waida, and H. Inoue. Bull. Jpn. Soc. Precis. Eng., Dec. 1983, 17, (4), 267-268, [in English]. ISSN 0582-4206. 53-0540 Study on Residual Stresses in Ground Layers--Analysis Considering Microscopic Residual Shear Stresses. Residual strains in annealed 0.54% C steel workpieces ground by an M-grade 150-mm dia. wheel were determined by a parallel-beam X-ray strain-measurement apparatus, lattice strains on 12t 1}, 12001, and I11oi planes were measured using CrK~ X-rays, and residual strains were determined from strains on the 121 t l plane. The results showed that stresses in the machining and perpendicular directions (i.e. axv and ~ryv) gradually shift to tensile stress with increasing depth of cut and work and wheel speeds, owing to increased generation of grinding heat by sub-surface thermalstress distributions. The microscopic shear stress, rzxw, is positive, and in general is generated by mechanical action of the cutting edges. The depth of penetration by the mechanical cutting action of the abrasive grains is less than that arising from thermal action.--J.R. M. Wakabayshi, M. Nakayama. and K. Tamamura. Bull. Jpn. Soc. Precis. Eng., Dec. 1983, 17, (4), 271-272, [in English]. ISSN 0582*4206.
530541 Temperature Distribution of Grinding Wheel Under No-Load Running C o n d i t i o n . The temp. distribution due to the heat flow was studied on a conventional vitrified-bond Ai203 wheel and a CBN wheel with an A|-alloy hub featuring high thermal conductivity and a large thermal-expansion coefficient. Infra-red tbermographs show that the temp. gradient is smaller than that for the conventional wheel, in which the heat-flow influence is restricted to the inner abrasive layer. The temp.-distribution differences between the two types of wheel are explained in terms of the different thermal conductivities and air-cooling abilities. --J.R. H. Inoue, H. Noguchi, and M. Hattori. Bull. Jpn. Soc. Precis. Eng., Dec. 1983, 17, (4), 277-278, ]in English]. ISSN 0582-4206.
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VOL. 4, NO. 1, JULY 1985
53-0551 S c a r f i n g Method and A p p a r a t u s . In a method and apparatus for scarfing the end face of a cylindrical steel ingot, a torch is disposed adjacent, and radially of the end face, and relative rotation between the ingot and the torch is carried out at constant speed so that, a relatively smooth surface results and, due to the variation of angular velocity between the centre and the periphery, the depth of cut increases from the periphery towards the centre where most segregation occurs. T. Moritani, M. Teramura, M. Shimizu, and Sumitomo Metal Industries Ltd. 11 Apr. 1984, Patent no. GB2127338A (UK), 27 Sept. 1983.
53-0552
Billet Shearing Method and A p p a r a t u s . A method and apparatus are disclosed for obtaining exact sheared lengths from steel billet material for use as blanks for solid-forming. After raising of the billet on a roller table to line-up with a feed path to shear blades, the billet is advanced by the roller table and by a gripper feed device until it engages an adjustable stop. During the feeding step, a partial clamping force is applied to the billet by a clamping device acting via a roller. When the billet engages the stop, a greater clamping force is applied to the billet, to fix it in the shearing position, by means of a hold down. A shearing stroke is initiated upon engagement taking place between the leading end of the billet and the stop. The fact that the shearing plane remains unchanged after lining-up of the billet, and that the billet is fed right up to the stop with a constant feed force contributes to the accuracy of the lengths sheared. D. Volksheimer, G. Hsrtke, and Eumuco AG fur Maschinenbau. 16 May 1984, Patent no. GB2129356A (UK), 3 Oct. 1983. 53.0553 E l e c t r i c a l Discharge Machining. An EDM system has a tool electrode positioned to face a workpiece to define therewith a machining gap which communicates substantially directly with a region of atmospheric air. A nonflammable (e.g. water-based) machining liquid is injected into the machining gap while electrical discharges are eftected therein to electroerosively remove stock from the workpiece. The resultant machining products including at least partially decomposed liquid, are ejected into the region of atmospheric air to accumulate at least partially as a pile of debris on a surface of the workpiece adjacent to the machining gap. Brush means are provided to sweep away the debris from the region of the machining gap. The brush may take the form of an endless belt. K. Inoue, and Inoue Japax Research Inc. 23 May 1984, Patent no. GB2129728A (UK), t0 Nov. 1983. 53.0554 Ion M i l l i n g a n d C o a t i n g S y s t e m s , Low energy ion beams find increasing application in machining of component surfaces. The technology is finding diverse roles in engineering, medical and other industries where materials can be textured and micromachined to impart unique catalytic, biological, adhesive or wear-resistant properties. Dedicated processing systems have been designed in which dual mill and coat processing of components can be achieved in a one-step operation. These emerging applications of low energy ion beam processing are outlined and a variety of typical systems available to users are described. 26 ref. --AA T.W. Jolly, and R. Clampitt. Ion Assisted Surface Treatments, Techniques and Processes [Prec. Conf.], Coventry, England, 14-16 Sept. 1982, The Metals Society, 1 Carlton House Terrace, London S W l Y 5DB, England, 1982, (Met.A., 8409-720613) 18.1-18.8, [in English]~ 53-0559 C o a t e d Chipped Tools for High-Speed C u t t i n g . Toshiba Tungaloy Co. Ltd. have developed two coated chipped tools for high-speed cutting, Model T821 for cast iron and Model T822 for steel and cast steel. They are coated with multiple layers of a new ceramic, AI(ON)x, which is claimed to give a surface layer of excellent texture, superlative bonding strength between coating and underlayer, and high wear resistance. Cutting speeds of 200-260 m/rain for steel and 220-300 m/rain for cast iron are possible. The tools have long service life expectancy.--E.J.S. Jpn. Ind. Techno/. Bull., Mar. 1984, 11, (12), 12, [in English]. ISSN 0385-6542.
53-0560
An I n v e s t i g a t i o n o f the Cutting Process With the Aid o f a P l a n e P o l a r i z e d CO= Laser Beam. A plane polarized power beam was used to investigate the reactive gas-assisted laser cutting process. This paper gives further experimental support for the theory of the existence of two different regimes in the oxygen-assisted cutting of steels and explains the dependence of the process on E e - - O 2 exothermic reactions. 8 r e f . - - A A M. Lepore, M. Dell'Erba, C. Esposito, and G. Daurelio. Opt. Lasers Eng., 1983, 4, (4), 241-251, [in English]. ISSN O143-8166.
J. APPLIED METALWORKING
53-0563 Composite Ceramic Cutting Tool. An abrasion resistant composite cutting tool consists of a particulate material selected from the group consisting of the refractory metal carbides, nitrides, carbonitridea and mixtures thereof of Ti, tungsten, Hf, Nb, Ta, vanadium and combinations uniformly distributed in a matrix comprising a modified silicon aluminum oxynitride, the particulate material comprising from ~ 5-60 vol.% of the cutting tool and having an average particle size of ~ 0.5-20 #m, modified silicon aluminum oxynitride having a modifier selected from the group consisting of the oxides of Si, yttrium, Mg, Hf, Zr, beryllium, the lanthanides and combinations; modified silicon aluminum oxynitride being formed from ~ 2-25 vol.% of modifier, from ~ 20-90% silicon nitride and from 5-60% aluminum o)~ide. S.-T. Buljan, V.K. Sarin, and GTE Laboratories Inc. Off. Gaz., 10 Jan. 1984, Patent no. US4425141 (USA), 20 May 1982. ISSN 0360-5132. 53-0564 C a r b i d e - C o a t e d Composite M o d i f i e d S i l i c o n Aluminum O x y n i t r i d e C u t t i n g T o o l s . A coated abrasion resistant composite ceramic cutting tool is comprised of a substrate body and at least one adherent refractory metal carbide coating layer, the substrate body consists essentially of a particulate material selected from the group consisting of the refractory metal carbides, nitrides, carbonitrides and mixtures uniformly distributed in a matrix comprising a modified silicon aluminum oxynitride, the particulate material comprising from 5-60 vol.% of the cutting tool and having an average particle size of between 0.5-20 /~m, modified silicon aluminum oxynitride having a modifier selected from the group consisting of the oxides of Si, yttrium, Mg, Hf, Zr, beryllium, the lanthanides and combinations thereof. V,K. Satin, S.-T. Buljan, and GTE Laboratories Inc. Off. Gaz,, 17 Jan. 1984, Patent no. US4426209 (USA), 20 May 1982. ISSN 0360-5132. 53-0565 C a r b i d e - C o a t e d S i l i c o n N i t r i d e Cutting Tools. A coated ceramic cutting tool is comprised of a densified silicon nitride substrate body having at least one adherent coating layer consisting of a first phase of silicon nitride and a refractory second phase comprising silicon nitride and an effective amount of a densification aid selected from the group consisting of silicon dioxide, aluminum oxide, magnesium oxide, yttrium oxide, hafnium oxide, zirconium oxide, the lanthanide rare earth oxides and mixtures thereof; the adherent coating layer consisting essentially of a refractory metal carbide. V.K. Sarin, S.-T. Buljan, and GTE Laboratories Inc, Off. Gaz., 14 Feb. 1984, Patent no. US4431431 (USA), 20 May 1982, ISSN 0360-5132. 53-0568 T i t a n i u m F a b r i c a t i o n . F i n a l R e p o r t . To meet design requirements, large thick wall extrusions were purchased and machined to a final configuration which weighed < 10% of the original extrusion. It quickly became obvious that this was not an effective use of either material or machine shop resources. Projects were initiated to evaluate more efficient methods of fabricating large structural components made from various Ti alloys. The areas studied in depth included resistance spot welding of T i - - 6 A I - - 4 V ; thermal mechanical forming and bonding and electrical discharge machining; and tool life studies of C-2 grade carbide inserts which were applicable to all machined parts. Results have been applied not only to the parts for which they were originally developed but also to others. --NTIS M.G. Ulitchny, and Bendix Corp. DE84004374, Dec. 1983, Pp 9, [in English]. 53-0570 1 0 0 0 0 H o l e s / T a p . Increased productivity and longer tool life for tapping operations have been achieved by the use of Flow-Thru taps. Coolant is pumped through the center of the Flow-Thru tap and flushes chips out of the blind hole through the tap's flutes. The coolant pressure, however, does not affect the tension and compression characteristics of the tap. Taps are capable of producing 10 000 holes in a variety of metals (1018 steel weldments and high-Si cast iron) before resharpening is necesaary.--G.P.K. G. Kappke. Mod, Mech. Shop, June 1984, 57, (1), 50-55, [in English]. ISSN 00268003. 53-0571 Chipless Tapping Comes of Age. Chipless tapping is now being used for a wide variety of applications. In this method, internal threads are formed through plastic deformation of the workpiece material. Chipless tapping offers higher speeds, longer tool life and the elimination of chips. This tapping technique can be used on a wide variety of metals from carbon steels to AI or Cu, as long as the workpiece material has at least 7% elongation. The application of hard and wear resistant coatings (TIN) to chipless taps is also discussed.--G.P.K. J. Abbott. Mod. Mach. Shop, June 1984, 57, (1), 58-65, [in English]. ISSN 00268003m 53-0573 Continuous-Dress Creep Feed--Should We Be Taking It M o r e S e r i o u s l y ? The basic elements of continuous-dress creep-feed (CDCF) grinding and its advantages are outlined. Latest developments are improved stability, speed and adaptive control. The first users were in the aerospace industry; some other application areas are mentioned. Future application areas are discussed. CDCF is still in the early days of development and some of the controversy relating to sacrifices in surface finish and conflicts with the components of CBN (cubic boron nitride or borazon) are addressed. Experiments performed on C1023 steel showed that the material could be creep-fed at speeds up to 60 mm/min before the part burned. With continuous dress, top speed leaped to 1060 mm/min and the failure mode was wheel breakdown, not part burning.--S.K.B. E.E. Sprow. Tool. Prod., June 1984, 50, (3), 53-59, [in English]. ISSN 0040-9243. 53-0577 L a s e r M e t a l w o r k i n g . Situations where industrial lasers have become a very useful metalworking tool are outlined. Advantages, disadvantages and some considerations in cutting with lasers are presented. The meaning of mode burn, polarity and their practical implications are explained. Multimode and single-mode lasers are compared, The roles of and the relationship between metal thickness and cutting speed for the most commonly used engineering alloys, including low-carbon and stainless steels, At-, Ti- and Ni-baae alloys, are presented. Some important considerations in laser welding are also diacusaed.--S.K.B. R.J. Saunders. Met. Prog., July 1984, 126, (2), 45, 47-48, 50-51, [in English]. ISSN 0026-0665.
J. APPLIED METALWORKING
53-0578 Microstructure and the Transverse Rupture Strength o f Cemented Carbides. The Transverse Rupture Stress (TRS) of cemented carbides which, for all tungsten carbide grain sizes, has a max. at a Co content in the range 12-20 wt.% is reviewed. Evidence presented shows that the TRS is a function of Co layer thickness and that the max. TRS occurs when the layers are most uniformly thick. 8 r e f . - - A A H. Le Roux. Int, J. Refract. HardMeL, June 1984, 3, (2), 99-100, [in English]. 53-0579 Measuring Cutting Tool Wear On-Line: Some Practical C o n s i d e r a t i o n S . On-line tool wear sensors can reduce costs by 40% in untended machining operations. Wear can be monitored indirectly by measuring force, temp. and vibration, or directly by measuring workpiece size, radioactivity levels and the distance separating the tool and workpiece, The application of computers and modern electronics has increased the reliability and advantages of the indirect methods.--G.P.K. S. Jetly. Manuf. Eng., July 1984, 93, (1), 55-60, [in English]. ISSN 0361-0853. 53-0580 S w i t c h i n g t o Diamond Tooling Optimizes Machining Uptime f o r Engine Manufacturer. A switch-over to polycrystalline diamond inserts by an engine manufacturer has increased tool life > 9000% in comparison with carbide tooling, Conventional carbide inserts were being used to mill engine cam housings of SAE 305, a Iow-Si AI alloy. Not only has the c o s t / p a r t been substantially reduced, machine uptime has been optimized,--G.P.K. J.E, Mitchell, Cutting Tool Eng., June 1984, 36, (3), 36, [in English]. ISSN 00114189. 53-0581 Machining Abrasion Resistant C a s t Iron W i t h A m b o r i t e . GIW, a manufacturer of pumps that handle abrasive solids, is using the new, superebrasive cutting tool Amborite (a ceramic composite) to machine tough cast irons. Amborite is substantially harder than conventional carbide cutting tools, yet retains a high level of hardness. Structural features of Amborite are discussed; results of comparative machining trials are described.--G.P.K. Cutting Tool Eng., June 1984, 36, (3), 38-39, [in English]. ISSN 0011-4189.
53-0582
Following Critical Application Variables Important When
Using Resin and Vitrified Bonded CBN Wheels. Process variables and operational practices can have a strong effect on the performance of resin and vitrifiedbonded CBN wheels. Resin-bonded CBN wheels are affected by part quality, material hardness, grinding fluid and trueing/dressing procedures. Vitrified-bonded CBN wheels can additionally be affected by compensation/skip dressing procedures and variables and procedure guidelines can optimize the service performance of CBN wheels.--G.P.K, D.L. Edwards, Cutting ToolEng., June 1984, 36, (3), 40, 42, 44, [in English]. ISSN 0011-4189. 53-0583 F u n d a m e n t a l s o f C h e m i c a l M i l l i n g . Historical developments and principles of the chemical milling process are described, along with advantages, limitations and applications. The chemical-milling terms are defined. Application of the process in C-5B airplanes in which some 8500 parts are produced by this method are discussed. The types of maskants used for various materials and the process of scribing are described. Economics of the process, the etching techniques, analytical control and the environmental issues are also covered. The chem-milling solutions for and its effects on materials properties of AI alloy 2024 and 7075, beryllium, steel, 4130, 4340 and 304L, Ren(~ 41 and Inconel 718, Ni alloys, Ti alloys T i - - 6 A I - - 4 V and T i - - 1 5 V - - 3 C r - - 3 A I - - 3 S n alloys and other miscellaneous metals are reviewed. 132 ref.--S,K.B. J.W, Dini. Am. Mach., July 1984, 128, (7), 113-128, [in English]. ISSN 0002-9858.
53-0584
S u b s t i t u t i o n o f Ceramics for Conventional Cutting Tools. Economic and technical considerations involved in the substitution of ceramics for tungsten carbide cutting tools are reviewed, Factors affecting substitution include insert mechanical properties and geometry, workpiece composition and geometry and insert chemical properties. The characteristics of ceramic cutting tools, such as sialon, "white" AI203 and "black" Ai203/TiC composite, are compared with cemented carbides. In spite of the need for critical material substitution, the wider use of ceramics is seen to be largely dependent on performance and cost advantages. Cutting parameters for cast iron, high-speed tool steel and Inconel 718 using various ceramic inserts are presented. 13 ref.--G.P.K. B. North. Mater. Soc., 1984, 8, (2), 257-270, [in English]. ISSN 0146-6399.
53-0585 The S u b s t i t u t i o n i n t h e U . S . o f Ceramic Tools for Conventional Cutting Tools C o n t a i n i n g S t r a t e g i c M i n e r a l s , Tungsten, T a n t a l u m a n d C o b a l t . Possibilities of reducing the domestic consumption of the strategic minerals tungsten, Ta and Co by the substitution of ceramic cutting tools for conventional tools are reviewed. Factors affecting the wider use of ceramic tools are discussed and the vulnerability of the U.S. to strategic mineral shortages is described. The impetus for substitution by ceramics is based on performance advantages rather than mineral shortages. 16 ref.--G.P.K. R. Komanduri. Mater. Soc., 1984, 8, (2), 271-281, [in English], ISSN 0146-6399,
5 3 - 0 5 8 6 Progress in Ceramics Research for Cutting Tools in the U.S., W e s t G e r m a n y , USSR, J a p a n and Sweden. Major advances have been made during the last 15 years in the development of ceramic tool materials. These advances not only make higher cutting speeds possible but also reduce dependency on vulnerable metals such as Co and tungsten. However, review of the technical literature during this time period shows that the U.S, has not been a leader, either in the development of new ceramic tools or in their implementation. To some extent, lack of implementation is due to the fact that in the U.S. many machine tools are outdated and must be modernized or replaced before ceramic tools can be used to full advantage. This is not the situation in West Germany and Japan, however. Starting with a brief review of the development of the ceramic tool, the progress which has been made in developing advanced ceramic tool materials such as cemented carbide, alumina and sialon and on areas where the U.S. appears to be lagging are discussed, 17 r e f . - - A A E.D, Whitney. Mater. Soc., 1984, 8, (2), 283-294, [in English], ISSN 0146-6399.
VOL. 4, NO. 1, JULY 1985
93
53-0587
Determination of Strain Distributions in Machined Chips.
Experimental and analytical procedures used to determine Lagrangian strain component in deformed chips obtained from orthogonal machining are described. Specimens were cut from 6061-T6 AI and T i - - 6 A I - - 4 V thick plates. Kodak thin film resist was used to form a grid on the specimen surface. Enlarged photographs of the deformed grids after machining were used to determine the displacement vector. Displacement derivatives were computed and the Lagrangian strain tensor was calculated. The measured strains in 6061 were reasonably uniform on the macroscopic scale. 19 ref.--C.J.H. D.S. Schnur, and D. Lee. Metal/. Trans. A, Sept. 1984, 15A, (9), 1777-1779, [in English). ISSN 0360-2133. 53-0588 Horsepower Influence in Conditioning Grinders. Through the use of low-horsepower grinders, in combination with optimized conditioning parameters, the conditioning costs in European steel mills have been reduced by > 40%. Close tolerances on grinding depth allow for yield losses in 0.2-0.3% range when spot grinding carbon steel billets. Preprogramed spot grinding allows accurate defect removal with min. yield Ioss.--AA A. Wahlander. Abrasives and Hi-Technology: a Two-Way Street [Prec. Conf.], Pittsburgh, Pa., U.S.A., 30 Apr.-2 May 1984, Abrasive Engineering Society, 1700 Painters Run Rd., Pittsburgh, Pa. 15243, U.S.A., 1984, (Met.A, 8410-72-0643) 5359, [in English]. 53-0589 The Wheel and Creep Feed Grinding. It is widely accepted that grinding wheels with a high percentage of porosity are an absolute necessity for creep feed grinding. This paper explains the reasons and comments on selecting the appropriate w h e e l . - - A A P.K. Gibree. Abrasives and Hi-Technology: a Two-Way Street [Prec. Conf.], Pittsburgh, Pa., U.S.A., 30 Apr.-2 May 1984, Abrasive Engineering Society, 1700 Painters Run Rd., Pittsburgh, Pa. 15243, U.S.A., 1984, (Met.A., 8410-72-0643) 67-72, [in English].
Integrating Creep-Feed C a p a b i l i t i e s I n t o Manufacturing Systems. The combination of continuous dressing with creep-feed grinding 53-0590
caused a revolution in the abrasive machining industry. In particular, the Europeans have designed a completely new generation of surface grinding machines and incorporated them into "Factory of the Future" grinding cell systems which are presently producing production hardware at high productivity rates. The machine tool designs and automated grinding cell systems are described. 7 r e f . - - A A S.C. Salmon. Abrasives and Hi-Technology: a Two-Way Street [Prec. Conf.], Pittsburgh, Pa., U.S.A., 30 Apr.-2 May 1984, Abrasive Engineering Society, 1700 Painters Run Rd., Pittsburgh, Pa. 15243, U.S.A., 1984, (Met.A, 8410-72-0643) 73-79, [in English]. 53-O591 A Closed-Loop Balancing System for Precision Grinding. Poor product surface finish may be caused by the spindle/wheel assembly being out of balance. To achieve precision balance, however, the following additional items should be evaluated: unbalanced drive and pump motors, floor isolation, contiguous heavy impact equipment, worn spindle bearings, single-plane and two-plane unbalance. There are several methods of reducing or eliminating vibration which results from unbalance in the spindle/wheel assembly, including the closed-loop o n - w h e e l b a l a n c e r w h i c h o f f e r s the g r e a t e s t p r e c i s i o n and o t h e r unique opportunities.--AA T.E. Schulte. Abrasives and Hi-Technology: a Two-Way Street [Prec. Conf.], Pittsburgh, Pa., U.S.A., 30 Apr.-2 May 1984, Abrasive Engineering Society, 1700 Painters Run Rd., Pittsburgh, Pa. 15243, U.S.A., 1984, (Met.A, 8410-72-0643) 81-84, [in English]. 53-0592 A b r a s i v e B e l t G r i n d e r s as Machine Tool Attachments: How to Improve Your Shop's V e r s a t i l i t y . Inexpensive, productive equipment utilizing today's coated abrasive advancements is described. Subjects covered are: lathe (metal and rubber roll), vertical boring mill and planar attachments. Case histories are cited for belt grinding carbon and C r - - M o steels, cast iron, Ti- and Ni-base alloys.--AA K.R. Foley. Abrasives and Hi-Technology: a Two-Way Street [Prec. Conf.], Pittsburgh, Pa., U.S.A., 30 Apr.-2 May 1984, Abrasive Engineering Society, 1700 Painters Run Rd., Pittsburgh, Pa. 15243, U.S.A., 1984, (Met.A., 8410-72-0643) 85-95, [in English]. 53-0593 Diamond Grinding of Carbides and Ceramics. The carbide industry has advanced from hard grinding of brazed carbide-tipped tools to highly automated grinding of indexable throwaway inserts. It has also progressed from extensive surface grinding of carbide blanks having considerable grinding stock to automated special machine grinding of near-net-shape-and-size inserts. Product development advances have resulted in inserts with fewer surfaces to be ground. Likewise, advances in manufacturing development yielded grinding wheels and grinding processes tailored to specific requirements.--AA J.M. Galimberti. Abrasives and Hi-Technology: a Two-Way Street [Prec. Conf.], Pittsburgh, Pa., U.S.A., 30 Apr.-2 May 1984, Abrasive Engineering Society, 1700 Painters Run Rd., Pittsburgh, Pa. 15243, U.S.A., 1984, (Met.A, 8410-72-0643) 97104, [in English].
frequency electrical energy into mechanical motion which is transmitted to the toolholder and cutting tool. This linear oscillation at ~ 20 000 t i m e s / s bombards an abrasive slurry flowing between the tool and the workpiece, thereby chipping or grinding an exact counterpart of the tool face into the work. This nonthermal, nonchemical process provides a capability of producing a limitless variety of shapes in virtually all hard and brittle m a t e r i a l s . - - A A M.A. Moreland. Abrasives and Hi-Technology: a Two-Way Street [Prec. Conf.], Pittsburgh, Pa., U.S.A., 30 Apt.-2 May 1984, Abrasive Engineering Society, 1700 Painters Run Rd., Pittsburgh, Pa. 15243, U.S.A., 1984, (Met.A, 8410-72-0643) 111-117, [in English).
53-0596 Increased Removal Rates and Improved Surface Integrity by Creep Feed G r i n d i n g . As a modern high-efficiency machining process for mass production, creep feed grinding is applied today when high removal rates are to be combined with high surface integrity. These characteristics are based on the relatively low level of the temp. field in the work surface layer provided that optimal working parameters are applied. By means of novel developments, such as continuous dressing and higher wheel speed, productivity in creep feed grinding will be increased further. 23 r e f . - - A A P.G. Werner. Abrasives and Hi-Technology: a Two-Way Street [Prec. Conf.], Pittsburgh, Pa., U.S.A., 30 Apr.-2 May 1984, Abrasive Engineering Society, 1700 Painters Run Rd., Pittsburgh, Pa. 15243, U.S.A., 1984, (Met.A, 8410-72-0643) 119127, [in English]. 53-0597 Diamond Grinding o f S t r u c t u r a l C e r a m i c s . Ceramics, long used for pottery and china, are assuming a new role in industry as a result of technological advances. Since the new engineered ceramics are being used in applications historically reserved for metals and carbides, surface finish and close tolerances will become critical. Therefore, grinding will be required. Several of the new applications and guidelines for grinding these super-hard materials are given. Efficient grinding will play a major role in the development of engineered c e r a m i c s . - - A A A.G. Pinson. Abrasives and Hi-Technology: a Two-Way Street [Prec. Conf.], Pittsburgh, Pa., U.S.A., 30 Apr.-2 May 1984, Abrasive Engineering Society, 1700 Painters Run Rd., Pittsburgh, Pa. 15243, U.S.A., 1984, (Met.A, 8410-72-0643) 129132, [in English]. 53-0598 New Experiments on the Temperature D i s t r i b u t i o n in Drilling. Using metallographic and microhardness techniques, temp. distributions have been determined in twist drills of M7 or M33 steels. The methods rely on the fact that certain high-speed steel materials exhibit microstructural changes when subjected to temp. > 600~ Quick-stop specimens have also been obtained to study the metal flow patterns over the drill flutes. These results have been used to comment on the different wear mechanisms that affect the performance of a twist drill. Preliminary results show that bulk plastic flow occurs near the margin of the drill where the temp. are in the vicinity of 9 0 0 ~ when machining AISI 1045 steel at 40 m/min. 11 r e f . - - A A A. Thangaraj, P.K. Wright, and M. Nissle. J. Eng. Mater. Technol. (Trans. ASME), July 1984, 106, (3), 242-247, [in English]. ISSN 0094-4289. 53-0599 T u n g s t e n - F r e e H a r d Alloy and Process for Producing S a m e . A process is presented for producing a tungsten-free hard alloy having porosity < 1% and containing the following components mass%: titanium diboride 40-60; a binder which contains an alloy of Cu, Ni and AI based on at least one metal of Subgroup 1B of the periodic system inactive relative to boron and a powder of the final alloy such as bronze powder or powders of Cu, Ni and AI 3-30, balance titanium carbide; and comprises preparation of a starting charge by intermixing powders of Ti, B and carbon, compression of the charge, local ignition for initiation of the exothermal reaction of Ti with B and C which further proceeds spontaneously under burning conditions while propagating within the charge due to the heat transfer from a heated layer of the charge of a cold one, and at the stage of the charge preparation a powder of at least one metal of Subgroup 1B of the periodic system is incorporated into the charge and a powder of an alloy based on one of the metals of Subgroup 1B, or powders of metals forming such alloy under the conditions of exothermal reaction, are incorporated into the charge and on completion of the exothermal reaction the resulting solid--liquid reaction mass is subjected to compression until a porosity of < 1% is obtained. A.G. Merzhanov, I.P. Borovinskaya, L.V. Kustova, and F.I. Dubovitsky. Off. Gaz., 14 Feb. 1984, Patent no. US4431448 (USA), 20 Feb. 1980. ISSN 0360-5132.
53-0600 Application o f S t a t i s t i c a l A n a l y s i s in E v a l u a t i n g Surface Microgeometry. (Translation: V R / 2 5 4 8 / 8 4 ) . B. Bumbalek. Kovov~ Mater., 1983, 21, (6), Pp 9, [in English]. ISSN 0023-432X. 53-0601 Evaluation of Surface Quality. (Translation: VR/2549/84). M. Marek. Kovov~ Mater., 1983, 21, (6), Pp 8, [in English]. ISSN 0023-432X. M e c h a n i c s o f C h i p F o r m a t i o n a n d Its E f f e c t on the S u r f a c e Integrity of Hardened S t e e l s . The cutting of hardened steels has become pos53-0602
53-0594 E D G m a New W a y t o G r i n d . Electrical discharge grinding uses a graphite wheel to machine conductive materials. The actual 'cutting tools' are thousands of sparks which erode even the hardest workpiece material away. The machinability of the graphite wheel creates a grinding operation which is versatile, yet economical. A form tool mounted on the machine's table enables dressing and machining to take place on the same plane, insuring accuracy and repeatability. --AA N. AIIston. Abrasives and Hi-Technology: a Two-Way Street [Prec. Conf.], Pittsburgh, Pa., U.S.A., 30 Apr.-2 May 1984, Abrasive Engineering Society, 1700 Painters Run Rd., Pittsburgh, Pa. 15243, U.S.A., 1984, (Met.A., 8410-72-0643) 105109, [in English].
sible due to the development of cubic boron nitride tools and the improvement o1 ceramic tools. However, the mechanism involved in the cutting of hardened steels is not clear and the surface characteristics of a machined surface have not been systematically investigated. The purpose of this investigation is to clarify these problems to help improve production efficiency and assure the quality of parts produced. A series of cutting experiments were conducted to study the mechanisms of cutting hardened steel and the chips produced were examined by scanning electron microscope and the optical microscope. The surface structure was also examined by reflection electron diffraction method. Adiabatic shear was observed when AIS14340 steel with hardness over HRC 50 was machined. The model developed was able to explain the reversal of residual stresses due to the mechanical deformation caused by a cutting tool. ( D A 8 4 0 7 5 7 8 ) . - - A A Y. Matsumoto, and Purdue University. Diss. Abstr. Int., June 1984, 44, (12), Pp 219, [in English]. ISSN 0419-4217.
53-0595
53-0603
Ultrasonic Impact Grinding: W h a t It Is; W h a t It Will Do. Ultrasonic impact grinding or ultrasonic machining is the conversion of high-
94
VOL. 4, NO. 1, JULY 1985
F r e e - C u t t i n g S t e e l C o n t a i n i n g Controlled Inclusions and the Method of Making the S a m e . A free-cutting stainless steel containing con-
J. APPLIED METALWORKING
trolled inclusions is characterized in that the steel contains inclusion A which softens or melts at a temp. < 1000~ and inclusion B which has a melting point > 1300~ but exhibits plasticity at a temp. between 900-1300~ The inclusion A and the inclusion B exist in a mutually adhered form and area percentage of inclusion A is at least 1% of area percentage of inclusion B. The stainless steel has good formability in cold forging characterized in that the steel contains carbon up to 2,0%, Si up to 2.0%, Mn up to 10%, Cr 10-30%, sulfur up to 0.4% and Te up to 0.5%, wherein % T e / % S are at least 0.4 and oxygen being up to 0,015%, balance substantially Fe, and at least 80% of the sulfide-based inclusion particles in the steel of a length of 2 /~m or longer have an aspect ratio ~ 10. T. Kato, S. Abeyama, A. Kimura, S. Sekiya, S. Nakamura, and Daido Tokushoko. Off. Gaz., 28 Feb. 1984, Patent no. US4434006 (USA), 17 May 1979. ISSN 03605132. 53.0604 C o a t e d Cemented Carbide Body and Method of Making S u c h a B o d y . Sintered cemented carbide body containing at least one metal carbide and a binder metal, on which body there is applied at least one thin, wear resistant surface layer consisting essentially of aluminum oxide is characterized in that at least 85% of the aluminum oxide consists of the ~ form, the balance if any, mainly constitutes the ~ form, being formed as surface portions or spots having a size of at the most 10 /~m. U.K.H. Smith, J.N. Lindstrom, H. Mantle, and Santrade Ltd. Off. Gaz., 28 Feb. 1984, Patent no. USRe31526 (USA), 9 June 1977. ISSN 0360-5132.
5 3 - 0 6 0 5 Hard Alloy Comprising One or More Hard Phases and a B i n a r y or Multicomponent Binder M e t a l A l l o y . A hard alloy comprising at least one hard phase and a binary or multicomponent binder metal alloy comprises a finely dispersed, homogeneous distribution of at least one hard phase in the binder metal alloy, at least one hard phase comprising a carbide of a transition metal of Group IVb, Vb or VIb of the Periodic Table, and the binder metal alloy comprising a solid alloy of a transition metal of Group IVb, Vb or VIb of the Periodic Table with Ru, Rh, Pd, Os, Ir or Pt, with the proportion of transition metal in the binder metal alloy comprising 2-60 mole %, balance 98-40 mole % of the binder metal alloy comprising Ru, Rh, Pd, Os, Ir or Pt, and 0-90 at.% Fe, No or Co, the at.% of Fe, Ni or Co being based on the total at,% of Ru, Rh, Pd, Os, It, Pt, Fe, Ni and Co %. H. Holleck, and Kernforschungszentrum Karlsruhe. Off. Gaz., 21 Feb. 1984, Patent no. US4432794 (USA), 19 July 1980, ISSN 0360-5132.
5 3 - 0 6 0 6 Milling of N i - H a r d 2C. A report on the milling of eutectic Ni-hard 2C workpieces of hardness 56-58 HRC with Amborite cubic boron nitride (CBN) tools is described. The report, M30.1, is available from De Beers Industrial Diamond Division, Ascot, UK and describes tests which show that 3 mm of stock can be removed per pass together with details of tool life, cutting speed and surface finish achieved with the tools.--G.C. Ind, Diamond Rev., 1983, 43, (499), 305, [in English]. ISSN 0019-8145. 53-0607
Korean Auto Parts Machined With Amborite. The use o f " A m b o rite" cutting tool inserts to machine chill cast iron tappets of hardness HRC 57-60 by Sungbo Industrial Co. Ltd, Korea, is described. Carbide and CBN inserts were tried but Amborite inserts increased tool life from 800 to 30 000. Statistics on motor vehicle production and the Korean economy are also given.--G.C. K. Ji-Myung. Ind. Diamond Rev., 1984, 44, (501), 88-89, [in English]. ISSN 00198145. 53-0610 C h o i c e o f Electrolyte for Electrochemical Machining From the P o i n t o f V i e w o f Intergranular Corrosion. In a study of electrochemical drilling, the influence of the electrolyte composition on intergranular corrosion of various Ni alloys and of hardenable stainless steel was investigated. The nickel-base alloys did not undergo intergranular corrosion in a solution of 15% NAN03 + + 20% NaCIO3 + 65% H20, but they did so in solutions of NaNO 3 alone and in solutions containing NaCI. Stainless steel did not corrode in any of the electrolyte solutions used. 8 r e f . - - A A P. Novdk, I. Rou~ar, and V. ( ~ a l . Collect. Czech. Chem. Commun., Dec. 1983, 48, (12), 3495-3499, [in English]. ISSN 0010-0765.
53-0613 Fine ED ( E l e c t r i c - D i s c h a r g e ) C u t t i n g o n P r o f i l e L a t h e Tools and Milling Cutters. All the new superhard sintered materials for tipping cutting tools, including semiconductors, can be "machined" and sharpened by ED, provided that they have an electrical conductivity of at least 0.1 ~ _ l c m - 1 . Cleanly cut edges, no grinding marks or thermal effects and an accuracy and an of 0.0020.006 mm are features of the method, which can be automated by feeding the profile to a computer. The technique is illustrated by photographs and diagrams. --G.A.S. U. Baumgartner. S. Aft. Mach. ToolRev., Jan. 1984, 17, (1], 5, 7, g, [in English], ISSN 0036-0848. 53-0614 F i n e B o r i n g o f P r e c i s i o n H o l e s . The two basic methods considered are: removal of metal by means of tools with a defined cutting edge (reaming, drilling, boring), and by means of tools with undefined cutting edges (honing, grinding). Some recent developments to improve reamer performance, deep hole boring, the use of precision boring tools with special cutting blade configurations are described, Other aids to precise drilling are cutting blade mounting, accuracy of adjustment and supporting pads to prevent deflection under load. Examples of some high precision boring are given.--G.A.S. D. Kress. S. Aft. Mach. Tool Rev., Mar. 1984, 17, (3), 5, 7, g, [in English]. ISSN 0036-0848.
53-O617
Sawing--Choosing the Right Coolant for the J o b . Some of the problems associated with cutting different materials are described, with the coolant characteristics that allow them to be o v e c o m e . - - A A T, Fleeming. Weld, Met. Fabr., June 1984, 52, (5), 202, [in English]. ISSN 00432245. 53-O619 E x t r u d e H o n e o f D i e s Increases Service Life. Extrude hone, or press lapping, is a direct and flexible method of fine machining in which the lapping
J. APPLIED METALWORKING
or hone abrasive is passed at 20-30 bar pressure through the aperature of the die workpiece clamped in a simple two-chambered machine. In effect the pressurized abrasive acts as a self-shaping tool with a force depending in the cross-sectional area of the aperture, multiplied by the press thrust. The processing time for a flat steel die is approx. 3-5 min and is completed after 3-5 cycles, each involving a transfer of the abrasive between the machine chambers. With carbide dies the processing time is approx, doubled, and borocarbide or diamond is added to the abrasive. The die-surtace coarseness is reduced by, about 90% and the technique de-burs, rounds, and polishes, giving high-quality edges as well as f a c e s . - - J , R . D. Mac de Ploeg, Wire Worldlnt., Mar.-Apr. 1984, 26, (2), 78-80, [in English]. ISSN 0043-6046,
53-0620
The B e h a v i o u r o f Grinding Wheels in the Machining o f Materials Displaying Different Levels of Grindability. g.--Symptoms of W e a r o n S i n g l e G r a i n s D u e t o Scratching Application t o M a t e r i a l s Displaying Different Levels of Grindability. Single grains of e l e c t r o corundum, ruby, or silicon carbide were mounted on wheels which were used to replace grinding wheels in surface grinding machines. Measurements of the force on the grain and the width of the scratch in the substrate material were carried out as functions of scratch length. The materials studied were ductile, quenched-andtempered, and high-speed steels. Single grain wear rankings were identical to grinding wheel wear rankings, indicating that wheel wear is due primarily to grain wear. 11 ref.--T.W. W. KOnig, and J, Messer. Ceram. Forum Int., 7 Oct. 1983, 60, (8), 291-296, [in English and German]. ISSN 0173-9913. 53-0625
Coating for MetalcutUng Tools. A coating for a metalcutting tool consisting of titanium nitride is characterized in that it additionally contains either chromium nitride in an amount of 10-30%, or aluminum nitride 3-18%, molybdenum nitride 2-8%, chromium nitride 2-10% and silicon nitride 0.5-10%, all being taken in combination and uniformly distributed within the volume of the coating. A.A. Andreev et al. Off. Gaz., 13 MAR. 1984, Patent no. US4436830 (USA), 2 Mar. 1981. ISSN 0360-5132. 53.0626 M e t a l B i l l e t C u t t i n g Apparatus and Method. In a metal processing apparatus wherein an elongated stand of metal is severed as it moves along a pass line by cutting means which is operative to cut the strand transversely of the pase line into billets of a given length, the improvement comprises: a material removing means located at a fixed position with respect to the longitudinal extent of the pass line and operable to engage an exterior surface of the strand of metal moving on the pass line along at least one continuous line of action extending throughout the lateral extent of the exterior surface for removing material from the exterior surface as the strand moves along the pass line in a manner that the material removal effected by the material removing means at the location of any such transverse severing progresses transversely of the exterior surface from one lateral side of the strand to the other lateral side thereof as the strand moves along the pass line. J. Rokop, N. Rokop, and Rokop Corp. Off. Gaz., 20 Mar. 1984, Patent no. US4437899 (USA), 25 July 1983. ISSN 0360-5132. 53.0627 A u t o m a t e d C u t t i n g o f P l a t e S t e e l . In a method of cutting metallic plate in which fuel and oxygen are admixed and burned as they exit from a torch tip as a preheat flame for heating a spot on the metal plate, in which cutting O is directed through the hot molten metal spot on the plate to complete a cut therethrough, in the process forming a kerr, and in which the torch tip is moved along a predetermined path to cut the metallic plate therealong, the improvement comprises: sensing the temp. at a plurality of points adjacent to the top and in the kerf of the cut of the metal plate; and responsive to the sensed temp., making appropriate predesignated changes to effect more nearly optimum cut of the steel plate. G.P. Singh, W.D. Jolly, Victor Equipment Co, and ESAB North America Inc. Off. Gaz., 27 Mar. 1984, Patent no. US443924g (USA), 22 June 1983. ISSN 0360-5132.
5 3 - 0 6 2 8 A l u m i n a - C o a t e d S i l i c o n N i t r i d e C u t t i n g T o o l s . A coated ceramic cutting tool is comprised of a densified silicon nitride substrate body having at least one adherent coating layer; which consists of a first hase of silicon nitride and a refractory second phase comprising silicon nitride and an effective amount of a densification aid selected from the group consisting of silicon dioxide, aluminum oxide, magnesium oxide, yttrium oxide, hafnium oxide, zirconium oxide, the lanthanide rare earth oxides and mixtures thereof, the coating layer consisting essentially of aluminum oxide. V.K. Sarin, S.-T. Buljan, and GTE Laboratories Inc. Off. Gaz., 3 Apr. 1984, Patent no. US4440547 (USA), 20 May 1982. ISSN 0360-5132. 53-0629
Robotic System Cuts Airplane P a r t s . Gruman Aerospace Corp. is using a robotic cell for the trimming and drilling of complex AI-base alloy sheetmetal parts for aircraft structural components. The Integrated Robotic Cell (IRC) has a close-tolerance capability of 0.016 in. and allows for six axes of programable motion. In addition to the robot, the IRC includes a linear track, tool-exchange module and cell controller. The mini-computer-based cell controller can store and automatically recall parts programs.--G.P.K. R.J. McCluskey. Am. Mach., Aug. 1984, 128, (8), 71-73, [in English]. ISSN 00029858. 53-0630
PCD T o o l s for Wheel Dressing: How Good? Polycrystalline diamond (PCD) tools reportedly offer significant advantages over single-crystal diamond tools for the dressing of aluminum oxide wheels. PCD tools consist of synthetic polycrystalline diamonds formed into the desired shape at high temp. and high pressure. The random orientation of the diamond crystals results in uniformly high hardness, abrasion resistance and toughness by eliminating weak cleavage planes that shorten the usable life of mined diamond tools. The use of PCD tools has resulted in tool life improvements of 2-1 to 20-1.--G.P.K. J. Annese, and R.C. Ladd. Am. Math., Aug. 1984, 128, (8), 77-80, [in English]. ISSN 0002-9858.
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95
53-0631 The Laser's Edge in Metalworking. The proven performance and potential of the laser in metalworking processes are examined, Laser fabrication procedures include cutting/trepanning, precision drilling, welding and surface treating. Robotic systems are being integrated with lasers, with robots performing loading/unloading and parts manipulation functions. The operational principles of lasers are reviewed and the capabilities of various commercially availabfe laser systems are described. Materials which readiiy lend themselves to laser metalworking include stainless steels, Ti-base alloys, AI-base alloys (2024, 7075 and 7475), N i - - C r - - M o steels, Ni-base alloys and some refractory metals. 11 ref. --G.P.K, J.A. Vaccari. Am. Mach., Aug. 1984, 128, (8), 99-110, 112-114, [in English]. ISSN 0002-9858. 53-0632 O p t i m i z i n g Productivity Through Computerized S t r u c t u r a l S t e e l P r o c e s s . McNally Pittsburgh, a structural steel fabricator, is realizing the benefits of installing computerized equipment. The plant features a DNC structural drill line and plasma cutting with NC layout, Problems encountered in the changeover to computerized equipment are discussed and cost benefits of the new automated processes are described.--G,P,K. H.E. Livingston. Fabricator, July-Aug, 1984, 14, (5), 1, 22-24, [in English]. ISSN 0192-8066,
Sintared Body for Use in a C u t t i n g Tool and the Method for Producing the Same. In a diamond sintered body or high-pressure form boron niS3-0633
tride sintered body for use in a cutting tool, the sintered body is supported by cermet in which carbide crystals in the form of (Mo, W)IC x where x is within the range of 0.8-0,98, chiefly consisting of Mo are bonded by Fe group metals with the interposition of an intermediate bonding layer consisting of a metal carbide < O. 1 mm thick. A. Hara, S. Yazu, and Sumitomo Electric Industries Ltd. Off. Gaz., 10 Apr, 1984, Patent no. US4442180 (USA), 14 May 1978, ISSN 0360-5132. 53-0634 C o a t e d C o m p o s i t e S i l i c o n N i t r i d e C u t t i n g T o o l s . A coated composite ceramic cutting tool comprises a densitied composite silicon nitride substrate having at least one intermediate adherent refractory coating layer and an outer adherent alumina coating layer. The substrate body consists of particles of a hard refractory material uniformly distributed in a matrix consisting of a first phase of silicon nitride and a refractory second phase comprising silicon nitride and an effective amount of a densification aid selected from the group consisting of yttrium oxide, hafnium oxide, the lanthanide rare earth oxides and mixtures thereof. V.K. Sarin, S.-T. Buljan, and G'rE Laboratories Inc. Off. Gaz., 10 Apr. 1984, Patent no. US4441894 (USA), 26 Sept. 1983. ISSN 0360-5132. 53-0635 Process for Producing Cubic System Boron N i t r i d e . A process for producing cubic system boron nitride comprises applying a thermodynamically stable shock wave compressing pressure of from ~ 100-1500 kbar to rhombohedral system boron nitride to convert the rhombohedral system boron nitride to cubic system boron nitride. T. Sato, T. Ishii, N. Setaka, and National Institute for Research in Inorganic Materials (Japan). Off. Gas,, 17 Apr. 1984, Patent no. US4443420 (USA), 26 Oct. 1981. ISSN 0360-5132. S3-0637 P h e n o m e n a in t h e S p h e r i c a l Surface Grinding of Prostheses. The phenomena which accompany the grinding of spherical surfaces with high surface quality and accuracy of shape as applied in the production of prostheses (artificial joints) are presented. Tests were carried out on a special grinding machine by a chordal grinding method with the use of alundum, SiC and synthetic diamond abrasive tools for metal (Co- and Ti-base alloys) and ceramic materials. The material removal rate, material removal parameter, roughness and out of roundness were determined. The results obtained for spherical sliding surfaces of high quality are in good agreement with tribological and clinical requirements for such joints. Some remarks are given as to the operation of the pregrinding and finish grinding processes on outer spherical surfaces observed during the tests. 7 r e f . - - A A K.E. Oczod, and T.S. Dzioch. Wear, 1 June 1984, 96, (1), 45-59, [in English]. ISSN 0043-1648. 53-0640 S u p e r p r e c i s i o n C y l i n d r i c a l M a c h i n i n g . A study has been made of the theory and techniques of turning precise circular components. The possibility of such high-accuracy cylindrical machining was analyzed according to the principle of making a precise circle. A form of chucking-type precision cylindrical machining was developed by combining an insensitive vibration cutting mechanism-using a main spindle system which features an air bearing--with superposition superfinishing. In the first process, the work is chucked on the main spindle and mschined using a continuously and systematically pulsating cutting force. In the second process, the work is finished by a newly developed superposition superfinishing device which features equivalent grades of ultrasonic vibration stone, Key points of the techniques are a torsional vibration mode tool for producing accurate, high-amplitude vibration of the cutting point, and a contrivance for making accurate movements of the superposition superfinishing device. Machined roundness of O, 1-0.2 #m and surface roughness of 0.03-0.09 /~m Rrna• were obtained with plain carbon steels, stainless steels and hardened steels (HRC 41. 53, 60). it is considered that turning to roundness ~ O, cylindricity ~ 0 and surface roughness 0 can be realized by means of this machining process and its lathe.--AA J. Kumabe, and M. Hachisuka. Precis. Eng., Apr. 1984, 6, (2), 67-72, [in English], ISSN 0141-6359. S3-0641 P r e c i s i o n I n t e r n a l T h r e a d i n g o f S t a i n l e s s S t e e l . Analysis has shown that vibration cutting is a suitable process for production of internal screw threads in thin 304 stainless steel cylinders, A precision vibration internal threading lathe has been developed. Experiments were carried out with this lathe to investigate the tool life, chip type, accuracy of machined thread, etc. The main results obtained by experiments are: the chips formed by this vibration cutting are unoxidized, white-gray, flow-type chips; a smooth machined flank is produced which has an iridescent surface; the desired sharp profile of the internal thread
96
VOL. 4, NO. 1, JULY 1985
can be machined; the relation between tool wear and cutting length was investigated; by this process and lathe, it is possible to thread 10 000 pieces/tool. This is a 200-fold extension of tool life, compared with 40-50 pieces in conventional cutting, The vibration internal threading machine has been used in mass production tests and the results confirmed on ~ 500 000 workpieces.--AA T. Saotome, F. Yokoi, and J. Kumabe. Precis. Eng., Apr. 1984, 6, (2), 73-78, [in English]. ISSN 0141-6359. 53-0642 C h a r a c t e r i s t i c N u m b e r s t o D e s c r i b e t h e D e t a i l Transfer Quality o f E l e c t r o c h e m i c a l M a c h i n i n g . For reproducing processes such as electrochemical machining (e.c.m.) of mild steel the accuracy of the reproduction is an important process parameter. Characteristic numbers which are a measure of this accuracy are proposed. Due to the nonlinearity of the process a detail transfer function, which is helpful in linear cases, cannot be used, as shown from experimental work. Based on the same experiments, a characteristic radius and the standard deviation of a normal profile are proposed to describe the quality of the detail transfer. These numbers, which are easily interpreted criteria for quality and accuracy, have been proved to be almost independent of the geometry. Although developed for optimizing the e.c.m, process, these values are also valid for e.d.m, and other reproducing processes. The usefulness of the characteristic numbers is illustrated by a comparison of continuous and pulsed e.c.m, processes. 7 ref.--AA J. Meijer, and J.C.M. Veringa. Precis. Eng., Apr. 1984, 6, (2), 79-82, [in English]. ISSN 014 t-6359. 53-0S43 Residual Stress Determination by Continuous E l e c t r o e t c h i n g . The production of precision parts requires manufacturing processes which produce low residual stresses. A technique has been developed to continuously electroetch a specimen of berylluim bronze and simultaneously measure the change in its dimension, then to compute the residual stress profile in that specimen. A 'specific instability potential' derived from the strain energy of the residual stresses was found to relate directly to the machining parameters. 8 r e f . - - A A A. Israeli, and J, Benedek. Precis. Eng., Apr. 1984, 6, (2), 95-97, [in English]. ISSN 0141-6359, 53-0644 A n a l y s i s o f Tool Temperature F l u c t u a t i o n in Interrupted Cutting. A unidimensional model for temp. distribution in the tool during intermittent cutting is presented. The tool/chip interface heating is approximated by a periodic rectangular heat flux, The effects of cutting time ratio, frequency of temp. fluctuation and thermal ditfusivity of the tool material on internal temp. distribution and on thermal stresses developed in the tool are discussed. With increasing cutting frequency, the temp. gradient in the cutting zone increases, but with higher thermal diffusivity of the tool material, it diminishes. The magnitude of thermal stresses increases with increase in amplitude of temp. fluctuation. 33 r e f . - - A A G. Chakraverti, P.C. Pandey, and N,K. Mehta. Precis. Eng., Apr. 1984, 6, (2), 99105, [in English]. ISSN 0141-6359. 53-0645
T e m p e r a t u r e F i e l d in Abrasive Grains of Arbritary Form.
(Translation: V R / 2 5 0 0 / 8 4 ) . A.A. Berezovskii, and V.D. Aleksanyan. Fiz. Khim. Obrab. Mater., 1983, 17, (4), Pp 8, [in English]. ISSN 0015-3214. 53-0646 C o a t e d S i l i c o n N i t r i d e C u t t i n g T o o l s . A coated ceramic cutting tool comprising a densified silicon nitride substrate having at least one intermediate adherent refractory coating layer and an outer adherent alumina coating layer consists of a frist phase of silicon nitride and a second refractory phase of silicon nitride and an effective amount of a densitication aid selected from the group consisting of silicon dioxide, aluminum oxide, magnesium oxide, yttrium oxide, hafnium oxide, zirconium oxide, the lanthanide rare earth oxides and mixtures. V,K, Satin, S.-T, Buljan, and GTE Laboratories Inc. Off. Gaz., 22 May 1984, Patent no. US4449989 (USA), 26 Sept. 1983. ISSN 0360-5132. 53-0647 M e t h o d o f Drill Sit Manufacture and P r o d u c t . A method of providing a bit body suitable for drilling and the like comprises providing a plurality o1 tungsten carbide elements, coating with a carbide compound wherein the cation is selected from groups III and IV of the Periodic Table and casting in molten steel to support the elements in parlially exposed condition, the elements having a contour to provide an internal lock with the steel. R.R. Miller, W.R. Barber, Jr., D.A. Hampel, J.E. Ault, and ESCO Corp. Off. Gaz., 12 June 1984, Patent no. US4454205 (USA), 9 Oct. 1981. ISSN 0360-5132. 53-0648 Cemented Carbide as an E n g i n e e r i n g M a t e r i a l , Cemented carbides (WC--Co, TiC--Fe, T i C - - N i types) are best known for their outstanding wear resistance and are most commonly used in metal cutting tools but their unique combination of properties offer wide scope to the materials design engineer, The range of cemented carbide grades available, their properties and some of their applications are reviewed. Design opportunities and limitations, in terms of shapes and sizes available, the methods of joining and attachment, are discussed, as are new developments, such as the use of coated cemented carbide for engineering applications, Cemented carbide is put in the context of other wear resistant materials, in particular the ceramics based on alumina, zirconia and silicon nitride,--AA D,H. Jack. Materials Engineering [Proc. Conf.], Leeds, U.K., 10-12 July 1984, Institution of Metallurgists, The Hub, Emson Close, Saffron Walden, Essex CBIO 1HL, 1984, (Met.A, 8411-72-0697) 125-131, [in English]. 53-0649 The Value o f Deposition Processes for Industrial Tools. The development of ionization-assisted physical vapor deposition processes for ceramic coatings (TIN) has meant that pure ceramics can now be deposited onto high-speed steel cutting tools and hot working die steel tools. The unrivaled hardness and chemical properties of ceramics have resulted in production life improvements of greater than ten times in some cases, compared to uncoated tools. Additionally significant improvements in cutting rates are being achieved. The net result is a considerable increase in productivity, less down-time and improved product quality. 17 ref.--AA
J. APPLIED METALWORKING
A. Matthews. Materials Engineering [Proc. Conf.], Leeds, U.K., 10-12 July 1984, Institution of Metallurgists, The Hub, Emson Close, Saffron Walden, Essex CBIO 1HL, 1984, (Met.A., 8411-72-0697) 175-f82, [in English].
5 3 - 0 6 5 0 Sputter Ion Plating of Titanium Nitride for Wear and Corrosion Resistance. Titanium nitride coatings on suitable substrates have been shown to produce considerable enhancement of component properties in cutting, wear and corrosion resistant and decorative applications. Sputter ion plating, pioneered by Harwell for the production of titanium nitride coatings, is now being developed at TI Research Laboratories for TI Abar. The process is described, some applications of titanium nitride coatings for drills, cutting dies and bearings are reviewed and possible reasons for the observed improvements in properties are advanced. 14 r e f . - - A A R.B. Newbery, A.G. Ooggett, and M.H. Jacobs. Materials Engineering [Proc. Conf.], Leeds, U.K., 10-12 July 1984, Institution of Metallurgists, The Hub, Emson Close, Saffron Walden, Essex CBIO tilL, 1984, (Met.A., 8411-72-0697) 209-219, [in English].
5 3 - 0 6 5 3 Research Shows That High-Speed Plasma-Arc Cutting of Gray Iron Engine Blocks Is Possible. The University of Rhode Island's Robotic Research Center has been experimenting with plasma-arc cutting to cleaning gates, risers and sprue from large engine block castings. Researchers are establishing parameters for cutting gray iron in sections from 1 / 8 to 1/2 in. thick at speeds between 30 and 70 in./rain. A thick cementite layer is formed on gray iron when using conventional arc-cutting methods but the plasma-arc produces only a layer 0.0030.005 in. thick. Plasma-arc cutting combined with a multiaxis robot would substantially increase cleaning room productivity; however, research is continuing for solving operating p r o b l e m s related to casting variabilities and to robot control programs and sensitivity to high-frequency electrical signals.--J.J.P. L. Gustafsson. Cutting Tool Eng., Aug. 1984, 36, (4), 24-26, [in English]. ISSN 0011-4189.
53-0665 Lubricant for Use in the Machining, Working or Abrasive Treatment of Metals. A cooling lubricant for use in machining, working, or abrasive treatment of metals, comprises a fluorochlorohydrocarbon, and esters of long chain carboxylic acids and monoalcohols with a total of 34 to 50 carbon atoms and or their sulphochlorinated or sulphided derivatives. The lubricant may be made by extracting vegetable material containing the above esters or an alcoholic extract thereof, with a C1--2 fluorochlorohydrocarbon of b.p. above 20~ H Buchwald, B. Raschkowski, and Kali-Chemie AG. 20 June 1984, Patent no. GB2131450A (UK), 17 Nov. 1983.
53-0666
53-0679 Structure and Properties (Translation). See Met. A., 8408-53-0408.
of Sintered
Hard
Alloys.
I.N. Chaporova, E.I. Rapina, Z N . Sapronova, and V.I. Kudryatseva. Met. Sci. Heat Treat. (USSR), Jan.-Feb. t984, 26, (1-2), 161-165, [in English]. ISSN 0026-0673.
53-0682
Computerized Numerical Control of Manufacturing Extrusion
T o o l s . The computerized numerical control (CNC) wire-cut EDM system and the CNC milling machine are reviewed. For the CNC wire-cut system, rotation, mirror imaging and wire dia. compensation are considered; for CNC milling, great potential is suggested, as in extrusion dies. Quality and price control are discussed. --C.M.LS. L.E. Bello. LightMet. Age, Aug 1984, 42, (7-8), 26-29, 45, [in English]. ISSN 00243345.
53-0685 Torque Controlled Machining for Numerical Control Machining Centers. Torque controlled machining (TCM) was developed primarily for the unmanned operation of machining centers. It is a microprocessor-based sensor system for measuring spindle drive torque and horsepower and for comparing these measurements with programed limits It automatically provides cutting tool overload protection, machine tool protection, workpiece surface sensing probe and feedrate adaptive control of the cutting p r o c e s s . - - A A D.R. Medcalf. International Machine Tool Conference [Proc. Conf.], Birmingham, England, 26-28 June 1984, IFS (Conferences) Ltd., 35-39 High St., Kempston, Bedford, England, 1984, (Met A., 8412-72-0738) 163-170, [in English].
53-0686
Benefits
of
Microprocessor
Control
of
Machines.
Microprocessor technology is penetrating various aspects of the machine tool and general manufacturing industries. The benefits that can accrue when microprocessors are applied to problems in these general areas are assessed. In particular, benefits can arise in the following areas when microprocessors are used to advantage: higher product quality, precision, productivity, flexibility, vastly improved diagnostics, performance monitoring and fault finding capability. A rigorous, and often expensive, software design is frequently required to maximize these benefits. This expense can be offset by the ability to apply well-designed software to machine families and to transport developed software to newer microprocessors when they become available. Relevant case studies from which these conclusions are drawn are c o n s i d e r e d . - - A A S.C. Martin. International Machine Tool Conference [Proc. ConL], Birmingham, England, 26-28 June 1984, IFS (Conferences) Ltd., 35-39 High St., Kempston, Bedford, England, 1984, (Met.A, 8412-72-0738) 171-180, [in English].
53-0687
A Computer-Controlled Fluid Power System for Machine Tool
Travelling-Wire EDM Method and Apparatus. A travelling wire Application. The design of a new computer-controlled fluid power system for conelectrode is laterally advanced, generally tangentially along a workpiece contour tour machining in machine tools, like a planing machine and shaping machine, are to electroerosively cut a precision contour with a depth of cut at most equal to the discussed. The programing methodology is simplified by the adaption of a microdiameter of the wire. Fluctuating machining pressure, induced by gap discharges processor. The application of a fluid power system on the cutting tool head of the and fluid injection, tends to divert the wire from a prescribed path of advance in the machine tool, programing techniques and the results of its implementation are cutting zone. A rotary mechanism, its axis of rotation coinciding with the straight- highlighted.--AA line path established for the travelling wire axis, between the wire positioning guide members, carries a wire-backing support member having wire supporting D. Shetty, and B. Copeland. International Machine Tool Conference [Prec. Conf./, surfaces parallel to the travelling wire against the machining pressure, and is ro- Birmingham, England, 26-28 June 1984, IFS (Conferences) Ltd., 35-39 High St., tated to orient the wire-backing support member so as to oppose those surfaces Kempston, Bedford, England, 1984, (Met.A., 8412-72-0738) 189-196, [in English]. with the area of the contour being cut and to avoid a collision of the support memA l l - E m b r a c i n g NC S y s t e m s . The logic sequence for machining a ber with the workpiece. Suction or machining fluid may be supplied to the groove " 5 3 - 0 6 8 8 particular part by CNC machine is divided into three distinct functions: process via a bore. p~anning; NC programing; and CNC controller. With DNC systems, a fourth function K. InDue, and InDue Japax Research Inc. 27 June 1984, Patent no. GB2131731A of on-line scheduling and communication must be added. Applying all-embracing/ (UK), 7 Nov. 1983. generative process planning phase to NC systems results in improvements of all aspects, economical and flexibility of operation This segment of the all-embracing 5 3 - 0 6 6 8 The Key t o S i l e n t S t a m p i n g s . Photochemical machining like elec- technology is d e s c r i b e d . - - A A trical discharge machining is a means of producing inexpensive prototypes, limited G Halevi. International Machine Tool Conference [Proc. ConL], Birmingham, Enrun quantities where a hard tool could not be justified. The various stages in the gland, 26-28 June 1984, IFS (Conferences) Ltd., 35-39 High S t , Kempston, Bedprocess are outlined and illustrated diagramatically. The process is limited to the ford, England, 1984, (Met.A, 8412-72-0738) 197-204, [in English}. production of complex 0.005-0.O90 in. thick flat parts (simple shapes are produced more economically by shearing, blanking, etc.). All metals commonly The Significance of Ceramic Tool Materials in the Pursuit of stamped can be processed by the technique which produces parts without burrs. 5 3 - 0 6 8 9 Accuracy is fairly high and depends on the metal, the thickness and the part size. P r o d u c t i v i t y . There are three categories of ceramic tool material available today, pure-oxide ceramic, mixed ceramic and nitride ceramic. Each category has As in conventioanl blanking, an absolutely straight edge is not produced. The techits own characteristic properties, which must be understood if these materials are nique is still more an art than a science.--J.M.S. to be most effectively exploited in extending the machining options available to the J. Hofacre. Sheet Met. Ind., June 1984, 61, (6), 323, 325, [in English]. ISSN 0037- tool user. The complex mechanical and chemical interactions which take place at 3435. the cutting edge make it difficult, however, to predict the behavior of different ceramic tool materials with certainty, but a combination of fundamental tool wear 53-0669 Cutting it Fine in the Sheet Metal Shop. The continuing demand studies, laboratory evaluations of performance and testing in the field makes it for still closer tolerances on more complex shapes, often in difficult to machine possible to offer guidelines on the appropriate choice of material to achieve optimaterials at faster cutting rate, is posing a challenge for designers and manufac- mum p e r f o r m a n c e . - - A A turers of metal cutting equipment. Coventioanl metal cutting techniques are still A.N. Grearson, and D.H. Jack. International Machine Tool Conference [Proc employed but most of this equipment has been upgraded by the introduction of nu- ConL], Birmingham, England, 26-28 June 1984, IFS (Conferences) Ltd., 35-39 High merical control (CNC) coupled with the use of microprocessor and microcomputer St., Kempston, Bedford, England, 1984, (Met.A., 8412-72-0738) 211-220, ]in Entechnology in all aspects of metal cutting operation. There are also new tech- glish]. niques including the use of lasers and ultrasonics as the metal cutting medium. Both these trends, the upgrading of conventional processes and the use of new cutting technology, are d i s c u s s e d . - - A A 53-0690 Polycrystalline Diamond Face Milling Cutter Design and A p p l i c a t i o n . The various polycrystalline diamond face-mill designs currently E. Ford. S. Aft. Mech. Eng., Feb. 1984, 34, (2), 47-48, [in English]. ISSN 0038available in the U.K., Europe, U.S and Japan are r e v i e w e d Industrial data are 2442. presented concerning the development and application of Compax diamond cutters in Austin Rover Ltd. Testing of both indexabte insert and bladed facemill de53-0670 Mill Roll Engraving by Laser for Better Product Consistency. signs on hypoeutectic S i - - A I alloy (4-9.5% St) automotive components suggests Precisely controlled "Lasettex" surface textures impressed on metal sheet by that adjustable bladed cutters employing the coarser grained type polycrystalline laser-engraved rolls are illustrated and described, and reproducibility and other diamond offers the best compromise in terms of tool life/performance and cost. advantages as compared with shot blasting are listed. The engraving is effected On straight comparative tests with carbide, polycrystalline diamond cutters have by an automatically interrupted laser beam traversing a rotating roll, to give impact resulted in improvements in tool life/edge of between 100 and 500 times. 18 ref. points forming craters along a helicoidal path. As the depth and spacing of the cra--AA ters are functions of the beam intensity and the roll-rotation rate, the roll-surtace relief is perfectly controlled and its design adaptable to customer requirements. D.K. Aspinwall. International Machine Tool Conference [Proc. Conf.], Birmingham, --J.R. England, 26-28 June 1984, IFS (Conferences) Ltd., 35-39 High St., Kempston, Bedford, England, 1984, (Met.A., 8412-72-0738) 221-234, [in English]. Steel Times Int., June 1984, 8, (2), 55, [in English]. ISSN 0143-7798.
J. APPLIED METALWORKING
VOL. 4, NO. 1, JULY 1985
97
53-0691 M u l U f l e x - - a Tool System for Automatic Turning. The automatic tool changing system is especially designed for turning on numerically controlled lathes. When combined with tool changer, tool magazine, process monitoring equipment and loading devices, the over-all concept makes a decisive contribution to improving lathe utilization and to permitting continuous production over a longer period without operatives. Its applicatiop is not restricted to single-spindle CNC lathes, but also covers, e.g. multispindle, multislide or vertical turret lathes. The whole system consists of standard components which have to be adapted to the lathe, including the automatic tool changer. A check should be made in each individual case as to whether it is more economical to adapt an existing lathe with the Multiflex system or to purchase a new one. 8 r e f . - - A A N. Reiter. International Machine Tool Conference [Proc. Conf], Birmingham, England, 26-28 June 1984, IFS (Conferences) Ltd., 35-39 High St., Kempston, Bedford, England, 1984, (Met.A, 8412-72-0738) 236-256, [in English]. 53-0692 A u t o m a t e d Cutting E d g e R e p l a c e m e n t . The various methods of automatically changing a cutting edge are described. The advantages and disadvantages of an insert holder replacement system vs. an insert only replacement system are discussed. Application guidelines for both types of systems are given. An in-depth study is presented of the desirable features of an inert holder replacement system. The Kennametal system is highlighted, citing its versatility, performance and engineering analysis. Machine interface information is provided. A working design is presented for an insert only replacement system. Both the adaptability and application range of the system are discussed. Machine interface requirements are also highlighted. Tool management and tool changing strategies are discussed. The effect of utilizing tool condition sensing with an automatic edge replacement system is p r e s e n t e d . - - A A R.A. Erickson. International Machine Tool Conference [Proc. Conf.], Birmingham, England, 26-28 June 1984, IFS (Conferences) Ltd., 35-39 High St., Kempston, Bedford, England, 1984, (Met.A, 8412-72-0738) 261-271, [in English]. 53-0693 Control o f a Sheet Metal Flexible Manufacturing System. A typical sheet metal FMS is described, including a CNC punch press, a CNC shear, storage and material handling devices, all communicating with a manufacturing computer, which may be linked to a main frame computer. The manufacturing (or FMS) computer supervises the machine CNC's and the material handling controls, performs file management part program generation and integrates the punching information with the shear nesting pattern, so enabling the automated shearing of prepunched multiple parts and realizing the benefits peculiar to F M S . - - A A G.J. Schorn, and N.H. Ashworth. International Machine Tool Conference [Proc. Conf.], Birmingham, England, 26-28 June 1984, IFS (Conferences) Ltd., 35-39 High St., Kempston, Bedford, England, 1984, (Met.A., 8412-72-0738) 393-402, [in English]. 53-0694 Getting Grinding Under C o n t r o l - - t h e Application of CNC to Grinding. The application o1 CNC (computer numerical control) to various types of cylindrical and surface grinding machines is described. The methods developed for programing and operating these machines is described along with details of some of the benefits which can ~'Je achieved by using such machines. Some of the problems that have had to be overcome to apply CNC to grinding tool steels are discussed and an indication of future trends is g i v e n . - - A A J. Liverton. International Machine Tool Conference [Proc. ConL], Birmingham, England, 26-28 June 1984, IFS (Conferences) Ltd., 35-39 High St., Kempston, Bedford, England, 1984, (Met.A., 8412-72-0738) 513-520, [in English].
53-0695
Optimizing the Milling Operation in an Industrial Environment.
In the machine shop of a major electronics company, machining of 6082 AI alloy was carried out on a three-axis CNC milling machine over a range of cutting conditions. During each machining cycle the cutting forces in the direction of all three machine axes and the true electrical power being consumed by the spindle drive were logged onto a microcomputer, enabling a 'tooth-by-tooth' history of each Cutting cycle to be stored on flexible magnetic disk. Subsequent to the cutting tests the machined specimens were inspected for geometrical accuracy and quality of surface finish and cutting tools were checked for wear and damage. The raw data were processed into a form for use by NC part-programers and recommendations were made concerning the most suitable type of cutting tools for use in production. The data are currently being compiled into a computerized data-base for use in the setting, planning and programing of minimally manned CNC machine t o o l s . - - A A P. Stewart. International Machine Tool Conference [Proc. Conf./, Birmingham, England, 26-26 June 1964, IFS (Conferences) Ltd., 36-39 High St., Kempston, Bedford, England, 1984, (Met.A., 8412-72-0738) 521-530, [in English].
53-0696
Developments in Grinding. Unlike turning or milling there are no standard feed and speed charts for easy reference when setting a grinding machine. Most information is in the head of a skilled operator who will use a rule of thumb method in selecting appropriate values for a particular component. The total acceptance of CNC controls to lathes and machining centers by industry has now led to the advent of the CNC grinding center. This, together with recent advances in creep-feed grinding techniques, is d i s c u s s e d . - - A A G. Alford. International Machine Tool Conference [Proc. Conf.], Birmingham, England, 26-26 June 1984, IFS (Conferences) Ltd., 35-39 High St., Kempston, Bedford, England, 1984, (Met.A., 8412-72-0738) 531-538, [in English]. 53-0697
Further British D e v e l o p m e n t s
in A u t o m a t e d Turning Cells.
Recent practical developments in turning cells and the various equipment needed for minimally manned machining are described. A description is included of a fully automatic two machine cell 'for producing automotive hub components which incorporates input and output conveyors, a robot and automatic measuring station. An automatic tool changing lathe which also has facilities for in-process gaging and tool setting is also d e s c r i b e d . - - A A M. Thorneycroft. International Machine Tool Conference [Proc. ConL], Birmingham, England, 26-28 June 1984, IFS (Conferences) Ltd., 35-39 High St., Kempston, Bedford, England, 1984, (Met.A_ 8412-72-0738) 573-581, [in English].
98
VOL. 4, NO. 1, JULY 1985
53-0704
Sintered Hardmetals. A sintered hardmetal is comprised of tungsten carbide, a binder comprising one or more metals or alloys of the Fe group and a mixed crystal material prepared by subjecting a mixture comprising zirconium and titanium carbides to heating at a temp. and for a time sufficient for the mixed crystal product to undergo spinodal decomposition upon cooling into a T i C - - Z r C phase rich in TiC and a T i C - - Z r C phase rich in ZrC. The amount of mixed crystal material present in the hardmetal is in the range 2-40% of the hardmetal. F.W. Hall, H.-J. Retelsdorf, and Gesellschaft Elektrometallurgie. Off. Gaz., 29 May 1984, Patent no. US4451292 (USA), 4 Mar. 1980. ISSN 0360-5132. 53-0705 Spark Erosion for Intricate Shapes. Electric discharge machining is described. The accuracy of cut and the quality of the cut are particular advantages. The advent of powerful CNC controllers has allowed the potential of this technique to be realised. Other features of the technique are its capability of cutting shapes with complex three dimensional profiles and its suitability for one off cuts.--R.E. Eng. Dig. (UK), Apr. 1984, 45, (4), 43-44, [in English]. ISSN 0013-8169. 53-0706
Sand Damage in Blasting Machines. The design, construction, and functions of shot-blasting machines are reviewed with reference to erosion and other damage by sand above the tolerable (less than 1%) limit in the recycled shot. The control cage, impeller, and other components are affected bul the damage is lirst evident and becomes most marked in the blasting-machine blades, replacement of which has been facilitated, with a significant reduction of the machine down-time, by a design requiring withdrawl of only a single pin. The blade wear patterns are illustrated and described and details given of old and highly efficient modern types of shot/sand separators, "birds nest" accumulations of core wires in scalping drums, cartridge-type filters, and reverse-belt shot-blasters incorporating pre-blasting sand*disposal arrangementa.--J.R. H J . Plaster. Foundry Trade J., 26 Apr. 1964, 156, (3283), 313-314, 317-318, [in English]. ISSN 0015-9042. 53-0707
Machining N i - H a r d - - a Problem Solved? The problem arises from the very microstructural and other properties contributing to the high wear resistance of the Ni-Hard composition, and involves machining difficulties giving low stock-removal rates and frequent down-times for tool changes and regrindings. These and other aspects are discussed in the light of the development o1 a new ultra-hard polycrystalline tool material produced by subjecting fine, carefully graded, cubic BN particles to conditions similar to those used in diamond synthesis. The product, designated Amborite, has also a thermal-shock resistance double that of ceramic tools liable to fail in machining Ni-Hard and remains chemically inert at the high (fully 800~ temp. generated. Test and industrial experiences cited and a case history of machining a Ni-Hard 2C pump liner with tooling comprising a 12.7-mm dia. chamfered Amborite insert demonstrate the significantly longer tool lives, higher feed and stock-removal rates, and lower machining-cycle and down-times obtainable. With the basic technology thus firmly proved there is now an apparent demand for 25 x 6 . 3 5 m m A m b o r i t e i n s e r t s . - - J . R . Foundry Trade J., 10 May 1964, 156, (3264), 376, 378-379, [in English]. ISSN 0015-9042. 53-0708 The Influence of T e m p e r a t u r e and Heating Time on PCD Performance. Potycrystalline diamond (PCD) materials will generally be heated at two periods of their life--during tool production and use. By observing the tam* perature, time and atmosphere recommendations given in this paper, it is possible to fabricate most tools and obtain optimum performance from the PCD. Data for all three SYNDITE cutting tool grades and for SYNDRILL drilling material are included. --AA P.A. Bex, and J.-R. Shafto. Ind. Diamond Rev., 1984, 44, (502), 128-139, [in English]. ISSN 0019-8145.
53-0709
Boring Sintered C a r b i d e Roils With Syndite PCD Tools.
Grinding the bore of sintered carbide roll blanks to high geometric and dimensional tolerances frequently took 4h or more at the Alblasserdam works of Nedstaal BV, part of the Thyssen Group. Boring with a SYNDITE PCD tool followed by finish grinding has cut the process time to 1~/4 h and reduced costs by 50%. The resuits of tests 1o establish optimum machining parameters are described in this report.--AA G. Ottevanger. Ind. Diamond Rev., 1984, 44, (502), 154-156, [in English]. ISSN 0019-8145.
53-0712 Multiple Ceramic Coated Cutting Tools. Types T821 and T822 tools produced by the Toshiba Tungaloy Co. Ltd. for the high-speed cutting of cast iron and steel, respectively, are coated with multiple layers of a newly developed AI(ON) x ceramic giving a superb texture which enhances the coatings/substrate bond strength. Thicker wear-resistant layers permitting cutting speeds of 200-300 m/min are thus applicable.--J.R. NewMater./Jpn., 1984, 1, (5), 7, [in English]. 53-0713 Photochemical Machining. A process for cutting metal sheets by etching is briefly described. The importance of understanding the relationships between photoresist mask geometry and final cut geometry are emphasised.--T.W. U. Ahud, and M.M. Suron. Materials Engineering Conference, 1981 [Proc. Conf], Haifa, Israel, 20-22 Dec. 1981, Freund Publishing House, P.O. Box 35010, Tel Aviv, Israel, 1981, (Met.A, 8412-72-0764) 22-25, [in English]. 53-0714
New Titanium Carbide Grade for Metal C u t t i n g . A new range of T i C - - M o - - N i tool materials containing TiN and VC has been developed. The new materials have improved resistance to plastic deformation and tensile strength compared to conventional carbide tools, and exhibit better turning and milling properties. 7 ref.--T.W. R. Sivan, R. Porat, and Y. Landau. Materials Engineering Conference, 1981 [Proc. ConL], Haifa, Israel, 20-22 Dec. 1981, Freund Publishing House, P.O. Box 35010, Tel Aviv, Israel, 1981, (Met.A., 8412-72-0764) 72-75, [in English].
J. APPLIED METALWORKING
53-0715 S o m e R e f l e c t i o n s on t h e C o m p e t i t i o n B e t w e e n H a r d Materials in Industrial Applications. With metal cutting as an appropriate example the competition between the new superhard materials (diamond and cubic boron nitride), ceramics, cemented carbide and high speed steel is discussed. The hardness-toughness relationship of the different materials is presented as is their consumption in industry over the latest few decades. It is pointed out that new materials are generally only slowly accepted by the market with coated cemented carbide as a conspicuous exception. Application areas for the new superhard materials and ceramics are indicated with emphasis on differences in their characteristic properties in comparison with new coated cemented carbide grades. As a result of recent development it appears unlikely, at least in the near future, that prices and availabilty of raw materials will be a very important factor in the choice between the different hard materials. 23 r e f . - - A A EL Aronsson. Specialty Steels and Hard Materials [Prec. Conf], Pretoria, South Africa, 8-12 Nov. 1962, Pergamon Press, Headington Hill Hall, Oxford OX3 0BW, England, 1983, (Met.A, 8412-72-0780) 163-171, [in English].
53-O716 The Current Status of Diamond and Cubic Boron Nitride Composites, The development of high pressure technology which has allowed the synthesis of diamond and cubic boron nitride has also resulted in the production of a new and exciting range of ultra-hard ceramic-type materials. These materials, polycrystalline diamond and cubic boron nitride composites, offer distinct advantages over their single crystal counterparts and hold the promise of a fascinating future in all areas connected with material removal and other specialist usages.--AA P.N, Tomlinson, and R.J. Wedlake. Specialty Steels and Hard Materials [Prec. Conf], Pretoria, South Africa, 8-12 Nov. 1982, Pergamon Press, Headington Hill Hall, Oxford O X 3 0 B W , England, 1983, (Met.A, 8412-72-0780) 173-184, [in English].
53-O717 Development and P e r f o r m a n c e of CVD-Coatings on Cutting Tools. Coatings of refractory hard substances on cemented carbide substrates during the past decade have resulted in a dramatic increase in performance of cemented carbide cutting tools. The thermodynamic fundamentals of the chemical vapour deposition of TiN, TiC, HfN, AI203 and of combinations of carbides, nitrides and carbonitrides on cemented carbide substrates are discussed, along with the practical implementation in larger scale industrial coating facilities. The improved performance of coated, in comparison with uncoated, tools is primarily due to the increased cratering resistance provided by coatings. The relative merits of different coating systems are strongly dependent on work material properties and chosen cutting parameters: Coatings of AI203 have excellent performance at higher cutting speeds and harder steels, but are generally inferior to nitride - and carbide based (TIN, TiC, HfN) coatings when cutting softer steels at intermediate and low cutting speeds. The combined effect of work material properties, and cutting parameters (principally feed and speed), and tool geometry on cutting performance can be characterized through a single quantity, the cutting shear angle. Thus, A[203 coatings generally provide superior performance under high shear angle conditions (harder steels, high speeds, negative rake geometry), where the principal mode of failure is cratering; while at low shear angles (soft steels, low speeds, positive rake geometry) the nitride and carbide based coatings tend to show better performance. Multiphase coatings, such as TiC/AI203 combine the benefits of TiC and AI203 in the low cutting speed range, but are generally inferior to single layer AI203 coatings in the range of higher shear angles at the same total coating thickness 8 ref - - A A E Rudy, B.F Kieffer, and T. Penrice Specialty Steels and Hard Materials [Prec. Conf.], Pretoria, South Africa, 8-12 Nov. 1982, Pergamon Press, Headington Hill Hall, Oxford O X 3 0 B W , England. 1983, ( M e t A , 8412-72-0780) 185-194, [in English]
53-0718 Alumina Coated Chips for High-Speed C u t t i n g . Sumitomo Etectriclnd L t d has developed on alumina coated chip on a cemented carbide alloy. It is available as Model ACIO for high speed (100-250 m/min) and wet coarse cutting of steel, and Model AC05 for higher cutting speeds (200-300 m/min).--B.C. NewMater. Jpn, 1983, 1, (1), 4, [in English]. 53-O719
F i n e F r i c t i o n C u t t i n g : a U s e f u l W e a r Process. Friction cutting of metals was first reported almost 160 years ago. This review concentrates on its latest development, the slitting of N i - - C r Ti and ferrous alloys by toothless, watercooled, mild-steel discs spinning with a rim speed between 50 and 100 m/s. Slits as thin as 0 2 5 mm can be produced with little surface damage. Slitting occurs by adhesive w e a r When oxidation leading to a mild wear state can be prevented, area slitting rates greater than 10 mm2/s can be achieved: this is the c a s e w i t h Ni--Cr and Ti alloys and with soft or hardened stainless and tool steels. Oxidation cannot be prevented with carbon steels and most cast irons, so these metals cannot in general be slit usefully by fine friction cutting. 32 ref.--AA T H.C. Childs Tribology Int,, A p r 1983, 16, (2), 67-84, [in English]. ISSN O301679X.
53-0720 The Embrittlement of Leaded Brasses During Hot W o r k i n g . The plasticity of CuZn40Pb2 leaded brass in the temperature range of 870-1070K was determined using the upsetting test as a method of evaluation. An analysis of structure of upset specimens from the point of view of linking plasticity with brass structure was carried out. It was found that small changes in chemical composition, which fall within the range conforming to the standard, affect the plasticity of brass to a large e x t e n t - - A A W. Malec, and L. Ciura, Wire Ind., July 1984, 51, (607), 517-520, [in English]. ISSN 0043-5011 53-0721 Electrochemical Machining. To prevent corrosion and stray attack by the electrolyte on surfaces which are not required to be machined, a cowl is provided around the workpiece and its fixture, a space being provided at the plane of the interface between parts to be machined and parts not to be machined. Oeionised water is pumped into the interior of the cowl, at a pressure just sufficient to prevent electrolyte entering the gap, thus protecting the necessary workpiece portions and the apparatus. C.R,R. Hill, and Roils Royce Ltd. 22 Aug. 1984, Patent no. GB2134926A (UK), 10 Feb. 1983.
J. APPLIED METALWORKING
53-0723
Grinding Wheel Containing Cubic Boron Nitride. A resin bonded cubic boron nitride wheel is disclosed in which the resin bond contains by volume 15-35% of a fluoride salt grinding aid, 0-16% of a dry film lubricant filler and 5 to 40% silver, the resin content of the bond being at least 30% by volume. Up to 50% of the Ag may be substituted Ni. The resin may be a phenolic resin or a polyamide. The dry film lubricant filler may be MoS2, hexagonal boron nitride, graphite or a fluorinated polymer. B. Oster, R.H. Sioui, E.B. Carver, and Norton Co. 12 Sept. 1984, Patent no. GB2136011A (UK), 10 Feb. 1984.
53-0725 Present State and Future T r e n d s in Precision Machining for VCR [Video Cassette Recorder] Production. Aspects discussed in a review of developments in precision-machining VCR components include numerical control of ultra-precision lathes, replacing AI and Zn tape-transport die-castings by plastic mouldings, factors influencing the choice of single-crystal M n - - Z n ferrite for magnetic heads, and the formulation of a forgeable A I - - S i eutectic alloy contributing to cylinder-drum accuracy by reducing secondary machining to light cutting by a diamond t o o / . - - J . R M. Matsunaga. Bull. Jpn. Soc. Precis. Eng., Mar. 1984, 18, (1), 1-5, [in English]. ISSN 0582-4206.
53-0726
Application o f a Spring Tool of F a c e M i l l i n g . A rotating spring tool of the type used for repeated cutting in turning, planing, and shaping for surface finishing was experimentally applied to face-milling the JIS $25C and FC20 steels, to assess the cutting characteristics of the technique in terms of surface roughness R. For the $25C steel under the same catting conditions as in rigid milling, R was smaller from the first pass onwards, while with the FC20 workpieces it was initially approx, the same but sharply decreased with further passes to Rrnax = 4.6/~m, as compared with 3-6/~m for the $25C steel. Differences in chip formation between the rigid and spring-face millings are also illustrated and discussed. --J.R. J. Minato, S. Anmi, and S. Okamoto. Bull. Jpn. Soc. Precis. Eng., Mar. 1984, 18, (t), 35-36, [in English]. ISSN O582-4206. 53-0002 Laser Beam C u t t i n g o f T h i c k S t e e l . Since commercial lasers of up to 10 kW have been available it is possible to cut thicker plates by the following three techniques: oxy-laser cutting, laser-sublimation cutting and laser-meltcutting. The commonly used one is the oxy-laser cutting-technique. Here the kerf mainly results from burning the kerf material. The laser beam essentially serves the purpose of heating the kerr zone up to ignition temp. whereas the oxygen jet burns the material and blows off the slag. The exothermic reaction heat provides a high fraction of the total process power. Therefore it is possible to cut steel plates . 30 mm thick with a 5 kW laser. Experiments had been carried out cutting mild steel and austenitic C r - - N i steel. The cutting set-up and some results are shown The results are discussed and compared with the results of conventional oxy-flame cutting.--AA G Sepold, and R. Rothe. ICALEO '83, Vol. 38. Materials Processing [Prec. ConL], Los Angeles, Calif., US.A., 14-17 Nov. 1983, Laser Institute of America, 5151 Monroe S t , S t e 118W, Toledo, O h i o 4 3 6 2 3 , U.S.A., 1984, (Met.A., 8501-72-0005) 156-159, [in English].
53-0003 A Quantitative Theory for the Role of Oxygen in the Laser Cutting Process, A quantitative theory giving a unified view of certain laser applications was developed. This theory distinguishes two regimes in the Oxygen assisted laser cutting process (OALCP): laser alone and laser + 0 reaction. Further experimental evidence, which supports the theory, was obtained by means of polarized laser radiation and cutting of carbon and stainless steels. 15 r e f . - - A A M Lepore, M DelrErba, C. Esposito, G. Daurelio, and A. Cingolani. ICALEO '83, V o l 38, Materials Processing [Prec. Conf.], Los Angeles, Calif., U.S.A., 14-17 Nov., Laser Institute of America, 5151 Monroe St., Ste. 118W, Toledo, Ohio 43623, U S A . , 1984, (Met.A., 8501-72-0005) 160-165, [in English].
53-0004 T h e D e s i g n of a C N C L a s e r Drilling M a c h i n e for t h e Production of High-Quality Holes in A e r o s p a c e Components. In the manufacture of gas turbine engines large numbers of holes have to be drilled to allow the flow of cooling air over the most severely thermally loaded components. Such parts vary from small blades to complete combustion assemblies 40 in. india, and 36 in. long. Other aerospace components contain similar holes and may be even larger but they are usually less complex. The holes to be drilled in production components are currently all circular, in the dia. range 0.010 to 1.O in., with the vast majority - 0.100 in. In addition, experimental designs require the production of noncircular holes. The modern laser is fast compared with EDM or ECM, is reliable and capable of providing a very high degree of flexibility since all the salient parameters are programable as part of the CNC part-program. The adoption of improved equipment means that hole q u a l i t y and throughput are improved dramatically. The more critical aspects of the design of a successful machine for the production of high-quality holes in gas turbine parts of Hastelloy X Ni-base superalloy are highlighted. AA T.M. Weedon. ICALEO '83, Vol, 38, Materials Processing [Prec. ConL], Los Angeles, Calif., U.S,A., 14-17 Nov. 1983, Laser Institute of America, 5151 Monroe St., Ste. 118W, Toledo, Ohio 43623, U.S.A., 1984, (Met.A, 8501-72-0005) 192-198, [in English].
53-0005
Basic Analysis of Metal Removal Neodymium Lasers. The laser drilling process has been modeled using a first-order thermal balance a p p r o a c h An algorithm defining the coupling of laser pulse energy with metals (carbon and stainless steels) has been derived. Incorporated in this algorithm are material, optical and geometrical properties required for adequate system modeling. Tests on both a N d - - g l a s s and a Nd--YAG*based lasers have been conducted. Results with two sets of optical settings indicate excellent correlation between predicted and actual pulse energies.--AA M.G. Jones, and G. Georgalas. ICALEO '83, Vol. 38, Materials Processing [Prec. ConL], Los Angeles, Calif., U.S.A., 14-17 Nov. 1983, Laser Institute of America, 5151 Monroe St., Ste. 118W, Toledo, Ohio 43623, U.S.A., 1984, (Met.A., 8501-720005) 199-207, [in English].
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53-0006 Laser Cutting o f S t e e l W i t h the Revolutionary ,'urbolase TIOOO CO2 Laser. The Turbolase T1000 is perhaps the first laser specifically designed for metal cutting. The T 1000 employs Photon's unique Turbotube that delivers 1000 W of solid laser energy to produce smooth, straight cuts with no more than four optical elements in the entire cutting system. Its design and use in the cutting of AI, carbon, stainless and galvanized ~;teel are d i s c u s s e d . - - A A J.S. Eckersley. ICALEO '82, Vol. 31, Materials Processing [Proc. Conf.], Boston, Mass., U.S.A., 20-23 Sept. 1982, Laser Institute of America, 5151 Monroe St., Ste. 118W, Toledo, Ohio 43623, U.S.A., 1982, (Met, A., 8501-72-0007) 131-134, [in English].
53-0007 The E f f e c t o f F # and Beam Divergence on Q u a l i t y o f Holes Drilled With Pulsed Nd:YAG Lasers. The laser is rapidly becoming an accepted tool for drilling of cooling holes in a variety of turbine components. The total cost savings are potentially great due to the large number of holes which must be drilled. Part of the increased acceptance and usage of lasers has come from improvements in equipment which has improved drilling performance while part has resulted from an acceptance of some of the characteristics of laser holes in areas in which those characteristics do not affect engine safety or performance. The most serious of those limitations affecting acceptance of the laser drill process are: taper, dia. variation, drilling depth limitations, recast and mierocracking. These limitations, with emphasis on minimizing beam divergence are discussed. The material used in the study was Inconel 7 1 8 . - - A A S.R. Bolin. ICALEO '82, Vol. 31, Materials Processing [Proc. Conf.], Boston, Mass., U.S.A., 20-23 Sept. 1982, Laser Institute of America, 5151 Monroe St., Ste. 118W, Toledo, Ohio 43623, U.S.A., 1982, (Met.A, 8501-72-0007) 135-140, [in English].
53-0008 Laser Fabrication o f a M o d e l H e a t Exchanger Using Laser Cutting and Welding Techniques. Conventional heat exchanger fabrication techniques usually employ either brazing or relatively high-heat-input joining methods such as Tig welding: The braze alloys may limit the operating temp. of the heat exchanger and the Tig welding may induce excessive distortion. Given comparable fit-up conditions, laser welding may be applied without the need for a second material and distortion will be minimized. Just as important, the elimination of braze alloy and residual brazing flux in the heat exchanger may provide an improvement in corrosion resistance and a reduction in contamination of high-purity working fluids or gases. To demonstrate the feasibility of laser fabrication for such high performance heat exchangers, a model heat exchanger was designed. The model is not intended to address any specific application, but rather serves 1o demonstrate the design and fabrication flexibility of laser manufacturing methods. All starting material forms were wrought 304 stainless steel, specifically sheet and tubular sections. These as-received materials were laser cut and laser welded with a min. of intermediate mechanical preparation and cleaning. The final heat exchanger model is described, including an assessment of product quality and laser use requirements.--AA D.B. Veverka, and S.L. Ream. ICALEO '82, Vol. 31, Materials Processing [Proc. Conf.], Boston, Mass., U.S.A., 20-23 Sept. 1982, Laser Institute of America, 5151 Monroe St., Ste. 118W, Toledo, Ohio 43623, U.S.A., 1982, (Met.A., 8501-72-0007) 141-148, [in English].
53-0009 Temperature Controlled Laser C u t t i n g . Any laser process is characterized by a large number of parameters affecting its performance. Since some of these parameters may change during the process and consequently result in reduced performance, a means for a real-time process control is required. A project carried out at the Technion (Israel Institute of Technology) where a complete on-line adaptive control system was built to optimize the laser cutting process is described. The adaptive control constraint (ACC) is based on the experimental results, indicating a significant correlation between the kert quality and the workpiece temp. at the close vicinity to the cut front. Temp. measurement method, cut quality and surface temp. correlation, the adaptive control system and experimental results are discussed. The experiments were carried out on AlSl 304 stainless steel 3 mm thick plates using a CO2 l a s e r . - - A A Y, Tal, E. Lenz, and A. Shachrai. ICALEO '82, Vol. 31, Materials Processing [Proc. Conf.], Boston, Mass., U.S.A., 20-23 Sept. 1982, Laser Institute of America, 5151 Monroe St., Ste., 118W, Toledo, Ohio 43623, U.S.A., 1982, (Met.A, 8501-720007) 149-161, [in English]. 53-OO10 Precision Parts W i t h J u s t One Pass o f a Grinding Wheel. Fulldepth form grinding is considered. Close accuracies can be achieved economically; fewer operations, reduced parts handling and less capital equipment contribute to efficiency. Form grinding is compared to conventional processing. Soft and hard wheels, dressing methods, crush roll considerations and accuracy are discussed. LTV Energy Products Co. is cited for its production of swivel joints on a Sheffield Model 787 Angleform form grinding m a c h i n e . - - C M . L . S . R. Mead. Mach. Tool Blue Book, Oct. 1984, 79, (10), 92-98, [in English]. ISSN 0024-9106. 53-OOll Choosing Wheels for Today's Jig Grinding. New abrasive materials are reviewed to match jobs with suitable wheels. Good machining practice is discussed. Conventional abrasives, superabrasives (diamonds, cubic boron nitride, amber boron nitride), types of bonds (electroplate, resin bond, metal bond), use of coolants, good jigging practice and special applications (small-hole grinding, bottom grinding, wipe grinding) are considered. Typical special wheelforms and properly dressed jig grinding wheels are illustrated. Recommended abrasives for various materials (cast iron, tool steels, high-carbon steels) are listed. --C.M.L.S. G.G. Rooney. Mach. Tool Blue Book, Oct. 1984, 79, (10), 102-106, [in English]. ISSN O024-9106.
53-0014 Investigations on Mechanical Properties and Chemical Composition of Thermally Treated TiCx Coatings on Steel ( C V D Technique). The described technology allows the production of dense TiCx coatings onto steel at standard pressure. The residual stress in the coatings is a compressive one with a level of some GPa. It is lowered with an increase of the coating
100
VOL. 4, NO. 1, JULY 1985
thickness a n d / o r a aubstrate hardening. Both the residual stress level and the constitution of the contact region substrate/coating mainly influence the mechanical behavior under external load. An occasional formation of cementite islands on the substrate surface in the initial stage of the deposition process reduces the adhesion of the coating. The coating failure of substrate-hardened samples has not occurred as a necessity at the contact region, but is possible also by breaking out inside the coating. The existence of voids along the contact region was also observed in this case. 19 r e f . - - A A W. Fischer, K Wetzig, and M. Seidler. Cryst. Res. Technol., 1984, 19, (8), 11331140, [in English]. ISSN 0232-1300.
53-O016
Sintered Iron-Based Material With Improved Machinability.
( T r a n s l a t i o n ) . See Met. A., 8409-53-0524. T.A. Pumpyanskaya, E.M. Faynshmidt, R.F. Ryabova, and V.N. Kudryashov. Met. Sci. Heat Treat. (USSR), Mar.-Apr. 1984, 26, (3-4), 217-220, [in English]. ISSN 0026-0673. 53-O017 Coolant Effects on Machinability. The effect of two types of coolant, an oil-based emulsion and a heavy duty synthetic, on the machinability of stainless steel (347) and AI (6061) work materials was investigated. Machining was conducted on two 25HP CNC lathes using carbide inserts. Tool life and surface finish were determined subsequent to machining. Best results were obtained with the chemical emulsion coolant, with tool life being increased by ~ 50%. --G.P.K. B J . Michaels, and J.H. Wright. Cutting ToolEng., Oct. 1984, 36, (5), 14, 16, [in English]. ISSN 0011-4189.
53-0018 Standard Indexable-Carbide-lnsert Drill Used on Exotic Aerospace M a t e r i a l . A manufacturer of jet-aircraft engine components is successfully using a titanium nitride coated carbide insert to machine Inconel 718 parts from bar stock. A Miyano 7BC CNC bar chucker is used to drill a required hole in one pass, then rough-bore by the outboard insert in a second pass. The inboard insert is able to produce five pieces before indexing is required.--G.P.K. M. Smelewski. Cutting Tool Eng., Oct. 1984, 36, (5), 28-30, [in English]. ISSN 0011-4189.
53-0019
Robot Handles Parts for Gear Inspection and Shaving
System. A gear inspection and shaving system that features the automatic handling of gears has been developed and built by National Broach and Machine. The system can finish the teeth on a variety of gears ranging from flat gears to threegear clusters. The robot is capable of five different motions and performs all loading / unloading functions.-- G.P.K. Cutting Tool Eng., Oct. 1984, 36, (5), 31, [in English]. ISSN 0011-4169. 53-0020 Roughing End Mills Cut Costs. A roughing end mill is designed to take metal off fast and is built to resist deflection and chatter After a final hogging pass, a workpiece can be brought to size by a close-tolerance pass with a standard tool. Roughing end mills vary in the number of flutes and in tooth profile. Generally, the tools are designed with four, five or more flutes, depending on the properties of the work material and the t o o l d i a . Roughing end mills of 9 1/2 in. dia. usually offer little or no advantage over standard tools. Roughing end mills with four to eight flutes are compared to standard two-flute end mills for slotting out 1040 carbon steel w i t h a B H N - 200. Materials, such a s A l a n d M g , aretroublesome when hogging because the generated chips weld to the tools flutes. This problem can be solved by using hard, wear-resistant titanium nitride coatings applied by physical vapor deposition or chemical vapor d e p o s i t i o n . - - D . O N . Tool. Prod., Oct. 1984, 50, (7), 32-35, [in English]. ISSN 0040-9243. 53-0021 O r b i t a l R i v e t i n g E n h a n c e s A u t o - P a r t Q u a l i t y . The use of orbital headforming of rivets for an automobile seat-back latch-assembly is described. Orbital riveting has a number of characteristics that often make it more desirable than other forms of riveting and related fastening processes, including impact heading, flanging, flaring and swaging. These advantages include: noise reduction; short-cycle times of 0.3 to 2.0 s; wider latitude to material suitability such that any malleable material with hardness up to 35 Rc can be formed; increased heading capacity, e.g. mild steel pins, rivets or studs between 0.01 and 1.5 in. can be headed with fraction of force required for staking or impact riveting; ability to form double-end or nonround head; no material damage; increased tool life.--D.O.N. D.B. Dobbins. Tool. Prod., Oct. 1984, 50, (7), 40-42, [in English]. ISSN 0040-9243.
53-0022
Broaching Tries for a B i g g e r Bite. In the automobile industry, large gears, like flywheels, have been traditionally made using relatively slow hobbing processes because available broaching machines did not have the capacity to handle 12 to 20 in. gears with the required quality levels. A tonnage potbroaching machine is described for the manufacture of 16 in. flywheel ring gears from 1060 steel. The ring gears are punched out at rates of 380/h, from ring blank to finished gear form in 3 s of actual cutting time, plus 6 s o l loading/unloading time. One pot-broad machine is expected to replace 15 existing flywheel-gearhobbing machines. Hobbing can still have advantages where higher gear quality is required.--D.ON. E.E. Sprow. Tool Prod., Oct. 1984, 50, (7), 59-63, [in English]. ISSN 0040-9243. 53-0023
How t o M a i n t a i n C B N W h e e l s . Recommended procedures for the trueing and conditioning of cubic-boron-nitride superabrasive wheels are presented. Best results for trueing have been achieved by using diamond trueing rolls with an abrasive-mesh size in the range 6 0 / 8 0 - 2 0 0 / 2 3 0 . A CBN-wheel speed of 1000-1500 sfm during trueing is suggested to prevent excessive wear of diamond rolls and wheels. Subsequent conditioning, required to remove excess wheel-bond material, can be accomplished with aluminum oxide conditioning sticks containing 220 grit a b r a s i v e . - - G P . K . A.C. Carius. Am. Mach., Oct. 1984, 128, (10), 79-82, [in English]. ISSN 0002-9858. 53-0025 S m a l l Indexable End Mills. Small, indexable carbide end mills are currently being used for the heavy roughing of cast iron, steel, high-temp, alloys and nonferrous metals. Heavy chip loads can be achieved with high cutting speeds
J. APPLIED METALWORKING
and a feed of at least 0.003 in./cutting station. Machining parameters for slab milling, channeling and profiling are recommended for a variety of metals: AI 6061, 7075 and 7475, beryllium bronze (Berylco 25), cast iron, carbon steel, stainless steels (410, 416, 316, 15-5PH, 17-4PH, 304, 13-8PH), T i - - 6 A I - - 4 V , Inconels (600, 706, 718), Incoloy 903, Hastelloy and Waspaloy.--G.P.K. R.T. Koblesky. Mod. Mach. Shop, Oct. 1984, 57, (5), 56-63, [in English]. ISSN 0026-8003.
53-0026
Two-Step Milling Chips Problems Away. A two-step milling process is solving more than one machining problem encountered during the fabrication of aerospace parts from solid stock. The process, called kitting, uses heavy duty machines to hog out most of the material to be removed, while precision CNC machines perform the final machining. Two developments that have made this possible are the Computervision graphics system and the availability of larger-sized AI stock. Advantages include increased material utilization by nesting and a large decrease in roughing l i m e s . - - G P . K . K. Gettelman Mod. Mach Shop, Oct. 1984, 57, (5), 66-71, [in English]. ISSN 00268003. 53-0040 Laser Machining: No Longer Nontraditional. The CO 2 gas and Nd-doped yttrium aluminum garnet solid-state lasers are most frequently used in industrial applications; however, a cardinal rule of machine justification is: if it is cheaper to do it another way, do not buy a laser. Lasers are the only way to process certain parts, and they can cut and trim metals, composites, plastics, ceramics, paper, rubber, leather and fabrics. No physical contact with the workpiece occurs which can reduce maintenance equipment and procedures. Numerous applications of lasers are discussed and their capabilities are stressed.--J.J.P. B Krauskopt. Maauf. Eng., Oct. 1984, 93, (4), 53-57, ]in English]. ISSN O361-O853. P r o d u c t i o n o f Zirconium Hafnium and Zirconium Niobium Carbides. Both zirconium hafnium and zirconium niobium carbide show great potential as substitutes for tantalum carbide in hardmetal. In addition to their intrinsic high hardness and high abrasion resistance, they can decompose spinodally which should impart a fine-grained structure in the final tool. Contrary to reports by other workers, there are no problems with the wettability of the zirconium carbide by Co and in fact the Co promotes the spinodal decomposition. It is recommended that the additives are used in the form o1 pseudoquaternaries with tungsten and titanium carbides. Technically the two additives are very similar but the low density of the zirconium niobium carbide allows greatly reduced addition rates. As it is also based on more widely available ingredients, it is also the cheaper of the two additives.--AA J.L.F. Kellie, P. Davies, and H.J. Retelsdorf. Int. J. Refract. HardMet., Sept. 1984, 3, (3), 136-141, [in English]. 53-0041
53-0042
Hardmetals With H f Z r and NbZr Carbides. The high price of Ta used as an additive in steel cutting grade hardmetals has evoked interest to substitute Ta for other refractory metals in hardmetals. The Z r - - N b - - T i - - W - and Z r - - H f - - T i - - W - - c a r b i d e s as mixed carbide phases were found to be useful for this purpose. Results s h o w that Z r - - N b - - T i - - W - and Z r - - H f - - T i - - W - carbides can successfully substitute T a - - N b - - T i - - W cubic phase in steel cutting grades of hardmetals. The properties of experimental alloys are compared 1o those of conventional hardmetal grades. While hardness and wear resistance are increased, toughness as measured by the TRS test was found to d e c r e a s e . - - A A E Kny. Int J Refract. HardMet., Sept. 1984, 3, (3), 142-145, [in English]. 53-0043 Influence of Carbide Grain Size on Elevated-Temperature Tensile Creep o f W C - - 1 0 % O o A l l o y . Although several investigations have been reported on tensile creep of WC--Co alloys, much remains unsolved, especially in regard to the deformation mechanisms. The investigation, utilizing a novel creep test assembly, measurements of various creep properties of W C - - 1 0 % alloy were carried out in relationship with carbide grain size 0.6-2.6 /~m in the temp. region 750-950~ under tensile loading of 15-30 k g / m m 2. It was found that stress exponent and activation energy in the equation for stationary creep rate increased with reduction in grain size. Dependence of stationary creep rate on grain size showed that a max. invariably appeared in the neighborhood of 1.5 ~m The origin of this max. is discussed in connection with the possible high-temp, deformation m e c h a n i s m s . - - A A H. Doi, F. Ueda, Y. Fujiwara, and H. Masatomi Int. J. Refract. Hard Met., Sept, 1984, 3, (3), 146-148, [in English].
53-0045 Improving Properties and Service Life of Spark-Machined Parts. (Abstract Only). During the spark machining process a layer is formed which differs both in constitution and in mechanical properties from the matrix, owing to the super-high temp. characteristics of the process. Cracks introduced into this layer lead to a reduction in the service life of the component. The authors studied the features and structure of the spark-machined layer and found ways of improving its q u a l i t y . - - A A Y. Li et a~ Heat Treatment Shanghai 1983; 3rd International Congress on Heat Treatment of Materials [Prec. Conf.], Shanghai, China, 7-11 Nov. 1983, The Metals Society, 1 Carlton House Terrace, London S W l Y 5DB, England, 1984, (Met.A., 8501-72-0034) 6.12, [in English].
53-0046 Metal-Cutting and One Hundred Years of Tool Material Development. The path of very rapid development of cutting tool materials over the last one hundred years has been dictated by the requirements of tools to cut steel and the demands of engineering industry for increasing productivity. Progress from carbon steel to high speed steel to cemented carbide and further to ceramic and cubic boron nilride tooling has been largely by empirical testing of cutting tools. New knowledge of the cutting process and of the structure/property relationships of tool materials will stimulate a new approach to cutting tool material d e v e l o p m e n t . - - A A E.M. Trent. Perspectives in Metallurgical Development [Prec. Cent.], Sheffield, England, 16-18 July 1984, The Metals Society, 1 Carlton House Terrace, London S W l Y 5DB, England, 1984, (Met.A., 8501-72-004,,A) 218-222, [in English].
J. APPLIED METALWORKING
53-0048
Plastomechanical Analysis of Cold Shearing. A shearing apparatus was constructed to investigate various parameters of the cold shearing process and to optimize the geometrical cutting quality and the energy consumption. The upper bound theory of plastomechanics gave detailed information about the extent of the plastic shear zone. I1 could be shown that the work hardening coefficient is of eminent importance for the kind of deformation of the sheared specimens. The measurement of temperature rise showed that the adiabatic limit was reached already at a shear velocity of 0.1 m / s . - - A A O. Pawelski, and R. Sauer. Arch. EisenhOttenwes., Aug. 1983, 54, (8), 307-310, [in English]. ISSN 0003-8962. 53-0052
Machining Characteristics of Microalloyed Forging Steels.
The machinability of forging steel grades, microailoyed with vanadium for precipitation hardening and used in the air-cooled condition, are compared with those of hardened and tempered steel grades. Standard laboratory tests, employing both high-speed-steel and cemented carbide tooling, have been used. In most instances, microanoyed steel proved to be at least as machinable as hardened and tempered steel grades o1 similar strength level. However, because of a higher dependence of machinability on workpiece hardness, microalloyed steels may have inferior machinability to hardened and tempered alloy steels, at tensile-strength levels above 1000 MN m - ~ . This higher dependence on workpiece hardness has been investigated using a range of experimental techniques and a tentative mechanism has been proposed. Finally, compositinal adjustments have been proposed, which might improve the machinability of microalloyed steels and thus eliminate this one potential problem area. 15 r e f . - - A A A.R. Chambers, and D. Whittaker. Met. Technol., Aug. 1984, 11, (8), 323-333, [in English]. ISSN 0307-1693.
53-0056
Evaluation of Methods of Optimizing the Grinding Process on
the Basis of Thermal Calculations. (Translation). See Met. A,, 8309-530601. N.V. Diligenskii, and Yu.M. Yanyushkin. Phys. Chem. Mater. Treat. (USSR), Jan.Feb. 1983, 17, (1), 23-26, [in English]. ISSN 0264 729X. 5 3 - 0 0 5 7 Calculation of the Depth of the Hardened Layer Formed in the Free Right-Angled Cutting of Materials. (Translation). See Met. A., 840553-0228. V.A. Kozlov. Phys. Chem. Mater. Treat. (USSR), May-June 1983, 17, (3), 336-341, [in English]. ISSN 0264-729X.
53-0058 Calculation of the Temperature Resulting From the Accumulation of Heat in the Workpiece in Cutting With Plasma Heating of Metal. (Translation: V R / 2 3 3 7 / 8 3 ) . A.N. Reznikov, and M L . Urilskii. Fiz. Khim. Obrab. Mater., 1983, (1), Pp 3, [in English]. ISSN 0015-3214.
53-0064
Turning Lathes Condition Monitoring Based on the Workpiece
Surface Spectral Analysis. A method for conditions monitoring of a surface generated in the turning process, based on spectral analysis of its geometrical structures, is presented. The surface generation system is briefly discussed 1o consider the influences affecting the surface state in a particular instance. A matrix of the power spectra levels and a schedule of the machine tool states are introduced to identify the abilities of a turning machine to generate a surface to the required specifications (for St 45). 22 r e f . - - A A A. Konczakowski, and J. Peklenik. Condition Monitoring '84 [Prec. ConL], Swansea, U.K., 10-13 Apr. 1984, Pineridge Press Ltd., 91, W. Cross Lane, W. Cross, Swansea, U.K., 1984, (Met.A., 8502-72-0071) 279-292, [in English]. 53-0065
Handbook of Machine ToOls, V o l . 1-4. ( B o o k s ) . This four volume set introduces and explains the functions of machine tools, provides the necessary data for the design and mathematical analysis of machine tool elements and their structural components, covers the automation and control technology of machine tools and defines the characteristics of machines and their performance accuracies, capabilities and effects on the environment. Volume 1 d i s c u s s e s casting, metalforming and joining machines, gear-cutting and metal-cutting machines, including lathes, planers, drilling and grinding machines, and includes chapters on special-purpose machine tools and standard and auxiliary machine tool equipment. Volume 2 covers the design of machine frames and frame components, installation and foundations of machine tools, guideways and bearing and main drives, including motors, transmission drives, couplings and clutches. Volume 3 discusses automated functions in manufacturing engineering and their practical applications, mechanical control, copying systems, electronic data processing, process controls, numerical control, geometry processing, feed drives, position measuring systems for NC machines, adaptive control systems, DNC systems, flexible manufacturing systems, operational data recording and machine diagnostics in automatic production. Volume 4 presents the topics of geometric and kinematic machine behavior, thermal effects on machine tools, static and dynamic behavior of machine tools, noise emission, work accuracy (workpiece examination) and limiting cutting capability. Numerous ref.--J.A.M. M. Weck. John Wiley & Sons, Inc., 1 Wiley Dr., Somserset, N.J. 08873, U.S.A., 1984, (Met.A, 8502-72-0079) Pp 1175, [in English]. 53-0066 Property Improvements in Bars and Forgings Through Microalloying and Inclusion Engineering. The present status of microalloying is reviewed from the perspective of bar products, forgings and castings. Many of the initial ideas concerning controlled rolling, accelerated cooling and the beneficial effects of low-carbon, nitrogen and sulfur contents were confirmed in laboratory experiments on round bar. Forgings and castings have emerged as an opportunity area for microalloying technology and there has been ;'apid assimilation of the technology developed in other product areas, in particular the search for higher strengths, elimination or abbreviation of heat treatments, simplified cold finishing or machining operations and improved toughness, has been combined with a simultaneous concern for other end-user properties such as machinability and weldability. The result has been an integrated approach, including proper se-
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lection of microstructure and transformation conditions, application of thermomechanical processing and adoption of inclusion engineering practices via control of deoxidation and solidification processes. Some of the steels developed through this comprehensive approach are reviewed. 54 r e f . - - A A J.M. Gray, S.V. Subramanian, and D.A.R. Kay. HSLA Steels, Technology and Applications [Prec. Conf.], Philadelphia, Pa., U.S.A.,.3-6 Oct. 1983, American Society for Metals, Metals Park, Ohio 44073, U.S.A., 1984, (Met.A, 8502-72-0072) 967979, [in English].
53-0067 Cutting Tools With Wear-Resistant Coating of Heat Resistant C o m p o u n d s of High-Melting Metals and Method for Manufacturing Same. A method for manufacturing cutting tools of the ceramic type such as aluminum oxide, comprises using condensation of plasma matter and ion bombardment to deposit an intermediate layer of a pure metal on the base material whose temp. is 0 5 T s > T > 0.33 T s, where T s is the melting temp. of the metal being deposited and Tis the temp. of the base material in ~ The condensation rate and the duration of deposition are selected bearing in mind that metal is to be deposited only on defects found on the surface of the base material; and using condensation of plasma matter and ion bombardment to deposit a wear-resistant coating of heat resistant compounds of high-melting metals on the intermediate layer. A.G. Gavrilov et al., and Vsesojuzny N-I Proektny Institut. Off. Gaz., 24 July 1984, Patent no. US4461799 (USA), 14 Feb. 1983. ISSN 0360-5132.
53-0068
A Productive Duo: C r e e p - F e e d Grinding With CBN. High productivity, low grinding costs and longer tool life are benefits of a creep-feed grinding program with retrueable cubic boron nitride (CBM) form wheels. The system is used to recondition teeth in hardened tool steel saw blades in one pass and to grind complex forms in hardened tool steel end mills and broaches from the solid in one pass. Work at the Borg-Warner Spring/Brummer plant is cited. It is suggested that the full productive potential of creep-feed grinding with CBN wheels has not yet been attained.--C.M.L.S. A.C. Carius. Mod. Mach. Shop, Dec. 1984, 57, (7), 50-57, [in English]. ISSN 00268003. 53-0069
Taking the Plunge With Full-Depth Form Grinding. Previously unattainable accuracies are achieved economically with full-depth form grinding Grinding wheel technology, new dressing methods, grinding machine construction. measuring and control systems and heat prevention with a jet wheel cleaner are considered. Justification of new equipment no longer relies on payback from improved accuracy alone, but in the elimination of machining and handling operations and reduction of inventory. Management value analysis justifies buying equipment that produces profits by more economical production of more accurate parts --C.M.L.S. J.E. Slouffman. Mod. Mach. Shop, Dec. 1984, 57, (7), 60-67, [in English]. ISSN 0026-8003. 53-0070
F l a t H o n i n g ' s N e w L o o k . Advantages of flat honing with silicon car bide or aluminum oxide abrasives are considered; parts which lend themselves to flat honing are those that require precision surfaces and are free from directional grinding lines and grinding-type burrs, such as ball bearing braces, valve plates. bimetallic plates, pump components, seals, wear surfaces and hydraulic valve components. Honing tools and processors are discussed, including flat, parallel honing machines, trueing devices, coolants, special single-wheel flat honing machines, small through-feed honing machines and workholders.--C.M.L.S. J.H. Indge. Mod. Mach. Shop, Dec. 1984, 57, (7), 70-75, [in English]. ISSN 00268003.
53-OO71
Laser Cuts Tough Machining Problems. Benefits of laser machin ing include rain. tooling costs, ease of prototype development, material savings in cutting sheet metal blanks, superior dimensional control and repeatability and close nesting, which allow faster delivery of parts to customers. Work at E.R.K Manufacturing, tnc., is cited; a laser is used to cut, drill and seam-weld the Ni-rich and very tough Hastelloy X. There has been only rain. downtime for routine maintenance.-- C.M.L.S. Mod. Mach. Shop, Dec. 1984, 57, (7), 78-83, [in English]. ISSN 0026-8003. 53-0075 Electrolytic Photoetching of Vitrovac 6 0 2 5 for the Production o f Magnetic Recording Heads. Magnetic recording head laminations have been successfully fabricated from Vitrovac 6025 (a hard, Co-based amorphous metal alloy, resistant to stamping and spray-etching in nontoxic etchants) by electrolytic photoetching in dilute hydrochloric acid. Photochemical machining (pcm] is an alternative method for the production of components from foils. To produce the component the foil is coated with a photoresist and exposed to ultraviolet light through a suitable phototool. It is developed to produce the required adherent resist stencils in register upon both sides of the foil and machined by spraying with an etchant, such as aqueous ferric chloride solution. Vitrovac 6025 exhibits a high resistance to etching with ferric chloride at concentrations and temp. used commercially for etching other metals. 10 r e f . - - A A D.M. Allen, and TN. Talib. Precis. Eng., July 1984, 6, (3), 125-128, [in English]. ISSN 0141-6359.
53-0076 Mechanism of Formation o f B u i l t - U p E d g e . A mechanism of formation of built-up edge is proposed. It is shown that preheating the cutting tool above the recrystallization t a m p can artificially prevent the formation of built-up edge. An experimental set-up has been developed for verification of the proposed mechanism using bearing steel and W C - - C o cutters. Results show that the coefficient of friction on the rake face decreases with increasing temp. of preheating the tool. 9 r e f . - - A A 8.P. Bandyopadhyay. Precis. Eng., July 1984, 6, (3), 148-151, [in English]. ISSN 0141-6359. 53-0078
On the Maximum Limit Value in the Cutting Speed With a
Plane Polarized Laser Beam. It is possible to predict the max. speed value (Vs) achieved when a plane polarized laser beam cuts a metal sheet with the plane of
102
VOL. 4, NO. 1, JULY 1985
polarization perpendicular to the cutting direction. For this purpose a simple approach, based on a modification to the line source solution of the classical heat flow equation, has been used. Good agreement with experimental data, relating to cutting of different metals (Sn, low-carbon and stainless steel, Pb) performed by a plane polarized 500 W CO2 laser has been f o u n d . - - A A M. Lepore, and C. Esposito. Appl. Phys. Commun., 1984, 4, (2-3), 121-134, [in English]. ISSN 0277-9374.
53-0079
Tips on Deburring With R o b o t s . Robots can be programed to deburr parts of varied size and shape and can provide high-quality finishes. Parts which can be deburred include cast iron crankshafts, AI cylinder heads and transmission cases, steel or cast-iron steering knuckles and housings and also various plastic components. Robots for deburring require at least five axes of motion, with deburring to an accuracy of a few thousandths of an inch, and having servocontrolled motion and prompt servo response, low inertia and freedom from backlash. Tool handling and tool selection are considered. Carbide rotary files are common; reciprocating files are best for hard or brittle materials; bench grinders, rotary brushes of nylon or steel wire; and honing tools are all available. Programing guidelines, as employed at Windsor Manufacturing, Windsor, Ont., Canada, are discussed.--J.J.P. L. Gustafsson. Am. Mach., Nov. 1984, 128, (11), 136-139, [in English]. ISSN 00029858. 53-0081 Inclined Moving Heat Source Model for Calculating Metal Cutting Temperatures. The analysis of an inclined plane heat source moving along the surface of a semi-infinite solid is presented. Material passing by the heat source is eliminated from the analysis to simulate its removal by an orthogonal cutting process. The solution, expressed in terms of dimensionless parameters, is obtained by solving the heat equation numerically with the finite element method for a wide range of cutting conditions. The solution is used to evaluate shear plane temp. in orthogonal machining and grinding zone temp. in conventional and creep feed grinding. 14 r e f . - - A A P.R. Dawson, and S. Malkin. J. Eng. Ind. (Trans. ASME), Aug. 1984, 106, (3), 179186, [in English]. ISSN 0022-0817.
53-0082
Buckling Loads and Natural Frequencies of Drill Bits and
F l u t e d C u t t e r s . The buckling loads, natural frequencies and mode shapes of twist-drill bits and certain fluted cutters under a variety of combinations of twist angle, cross-section geometry and axial loading have been obtained. The drill bit is modeled as a twisted Euler beam under axial loading that is clamped at both ends. The governing system of differential equations is solved by the Galerkin procedure. Explicit forms for the basis functions used to generate the Galerkin coefficients are presented in general form in an appendix. They may be used for obtaining numerical results for that class of problems which use the Rayleigh-Rilz--Galerkin methods with beam-type functions as the basis functions. The representative set of modes obtained exhibit a complex out-of-plane twisting-type motion thai suggests a possible explanation for the out-of-roundness of certain drilled holes. 17 r e f . - - A A EB. Magrab, and D.E. Gilsinn. J. Eng. Ind. (Trans. ASME), Aug. 1984, 106, (3), 196204, [in English]. ISSN 0022-O817.
53-0083
Data-Dependent Systems Approach to Surface Generation in
Grinding. A new approach to the analysis of surface generation is initiated by fitting mathematical models to wheel and work surface profiles under actual grinding conditions. Data Dependent Systems (DDS) methodology has been used to model work surface profiles in 1he longitudinal (across the width of cut) and transverse (along the direction of feed) directions and the wheel profile along the longitudinal direction. A model for the "characteristic grain" consisting of the superimposition of a large and small wavelength is used to provide an indication about the grainwear and surface roughness The large wavelength representing the grain has been used in establishing the deflection of the grain Due to the elastic deflection, the small wavelength representing the cutting edges cuts a smaller groove, which provides a prediction of the rms value of the ground surface in the transverse direction. From the wavelength decomposition of longitudinal profi!es, the superimposition of components due to topography of the wheel and kinematic conditions have been identified. The mechanism that leads to such a superimposition is analyzed. Experimental verification of the theory (on AISI 1095 steel) and predictions is given. 31 r e f . - - A A S.M. Pandit, and G. Sathyanarayanan. J. Eng. Ind. (Trans. ASME), Aug. 1984, 106, (3), 205-212, [in English]. ISSN 0022-0817. 53-0084 R e a l - T i m e E s t i m a t i o n o f C u t t i n g P r o c e s s P a r a m e t e r s in Turning. A simple method for real-time estimation of the parameters which characterize the relation between cutting force and feed in turning is described. The method produces very accurate results which make it suitable tor use in Adaptive Control Constrain (ACC) and Adaptive Control Optimization (ACO) syslems. In both cases, models describing different cutting process variables are assumed in which constants are predetermined by off-line experiments. The method will make it possible to determine these constants on-line. 7 r e f . - - A A O. Masory. J. Eng. Ind. (Trans. ASME), Aug. 1984, 106, (3), 218-221, {in English]. ISSN 0022-0817.
53-0085 Self-Excited Chatter and Its Marks in T u r n i n g . Investigations were made on self-excited chatter of the work (brass) which is held at one end on a lathe machine. Analysis was carried out by a two-degrees-of-freedom system It was verified that introduction of the multiple regenerative effect governs the finite amplitude of the vibration after it is excited. It was also shown that behavior of the work displacement rolaling around the origin during the vibration could be explained by taking into account a resistive force which is inversely proportional to the cutting speed and is proportional to the velocity of the vibration. Phase difference of the vibration occurring for each turn of the work was measured by making use of a microcomputer system. Correlation of the pattern left on the work with the phase difference and with the multiple regenerative effect was studied. 8 r e f . - - A A T. Kaneko, H. Sato, Y. Tani, and M. O-hori. J. Eng. Ind. (Trans. ASME), Aug. 1984, 106, (3), 222-236, [in English]. ISSN 0022-0817.
J. APPLIED METALWORKING
53-0086 T h e C r e e p - F e e d G r i n d i n g o f H a r d a n d S o f t S t e e l s . The process of "creep-feed" grinding is explained and experimental results, obtained after creep-feed grinding a number of hard and soft low-alloy steels, are reported. Surface grinding and deep-form grinding results obtained by previous workers are reevaluated and the possible effect of the presence of hard carbide populations in the workpiece matrix is discussed. The results, both with and without continuous dressing, show that the bulk homogeneous hardness value of the workpiece directly affects the magnitudes of the specific energies obtained during creep-feed grinding. This hardness-related effect may not necessarily be observed during conventional surface grinding. 10 r e f . - - A A J.E. Morgan, and N.D. Salter. J. Eng. Ind. (Trans. ASME), Aug. 1984, 106, (3), 229232, [in English]. ISSN 0022-0817. 53-0087 S o m e P r o b l e m s C o n n e c t e d W i t h B a l a n c i n g o f Grinding W h e e l s . In most publications, the unanimous opinion prevails that an increase of grinding machine vibration and deterioration of workpiece quality are observed when the grinding wheel imbalance is on the increase. However, various data on the qualitative influence of wheel imbalance on the realization of the grinding process occur. A theoretical explanation of the influence of wheel imbalance on the dynamics of grinding and the course and results of investigations proving theoretical considerations are described. The widely known opinion is that only one-plane balancing of the grinding wheel is sufficient. Also most wheel balancing equipment has the capability of only one-plane imbalance corrections. The purpose of the present paper is to prove that the wheels used in precision grinding always should be balanced in two planes. 8 r e f . - - A A G. Gawlak. J. Eng. Ind. (Trans. ASME), Aug. 1984, 106, (3), 233-236, [in English]. ISSN 0022-0817. 53.0088 A n A n a l y t i c a l I n v e s t i g a t i o n o f t h e H o n i n g M e c h a n i s m . The cutting mechanism in the honing operation is analyzed theoretically, assuming that one stick co~r to a single point tool with a long cutting edge. As a result, an evaluating function to present the over-all severity of honing conditions and an equation to calculate the specific cutting force are derived. Moreover, some experiments are carried out (on carbon steel and ductile Fe) to confirm the propriety of these results.--AA T. Ueda, and A. Yamamoto. J. Eng. Ind. (Trans. ASME), Aug. 1984, 106, (3), 237241, [in English]. ISSN 0022-O817. 53-0091 P u t t i n g C a r b i d e s in T h e i r P l a c e . On selected pages from 87-126. charts are given based on manufacturers' latest data, adjusted to take account of composition and structure, as well as physical and mechanical properties. Comparisons are as a guide only: grades shown under the same heading may differ widely in performance. Where more than one grade of a single manufacturer is shown under a single ISO category, the grades are given in alphanumerical o r d e r - - n o t in order of choice, performance or any property. A brief commentary on the state of the industry is given on pages 8 2 - 8 3 . - - A A K.J.A. Brookes. Metalwork. Prod., Sept. 1984, 128, (10), 82-83, [in English]. ISSN 0026-1033
53-0093 Surface-Coated B l a d e M e m b e r o f S u p e r H a r d Alloy for C u t t i n g Tools and Process for Producing S a m e . A process for producing a surface-coated blade member for cutting tools comprises: placing a substrate in a vacuum chamber; vapor depositing ~- 0.9 /~m thick layer of Ti metal on at least one surface of the substrate; and subsequently vapor depositing at least one layer of Ti compound onto the layer of Ti to form a coating of titanium carbide, titanium nitride, titanium carbonitride, titanium oxycarbide and titanium oxycarbonitride, the improvement is: the substrate is a cemented carbide containing 2-30% of at least one metal selected from the Fe family and a major proportion of at least one compound selected from the group consisting of carbides, nitrides and carbonitrides of metals in Groups IV A, V A and VI A of the Periodic Table, and the substrate is maintained at temp. between ~ 700-800~ during the vapor deposition. T, Itaba, S. Matsumoto, T. Abe, and Mdsubishi Kinzoku KK. Off. Gaz., 22 May 1984, Patent no. US4450205 (USA), 26 Oct. 1979. ISSN 0360-5132. 53-0094 S t r i p P e e l i n g o f C a r b o n a n d S t a i n l e s s S t e e l s . Strip peeling produces metal strip by machining: the chip is changed to a thinner, less strained, sound product by pulling on it during its formation. It is shown how strip thickness, tool forces and energy consumption are decreased as tool rake angle, a, pulling force and the angle, /~, between the direction of pull and the rake face are increased. Strip is formed curled and subsequently straightened by the pulling action. A slip line field analysis is presented in which the line of action of the pulling force is determined by the subsequent straightening. The analysis and experiments on four different steels (low-carbon steels and 304L steel) together suggest that best geometrical conditions for the process are 20 ~ < (~ < 30 ~ and 10 ~ < /~ < 20 ~ However, there are differences between the response of different materials to peeling which cannot be explained by slip-line field theory. 9 ref. --AA T.H.C. Childs, and M.H. Waiters. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1964, (Met.A., 8503-72-0109) 781-786, [in English].
53-0095 B u r r - F r e e S h e a r i n g . The irregularity of so-called "burrs" always causes some trouble during a n d / o r after the manufacturing process of blanking, shearing and slitting. Therefore, these burrs are usually removed by such expensive and laborious deburring processes as barreling, mash rolling and grinding. The development of burr-free shearing methods which cause, in principle, no burr on the product (carbon steels, AI) is described. The mechanism of burr formation and the fundamental principle for the prevention of shearing burr are also discussed. 8 r e f . - - A A M. Murakawa. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minatoku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 805-814, [in English]. 53-0096
B l a n k i n g o f A m o r p h o u s A l l o y . An investigation was made of the blanking characteristics of ferrous amorphous alloys, Blanking and shearing tests
J. APPLIED METALWORKING
were carried out using three kinds of soft magnetic amorphous alloys and a conventional crystalline metal. Influence of clearance, tool tip geometry and supporting conditions was studied. From the point of view of tool life, wear of cutting edge for some tool materials was also studied. As a result of a comparison between amorphous alloy and crystalline metal, it was found that the sheared surface of amorphous alloy is composed of smooth sheared surface, fractured surface with special vein pattern, shear droop with deformation band and burr. For clearance near zero, a smooth surface can be obtained. It is also confirmed that plastic deformation occurs at the cutting edge when ordinary alloy steel is used as a blanking tool, and hence the importance of selecting the suitable tool materials for preventing deformation and severe wear is e m p h a s i z e d . - - A A I. Aoki, and T. Nakagawa. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 827-832, [in English].
53-0097
Statistical Analysis of Blanking Tool Wear by a Group Method
o f D a t a H a n d l i n g . A statistical method is applied to analyze blanking tool wear. The method is a revised Group Method of Data Handling (GMDH) developed by Kondo and Tamura. The purpose of analysis is to obtain mathematical models of blanking tool wear represented by nonlinear high-order polynominals and to gain an insight into relationships among tool wear and process conditions. Numerical calculations were carried out on the experimental data obtained by Maeda and Aoki and Takaishi and Maeda. Analytical results show that formulas can be obtained which predict tool wear in arbitrary p r o c e s s conditions which represent a physically meaningful structure of wear phenomena. 7 r e f . - - A A K. Takaiahi, T. Kondo, S. Sugiyama, and M. Mizutame. Advanced Technology of Plasticity, Vol. 2 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 860372-0109) 833-838, [in English].
53-0098 Further Investigation of MulUfacet Drills (MFD's)mMathemaUcal Models, Methods of Grinding and Computer P l o t t i n g . The geometric characteristics of nine representative multifacet drills (MFD's) are summarized. Mathematical models of the various component surfaces are derived and analyzed using coordinate transformations. The mathematical models of the geometric elements are used to deduce appropriate grinding methods. Computer plots of MFD's are also presented to check the mathematical models and to lay a foundation for future work on computer-aided design (CAD) of MFD's. Optimal drill designs are illustrated for cast irons, brasses and AI alloys. --AA L.H. Chen, and S.M. Wu. J. Eng. Ind. (Trans. ASME), Nov. 1984, 106, (4), 313-324, [in English]. ISSN 0022-0817.
53-01OO
C N C + C B N = Formula for H i g h G r i n d i n g P r o d u c t i v i t y . The combination of CNC cylindrical grinding machines and cubic boron nitride (CBN) grinding wheels can remove stock (case hardened alloy steel) at rates far superior to conventional grinding systems with the additional benefit of reduced wheel w e a r rates. Toyoda Machine Works, Kariya, Japan, has designed a new type of CNC grinding machine that has been specifically developed for the use of CBN and microcrystalline CBN wheels. The machine features repeatable accuracy within 1 /~m, with surface finishes between 10-15 #in. for some operations.--G.P.K, J. Gleason. Manuf. Eng., Dec. 1984, 93, (6), 45-48, [in English]. ISSN 0361-0853.
53-0102 L a s e r s , F i b e r s J o i n in Machining. A new and innovative application for lasers and fiber optics in the manufacturing area has been developed by General Electric's Aircraft Instruments Dept. where a high-power laser/fiber optic beam-delivery system is being used as a flexible cutting tool in a thermocoupleturnback operation. A semiautomatic laser turnback station was installed and a completely automated workcell is scheduled to be in operation soon. The turnback process removes a specific amount of casing (Hastelloy, Inconel or stainless steel) from the end of the thermocouple (Tc) exposing the internal wires (alumel and c h r o m e l ) . - - A A J. Bernstein. Photonics Spectra, Dec. 1984, 18, (12), 55-57, [in English]. ISSN 0030-395X, 53-0104 C o m p u t e r - C o n t r o l l e d C u t t i n g : t h e S a v i n g s M u l t i p l y . Automation of fabrication operations at Erie Strayer (Co.) is reviewed. Computerized nesting, computer-numerical controlled cutting and plasma-arc cutting (PAC) of A36 mild steel plate is discussed. The computerized nesting procedure is discussed in detail. With the OFC-PAC system, 90% of holes mate at assembly; nonmating holes are ascribed to errors in bending, piercing or drilling. Except for some easily removed dross, PAC edges need no weld preparation and OFC edges need light grinding. Zinc marking has significantly reduced layout for a s s e m b l y . - - C . M . L S . J.R. Birchfield. Weld. Des. Fabr., Dec. 1984, 57, (12), 31-36, [in English]. ISSN 0043-2253.
53-0105 Tough Nickel Alloys Yield to Plasma C u t t i n g . Reynold's Aluminum St. Louis Center cuts Ni (200 and 201) and Ni alloys (400, KhO0, 600, 625, 800, 825) with Linde-engineered plasma arc equipment; a 750A CM56 machine equipped with a PT-7 water-injector torch that takes nitrogen as the plasma gas. Adjustments are made to counteract the gummy slag from the bottom of the cut. An abrasive cutoff machine is used for cuts to • 1 / 16 in. A table of Ni and Ni alloy compositions, characteristics and uses is p r o v i d e d . - - C M . L S . C.R. Weymueller. Weld. Des. Fabr., Dec. 1984, 57, (12), 37-39, [in English]. ISSN 0043-2253. 53-0107 New Bonds Prolong A c t i v e L i f e . One of the recent trends on the abrasive machining front has been the move toward grinding centers, with their ability to change wheels or arbors automatically. But such ways of.working have placed extra demands on the grinding wheels, requiring new developments in grits and bonds which are examined. For example, Normax wheels are compared with conventional vitrified wheels to show longer life and superior stock removal ability. Normax wheels can sometimes be used to replace cubic boron nitride (CBN) wheels for grinding hardened steel tools. Wheel dressing and dressing tools are discussed. The article also discusses: etectroplafed superhard abrasive wheels, diamond or CBN profile grinding wheels, Process E CBN wheel, Aztec III CBN
VOL. 4, NO. 1, JULY 1985
103
wheel, metal bonded diamond or CBN wheel, vitrified CBN grinding wheels and the improvements in disks and belts.--S.K.B. G. Sweeney. Mech. Prod. Eng., 3 Oct. 1984, 142, (3657), 18-19, 21-22, [in English]. ISSN 0024-919X.
53-0108
A Study of Material Pick-Up to'Tool Surface in Metalforming.
indentation of a flat tool onto a trapezoidal thread around a cylindrical workpieca rotated on a lathe is carried out to evaluate material pick-up to tool surface by using AI and stainless steel as workpiece materials with several lubricants. The effects of f a c t o r s - - s l i d i n g speed, extension of surface area, viscosity of lubricant and tool p r e s s u r e - - o n material pick-up are investigated by varying the factors widely and independently. Empirical equations representing a critical condition under which material pick-up occurs are presented for a combination of AI (JISA t 1 0 0 B D ) - - t o o l steel (JISSKD 11) and stainless steel (JISSUS304H)-SKD 11. It is shown that the viscosity of the lubricant has the greatest effect on the material pick-up for a combination of A1100BD-SKD11, but the extension of surface area has the greatest for a combination of SUS304H-SKDt 1 . 8 r e f . - - A A Y. Cote, S. Wakaaugi, and T. Furukawa. Advanced Technology of Plasticity, Vol. 1 [Prec. Conf.], Tokyo, Japan, f 984, Japan Society for Technology of Plasticity, 52-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 162167, [in English]. 53-0109 E v a l u a t i o n o f A d h e s i o n a t S l i d i n g a n d R o l l i n g C o n t a c t Surface in S i m u l a t i o n o f M e t a l f o r m i n g . A simulation test is proposed to evaluate the adhesion generation at the sliding-rolling contact surface between a tool and a workpiece. The simulation test has been developed to evaluate quantitatively the effects of tool pressure, enlargement ratio of surface area of a workpiece at the contact surface and the sum of the velocities of a rotating tool and a sliding workpiece. The empirical formula for evaluating the adhesion generation is derived in the case of using two different lubricants. In this simulation test, stainless steel (SUS 304 JIS) is used as a workpiece and alloy tool steel (JIS SKD 11) as a tool. --AA K. Yoahikawa, and T. Sate. Advanced Technology of Plasticity, Vol. f [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 273-278, [in English].
5 3 - 0 1 10 Manufacturing of Laminated Deep Drawing Dies by Laser Beam Cutting. In an attempt to implement a trend of flexible manufacture in processes like metalworking and mold forming, a quick method of making drawing and trimming dies by laminating sheets with profiles cut by CNC turret punch press and CNC laser cutting machine has been tried. The idea is based on the fact that if a number of sheets with gradually changing profile dimensions cut on them are laminated, a three-dimensional arbitrary curved surface will be generated, which will be stepped or discrete. In a similar manner, if a known form of die or punch surface is divided by equally spaced planes and the known profiles on these slices are cut on sheets of same thickness and then assembled, the form desired can be achieved but with steps. By grinding, these steps can be removed to give the surface of the die. This method was tried to manufacture dies and punches which revealed that both the delivery time from the date of order and cost of manufacturing can be reduced drastically if the sheet profiles are cut by laser beam. The work includes the investigation of the practical limitations of such dies. To use this method of manufacturing for dies of injection molding and die casting, diffusion bonding of laminated sheets has been tried to get perfectly smooth die surface after polishing. The results showed great scope of realizing FMS in the field of plastic working and mold forming p r o c e s s e s . - - A A M. Kunieda, and T. Nakagawa. Advanced Technology of Plasticity, Vol. 1 [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A., 8503-72-0109) 520-525, [in English]. 53-Olll
The
Effect
of
Strain
Hardening
Factor
on
Limiting
Displacements During Transverse Shearing. The effects of concentration of strains during shearing of bars are discussed. The concentration of strains is treated as a beneficial phenomenon--contrary to other processes of plastic working, e.g. sheet metal forming. The tendency towards localization of strains during shearing depends on the strain hardening ability of the material. Reduction of the strain hardening ability of the material constitutes the basic condition for minimization of plastic distortions of the sheared material. The role of the strain hardening coefficient n in the estimation and modification of the properties of materials destined for shearing is discussed. The materials tested included carbon, stainless, Cr and bearing steels and b r a a s . - - A A S. Dzidowski. Advanced Technology of Plasticity, Vol. 1 [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minatoku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 617-622, [in English].
53-0112
Bauschinger Effect in Planar Shear Deformation of Sheet
M e t a l s . A newly developed test of planar simple shear is used to investigate the Bauschinger effect in dual-phase and rephosphorized steel and AI sheets. The Bauschinger effect in simple shear in sheet metals can give a better understanding of the planar directionality of sheet metals and more basic nature of plastic deformation rather than the torsion test. The Bauschinger effect is similar in many respects between the planar simple shear and torsion tests. Work softening in the reverse process which occurs between the transitional and permanent softened areas is discussed in connection with the dislocation behavior. The deforming behavior under the Bauachinger effect may be divided into the three ranges: transitional softened range, intermediate range in which work softening occurs and permanent softened range. 8 r e f . - - A A K. Miyauchi. Advanced Technology of Plasticity, Vol. 1 [Prec. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minatoku, Tokyo 106, Japan, 1984, (Met.A, 8503-72-0109) 623-628, [in English]. 53-0113 R o b o t i c P l a s m a C u t t i n g Speeds Sidemember Production for Volvo Trucks. A vision controlled cutting station, supplied by Torsteknik, and two Motoman L10W industrial robots are in operation at the Volvo Gothenburg truck
104
VOL. 4, NO. 1, JULY 1985
plant. Two Mansfelde PA 40 air plasma units provide the cutting power for the truck sidemembers, taking 6 min instead of 30 min; these may be 210-275 mm wide, 70-90 mm high, 4-13 mm thick. The vision controlled system scans for hole locations to identify each part with computer control storing the code for a specific sidemember package. Typical cutting speeds are 8 m / min on 7 mm thick material and 4 m / m m on 13 mm thick material.--J.J.P. R. Smith. Met. Constr., Dec. 1984, 16, (12), 751-752, [in English]. ISSN 0307-7896.
53-01 14
Numerical Prediction of Hole Shape in Energy Beam Drilling
o f Metals. A procedure for the prediction of energy beam drilling in metals is described. This procedure is based on appropriate zoning of the region to be drilled and on the assumption that as metal is melted it is forced out of the hole by forces exerted by vaporizing metal, Calculations of drilling in several metals and alloys have been made for different conditions of pulse duration, power and number of pulses. Data were obtained for mild steel, Cu, AI and Me. The depths, dia. and shapes of the drilled holes predicted by the proposed procedure are in close agreement with experimental results. During drilling by multiple pulses there is normally a fixed time interval between pulses. Because of heat diffusion during this time, molten metal removal does not begin immediately at the start of the next pulse. The lag time, defined as the time required to initiate molten metal removal from the hole at the beginning of each pulse, can be predicted by the proposed method. When a hole is drilled by multiple pulses, the lag time increases as the hole becomes deeper. 8 r e f . - - A A S. Yoshioka, and T. Miyazaki. Precis. Eng., Oct. 1984, 6, (4), 181-186, [in English]. ISSN 0141-6359.
53-O1 15 Feed Rate of Wire Electrochemical Machining U s i n g P u l s e d Current. The effect of various parameters on the feed rate in electrochemical machining of 0.48 carbon steel has been investigated. Parameters considered were velocity of the electrolyte flow, nozzle dia., material, dia. and tension of the wire, pulse period and peak value of the applied voltage. On the assumption that the feed rate is limited by accumulation of generated sludge or gas, the feed rate equation and favorable pulse conditions were derived and verified experimentally. The rate was improved by applying a shorter pulse period than the 'residential' time of the electrolyte between electrodes. Above the critical pressure, at which the feed rate is a max., the adverse effects of wire vibration cannot be neglected. Measures proposed to prevent it were reduction of nozzle dia. and length of wire span and increase in applied voltage and wire tension. 10 r e f . - - A A R. Maeda, K. Chikamori, and H. Yamamoto. Precis. Eng., Oct. 1984, 8, (4), 193199, [in English]. ISSN 0141-6359. 53-O1 l S B r e a k i n g C a s t I r o n ' s V i c i o u s C y c l e . Careful alloying produces high-strength gray iron without sacrificing machinabilit~. Described tests show that Cu and Me replacing Cr, Ni and Cu in 45 000 Ib/in" samples, can triple tool life. Alloy functions in minimizing carbides and maximizing and refining pearlite are described.--J.V.R. J.F. Janowak. Tool. Prod., Dec. 1984, 50, (9), 36-38, [in English]. ISSN 0040-9243. 53-Ol17 Drilling With PDC. Polycrystalline diamond compact (PDC) tool life is 20 times carbide when cutting abrasive nonferrous materials (reinforced plastics, filled rubbers, hard bronzes) and improves size and finish. PDC manufacture and use are outlined, giving speeds and feeds. Production gundrilling, turning, boring, cutoff and drilling experience is described showing productivity and quality improvements.--J.V.R. R.H. Sauer. Tool. Prod., Dec. 1984, 50, (9), 53-55, [in English]. ISSN 0040-9243. 53-0119 M u l t i e t r a n d C u t t i n g t o S i z e D i r e c t F r o m t h e Coil. Skillful plant combinations mobilize output reserves in the cutting to size of sheets with fixed dimensions and panels. A sizing plant for thin sheet strip is designed for flexible operation direct from the coil. Up to 15 longitudinal strips can be cut and simultaneously cross-cut. The cross-cutter operating on the start/stop principle is preceded by a bridge table equipped with a separator for the longitudinal strips. If only some of the strips are to be cross-cut, the remaining strips are wound onto a reel. The plant cuts up to 525 u n i t s / m i n . - - A A G. Steltner. Strips, Sheets, Tubes, Sept. 1984, 1, 28-30, [in English].
53-0120
L a s e r s M a k e T h e i r M a r k . Brief details are given of a robotic laser system for inscribing code-marks on curved Diesel-engine injectors at the Darlington works of the Cummins Engines company.--J.R. Engineer, 19 July 1984, 259, (6695), 32, [in English]. ISSN 0013-7758. 53-0121 B A e [ B r i t i s h A e r o s p a c e ] P u t s R o b o t s I n t o the Firing Line. Use of robots to handle the potentially lethal high-pressure (up to 55 000 Ib/in 2) waterjetting lances used for cutting and profiling hard materials is illustrated and briefly described.--J.R. Engineer, 19 July 1984, 259, (6695), 32, [in English]. ISSN 0013-7758. 53-0122 Role o f C r y o g e n i c s in M e t a l C u t t i n g I n d u s t r y . A cryogen like liquid nitrogen if applied suitably is expected to be very effective and efficient compared to the conventional cutting fluids in reducing the cutting temp. which is responsible not only for rapid wear leading to dimensional inaccuracy and frequent tool failures but also for poor job-quality due to surface roughness, residual stresses and microcracks at the job surfaces. Cryogenic machining and grinding have been found to be economically justifiable and often essential for machining components made of very difficult-to-machine materials and requiring fine accuracy and surface integrity as needed in modern fields such as aerospace technology, nuclear science etc. The authors of the present paper carried out experimental investigations on cryogenic machining and grinding. It has been observed that apart from the beneficial effects, mentioned above, of cryogenic application to machining it can also reduce the cutting forces and the power requirements quite significantly when machining some ductile materials.--AA J.R. Jainbajranglal, and A.B. Chattopadhyay. Indian J. Cryog., 1984, 9, (1), 42-46, [in English]. ISSN 0379-0479.
J. APPLIED METALWORKING
53-0127
Bureau of Mines Researches Carbide. Current research activities by the U.S. Bureau of Mines are reviewed. Attempts to develop low-Co substitutes for C/5 grades of cemented carbide (rough machining of steel) have been based on TiC with 20-40% of a Ni, Mo, W binder, with promising results. Another area of research is the development of improved coal-face tools, including non-sparking cutting tools based on materials such as WC, TiB2 and TiN, and hard-faced tools that can be produced at less cost than present tools.--T.W. K.J.A. Brookes. MeL PowderRep., July 1984, 39, (7), 379, 380, 362, [in English]. ISSN 0026-0657. 53-0128
mirror being concavely curved in a plane st right angles with respect to the mirror forming the resonator. H. Opower, and Heraeus GmbH. 21 Nov. 1984, Patent no. GB2139936A (UK), 5 Apr. 1984.
53-0144 Investigation on the Improvement of Cutting Properties of Tool Steels by the Addition of Rare Earth Elements. (Translation: BISI 22710). See Met, A.. 8211-53-0702, R. Sun, and S. Hap. Iron Steel (China), May 1982, 17, (5), 55-60, [in English].
Marwin Hits an Upward Spiral. The activities of two of the Marwin
group of companies are briefly described. Marwin Cutting Tools produce a range of WC/Co cutting tools utilising helically deformed carbide inserts formed by novel and patented processes. Marwin Hard Metals produce mining tool tips and inserts from a wide range of carbide powders.--T.W. K.J.A. Brookes. Met. Powder Rap,, July 1984, 39, (7), 392, 393, 395, [in English]. ISSN 0026-0657.
54-0603 Pressing Characteristics of Tungsten-Free K N T 1 6 A l l o y Powder. (Translation). See preceding abstract.
53-0129
S,P. Popova, N.S. Myrka, G.P. Ziobin, and V.Ya. Logunov. Sot,. Powder MetalL Met. Ceram., Oct. 1983, 22, (10), 803-804, ]in English], ISSN 0038-5735.
Substitution of Ceramics for Conventional Cutting Tools. The mechanical, thermal, and relevant chemical properties of ceramic cutting tool materials such as white AI203, black AI203/TiC and Si3N4/sialon, are compared to those of conventional carbide materials. The relative advantages of the two types of material are discussed in relation to performance, ease of fabrication, design trends, and costa. Current uses of, and markets for, ceramic tool inserts worldwide are also briefly reviewed. 13 ref.--T.W. B. North. MeL Powder Rap.. July 1984, 39, (7), 403-405, )in English]. ISSN 00260657, 5 3 - 0 1 3 0 Cutting T o o l Innovations From Carboloy Systems. New cutting tool developments by the Carboloy Systems Dept. of the General Electric Co., Detroit, are briefly reviewed. These include TiN/TiC coated positive-rake 'ProMax 550' carbide inserts, toughened positive-rake slumina--zirconia~tungsten ceramic inserts, novel tool geometries, synthetic diamond tools, and cemented carbide inserts tipped with cubic BN,--T.W. MeL Powder Rap., July 1984, 39, (7), 4 t 1-412, [in English]. ISSN 0026-0657. 53-O131 Laser Processing o f T h i c k - W a l l e d Composite and C o m p o s i t e ~ M e t a l l i c Structures. (Abstract Only). Studies were conducted to evaluate the effectiveness of using high-power laser beams for cutting and drilling holes in thick-walled composite and composite--metallic structures and to study the effects of welding metallic members in the vicinity of composite metallic joints. A 25 kW continuous wave carbon dioxide laser, producing an intense beam of infrared radiation at a wavelength of 10,6 #m, was used for the studies. Laser output was fully programmable and controllable from a threshold value of 1 kW to a maximum of 25 kW, including ramp-up, ramp-down and extended continuous duty cycles, thereby permitting parametric variation in power input (pulsed and steady state) to the process. A system of reflective optics was used to direct the beam for focused or defocused penetration for burrowing through or trepanning operations. Materials used for the evaluation included glass, aramid (Kevlar) and graphite fibers with epoxy and polyester resin systems and high strength steel for the composite-metallic structures. Composite structure thicknesses up to 2 inches were investigated. For broad beam drilling, the heat of combustion generated delaminated zones in the composite matrix surrounding the penetration. Comparisons are made of the relative delamination, as well as the quality of penetration, distortion and other degradation of the material over the power input range for the material systems investigated.--AA K.S. Kaye. Progress in Science and Engineering of Composites [Proc. Conf.], Tokyo, Japan, 25-28 Oct. 1982, Japan Society for Composite Materials, Business Centre for Academic Societies (Japan), 2-4-6-Yayoi, Bunkyo-Ku, Tokyo 113, Japan, 1982, Vol. 2, (Met.A, 8503-72-0139) 1417, [in English]. 53-0134 Travelling-Wire Electroerosion Method and Apparatus With Means for Regulating Flushing Liquid in the Cutting Slot. To regulate the flushing liquid in the cutting zone, an elongate element is introduced into the cutting slot formed behind the advancing wire electrode and is maintained immediately behind the wire electrode and in parallel therewith, and thus dams the flushing liquid in the space between the wire electrode and the element while holding the electrode against deflection rearwards. The elongate element may be a tube having one or more apertures formed in a lateral wall, juxtaposed with the electrode, through which apertures the liquid is discharged into and/or sucked from the cutting zone to ensure an equalized distribution in the rate of flow in the cutting zone across the thickness of the workpiece. During cutting the elongate element may be axially moved or reciprocated, or laterally oscillated. A sensing circuit is provided to respond to a change of the course of the electrode along the cutting path to act on a drive unit mounted on a wire guiding system or a liquid-delivery nozzle assembly and so adjust the angular position of the elongate element about the electrode through the workpiece so that the elongate element moves behind the electrode along the cutting path in the cutting slot. K. Inoue, A. Shimizu, Inoue Japax Research Inc, and Japax Inc. 21 Nov. 1984, Patent no. GB2139935A (UK), 15 Feb. 1984. 53-0135 Material Working Plant Using a Laser. In a high performance laser apparatus, in particular a CO2 laser, particularly for working metal, the laser beam after issuing from an optical resonator is deflected in the direction of the workplace and focussed, by means of a mirror. An image rotating system which comprises an odd number of fully reflective mirrors, having at least three mirrors, is situated in the optical beam path after the deflecting mirror. Means for electronically controlling the angle of rotation of the image rotating system around the optical beam axis as a function of the direction of the machining path are provided, A focussing system may be located between the system and the workpiece or at least one of the mirrors of the image rotating system focussing the laser beam on the surface of the workpiece. A laser comprising an unstable optical resonator incorporating at least three fully reflective mirrors of cyclindrical curvature, is preferentially utilised two of the mirrors whose planes of curvature extend parallel to each other forming the optical resonator and the third mirror or each additional
J. APPLIED METALWORKING
54
Powder Technology
54-0605 Stripping o f Shells From Compacts by Pulse Magnetic Field Forces. (Tranlation). See preceding abstract. V.M. Mikhailov, V.A. Mironov, and V.D. Zemchenkov. Soy. Powder Metall. Met. Ceram., Oct. 1983, 22, (10), 805-809, [in English]. ISSN 0038-5735. Energy Expenditure in the Hot Isostatic Pressing of Metal Powders. (Translation). See preceding abstract. 54-0607
V.A. Pavlov, B.V, Popov, and V.G, Kucherenko. Sov. Powder Metall. Met. Ceram., Oct, 1983, 22, (10), 809-813, [in English]. ISSN 0038-5735. 54-0615 Details o f Progress in Powder Metallurgy. Recent advances in powder metallurgical processes for hot forging/forming, injection molding and high-temp, sintering of alloy powders of Ni--Mo steels, stainless steels, precipitation hardened steels, Ni-baae superalloys and tool steels are summarized. A procedure is outlined for a new hot forging process that can be used for nonsymmetrical parts. The Cabot Corp. has developed a process for the injection molding of metal powders based on the use of water-soluble methyl cellulose as the organic binder. Equipment advances for high-temp, sintering are also reviewed. 41 ref.--G.P.K. L.F. Pease, Ill. Ind. Heat., May 1984, 51, (5), 11-12, 14, 16-17, 36, [in English]. ISSN 0019-8374.
Superior High-Temperature Capabilities o f MA Superalloys Developed by Thermomechanlcal and Heat Treatment Processes. The 54-0616
fundamentals of mechanical alloying (MA), a powder metallurgical process, are reviewed. In the MA process, powder metals and refractory oxides are mixed in a high-energy ball mill that produces homogeneous powders with a controlled microstructure. MA is followed by hot extrusion, hot rolling and heat treatment of the resulting bar or sheet stock. Three MA superalloys are currently being produced, Inconel MA 754, Inconel MA 6000 and Incoloy MA 956, for such applications as gas turbine components and advanced energy conversion aystema.--G.P.K. R.K. Wilson, and F.L. Perry. Ind. HeaL, May 1984, 51, (5), 27-30, [in English). ISSN 0019-8374.
5 4 - 0 6 1 7 The Role o f Refractory Elements in Powder Metal Superalloy Development. (Pamphlet). For the past decade the important improvements in turbine disk superalloys have been paced by advances in powder metal alloying and processing. These advances have permitted significant increases in the refractory element content of superalloys, which led to both higher alloy strength and higher temp. capability. However, present Ni-base alloy, *(/3" systems have very limited remaining growth potential in the traditional sense. Further advances in turbine disk alloys are projected to depend on novel alloying concepts and breakthroughs. Refractory elements will play an exciting and paramount role in these developments via Rapid Solidification Technology (RST). The history of cast-wrought Ni-base superalloys development and producibility problems which led to the initial P/M superalloy work is reviewed. P/M superalloy development efforts and some insights into potential paths for advanced P/M superalloy initiatives are also discussed. 8 ref.--AA R.E. Duttweiler. Metals/Materials Technology Series [Proc. Conf.], Rio de Janeiro, Brazil, 6-13 Apr. 1984, American Society for Metals, Metals Park, Ohio 44073, U.S.A., 1984, Paper No. 8402-007, Pp 12, ]in English]. 54-0618 Conserving Strategic Elements in Superalloys Through P / M Dual Structures. (Pamphlet). A number of options are being explored to conserve strategic elements in Ni-base superalloys used in the gas turbine industry. One such option includes powder metallurgy (P/M) dual alloy structures. These designs would replace components made traditionally from single alloys, thus conserving strategic metals by using them only where they are specifically needed. Recent and on-going studies at TRW and NASA-Lewis are presented which are aimed at applying this dual alloy concept to disk components, where the strategic material savings can be maximized because of the size of the components involved. An evaluation of HIP joining approaches, heat treatment and mechanical property responses for various alloy combinations is presented. An assessment of this technology is also presented in terms of fabrication problem areas and projected savings of critical/strategic elements, including such refractory metals as Nb and Ta. 8 ref.--AA C.S. Kortovich, and F.H. Harf. Metals/Materials Technology ,Series [Proc. Conf.], Rio de Janeiro, Brazil, 6-13 Apr. 1954, American Society for Metals~ Metals Park. Ohio 44073, U.S.A., 1984, Paper No. 8402-011, Pp 16, [in English]. 54-0619 Improved Properties of Double-Pressed Double-Sintered Cupronickel Coinage Alloy, The mechanical properties of sintered cupronickel (75Cu--25Ni) coinage alloy were studied as a function of briquetting pressure, sinlering temp. and sintering time. The mechanical properties were established
VOL. 4, NO. 1, JULY 1985
105
using an MTS tensile apparatus. The sintered alloy was examined by scanning electron microscopy. The residual stresses of the sintered tensile specimens were evaluated by X-ray diffraction. It was found that the double-pressing and resintering process at 11200C for 30 min results in an elongation of up to 45%, which is almost the same as or even higher than those of the normal cast and rolled material. A density of ~ 98% of the theoretical density was observed after coining. This behavior is not dependent on the powder grain size or the first-sintering-cycle parameters, such as the compacting pressure, the sintering temp. (1050-1120~ and the sintering time (15-30 min). It is suggested that, as a result of the internal stresses existing after the repressing operation, the product properties obtained are controlled by a strain-activated enhanced diffusion p r o c e s e . - - A A A. Sharon, and D. Itzhak. Mater. Sci. Eng., May 1984, 64, (1), 1-4, [in English]. ISSN 0025-5416.
54-0620
Titanium-Diboride Dispersion Strengthened Iron Materials. A
high-strength Fe-base material consists of a ferrite matrix which contains ~ 0.210% XB2 precipitate particles where X is selected from the group consisting of Ti, Zr and Hf and mixtures thereof, with the particles being present in a number density of at least t 0 1 ~ 3. E.R. Slaughter, and United Technologies Corp. Off. Gaz., 6 Dec. 1983, Patent no. U S 4 4 1 9 1 3 0 (USA), 12 Sept. 1979. ISSN 0360-5132. 54-O621 P r o c e s s o f Improving Corrosion R e s i s t a n c e in Porous S t a i n l e s s S t e e l Bodies and A r t i c l e . A process for improving the corrosion resistance to aqueous nitric acid, 10%, of austenitic stainless steel foraminous body comprises: compacting water atomized auetenitic stainless steel alloy powder in the form of foraminous body and containing from 0.1-10% prealloyed Sn to form a compact; sintering the compact in a dissociated ammonia or synthetic nitrogen atmosphere at a temp. of at least ~ 1125~ to a final density < 80% of theoretical density; and cooling the sintered compact in a dissociated ammonia atmosphere. E. Klar, M.A. Pap, and SCM Corp. Off. Gaz., 13 Dec. 1983, Patent no. US4420336 (USA), 11 Feb. 1982. ISSN 0360-5132. 54-0649 Deformation Measurement During Powder Compaction by a Scanning-Moir6 Method. The mechanical behavior of Cu powders during compaction has been studied in previous papers. It has been shown that a Moird method may be used to determine the resulting strain distribution. Some difficult i e s w e r e encountered, however, in t h e m e t h o d used. Therefore, an imageprocessing system employing a personal computer to analyze the Molt6 pattern is introduced. Many strain distributions obtained in this way from Moird-fringe patterns are presented. Using this image-processing system, a scanning-Moir~ technique is developed in which the master grating is replaced by the scanning lines of a television camera. The use of image processing in conjunction with the mismatch technique allows measurement of both small and large strains from one image picture. 14 r e f . - - A A Y. Morimofo, and T. Hayashi. Exp. Mech., June 1984, 24, (2), 112-116, [in English]. ISSN 0014-4851. T h e E f f e c t o f P o r e S i z e a n d H e a t Treatment on the F r a c t u r e Toughness of Pressed and Sintered Ancoloy SA Powdered S t e e l . Ancoloy SA powder, adjusted by addition of carbon to give a composition which was slightly hypoeutectoid, was tested in a pressed and sintered condition. Porosity was varied by changing the pressing pressure and structure was varied by heat treatment. The effect of pressing pressure, through void content and shape, dominated the toughness change, although heat treatment produced a large increase in yield stress, t 0 r e f . - - A A J.T. Barnby, and D.C. Ghosh. J. Mater. Sci., June 1984, 19, (6), 2073-2078, [in English]. ISSN 0022-2461. 54-0650
The Breakup and D i s t r i b u t i o n o f S u r f a c e O x i d e s Through Processing of P / M Aluminum Alloy 7091. ( P a m p h l e t ) . Surface oxides on P/ 54-0651
M AI alloy 7091 powder were followed through the standard processing steps to define their identities, breakup and distribution and the resulting microstructure. The surface oxide layer consists mainly of AI203, its hydrates and a small amount of fine MgO crystallites. Vacuum degassing after cold compaction dehydrates the layer into AI203 film and forms additional MgO crystallites. Trace amounts of ZnO, 3,-AI203 and MgAI204 crystallites are also formed during degassing. Hot pressing and forging or extrusion do not change the composition. Hot pressing crumbles the oxide film and separates MgO crystallites. These are present as dense arrays in p o w d e r particle boundaries (PPB's). Subsequent processing redistributes the oxide arrays into aligned stringers and breaks up large fragments and clusters. Stringer spacing and grain size decrease and PPB area increases. Inter-oxide spacing in stringers is increased with increasing PPB area. A-upset forging results in continuous stringers associated with PPB's and grain boundaries. This association continues until a critical strain is e x c e e d e d in the case of extrusion. Beyond this critical strain PPB's are not observed and oxide stringers are no longer continuous. The uniformly distributed oxides apparently do not affect mechanical properties and microstructural stability. 31 r e f . - - A A Y.-W. Kim, W.M. Griffith, and F.H. Froes. Metals/Materials Technology Series [Proc. Conf.], Philadelphia, Pa., U.S.A., 3-6 Oct. 1983, American Society for Metals, Metals Park, Ohio 44073, U.S.A., 1983, Paper No. 8305-048, Pp 19, [in English]. 54-0652 The Microstructure of Mechanically Alloyed Aluminum Alloys. ( P a m p h l e t ) . An in-depth microstructural characterization of each processing step of MA A I - - M g - - F e alloys has p r o d u c e d a g e n e r a l i z e d description of the microstructural evolution of the alloys. The basic mechanism of the microstructural evolution was found to be recrystallization a n d / o r grain growth. Both grain boundary and dislocation energy set as driving forces, while dispersoid particles exert a retarding force. In the as-attrited MA AI powder, grain growth was readily induced, whereas the as-extruded material showed a strong resistance to further recrystallization a n d / o r grain growth. The microstructure of MA AI alloys was very stable in terms of grain growth and dispersoid coarsening when heat treated as high as 540*C. It was also found that IN-9021 was more stable than IN-9051. 14 ref.--AA
106
VOL. 4, NO. 1, JULY 1985
S.K. Kang. Metals/Materials Technology Series [Prec. Conf.], Philadelphia, Pa., U.S.A., 3-6 Oct. 1983, American Society for Metals, Metals Park, Ohio 44073, U.S.A., 1983, Paper No. 8305-051, Pp 10, [in English].
54-0662
D e n s i f i c a U o n K i n e t i c s o f M e t a l P o w d e r s in Hot Pressing in Porous Shells. IlL--Experimental I n v e s t i g a t i o n . ( T r a n s l a t i o n ) . See preceding abstracts. V.M. Gorokhov, M.S. Koval'chenko, and O.V. Roman. Soy. Powder Metal/. Met. Ceram., Sept. 1983, 22, (9), 708-712, [in English]. ISSN 0038-5735. 54-0666 P r o d u c t i o n o f Composite Magnetoabrasive Materials Under S o l i d - P h a s e C o m b u s t i o n C o n d i t i o n s . ( T r a n s l a t i o n ) . See preceding abstract. A.B. Lyashchenko, M.D. Krymskii, L.N. Tul'chinskii, and B.V. Khaenko. Sov. Powder Metal/. Met. Ceram., Sept. 1983, 22, (9), 726-731, [in English]. ISSN 00385735.
5 4 - 0 6 7 0 Wear Resistance of Hard-Metal M a t r i x M a t e r i a l s Alloyed With Phosphorus. ( T r a n s l a t i o n ) . See preceding abstract. D.Kh. Bronshtein, E.S. Simkin, and A.N. Mikhnovskaya. Soy. Powder Metal/. Met. Ceram., Sept. 1983, 22, (9), 770-773, [in English]. ISSN 0038-5735. 54-0673 H o t Forming P / M P a r t s . A brief review of parts of the hot forming system is presented. The first two steps are making preforms and sintering, followed by hot forming in which both the tool and the part are heated. The typical processing sequence for hot forming P / M parts is described. Machining, heat treating and quality control following the hot forming operation are described. Improved properties due to nearly theoretical density achieved are the reasons for hot forming. Typical properties of hot formed P / M parts with modified 4600 series steels (H-01), low alloy (H-02) and 1040 type steels are presented. Magnetic properties of hot formed P / M irons are also provided. Considerations in design of parts, tolerances and uses of hot formed P I M parts are discussed.--S.K.B. J.R. Gleixner. Met. Prog., Dec. 1983, 124, (8), 33-37, [in English]. ISSN 0026-0665. 54-0684 The Improvement of Damage Tolerance in S i n t e r e d a n d C a s t Components Due t o t h e E l i m i n a t i o n o f I n t e r n a l D e f e c t s by Hot I s o s t a U c Pressing. A HIP (hot isostatic pressing) treatment can remove residual porosity in cast or sintered materials if the pores are not surface connected. Consolidation conditions can be determined from the rheological behaviour of the materials. HIP treatments are generally applied as a preventative measure to increase damage tolerance. A number of examples are presented (Ti alloy castings, AI alloy castings, superalloy castings, sintered components) in which HIP treatments have beneficial effects. Applications in other areas are envisaged, for example the HIP treatment of welds to improve their soundness. 21 ref.--J.M.S. G. Raisson. Matdr. Tech. (Paris), Nov.-Dec. 1983, ( t 1-12), 339-344, [in English and French]. ISSN 0032-6895. 54-0685 [ C e r a m i c ] Density Means T o u g h n e s s . Engineering ceramics offer the best possibility of raising the operating temp. and efficiencies of diesel and turbine engines, and widespread use could save the European Economic Community s billion/year. The susceptibility to thermal shock is reviewed in terms of Griffith cracking, ceramic microstruclures, and transformation toughening giving bending strengths c o m p a r a b l e with t h o s e of high-tensile steel. The transformation-toughening mechanism is illustrated and the importance of densification of the ceramic powders is emphasized with reference to its augmentation by trace additions of, e.g. MgO. The phase diagram of sialon at 1750~ is specifically considered.--J.R. R. Brook, and F. Riley. New Sci., 26 Jan. 1984, 101, (1394), 17, [in English]. ISSN 0028-6664. 54-0688 A l u m i n i u m Nitride Powder a n d S i n t e r e d P r o d u c t . A fine powder of aluminum nitride having an average particle diameter of not more than 2 microns and comprising at least 94 wt.% aluminum nitride, at most 3 wt.% bound oxygen and at most 0.5 wt.% as metal of metal compounds as impurities is prepared from a fine alumina powder and a fine carbon powder as starting materials. The alumina and carbon powders are intimately mixed, fired at 1400-1700~ and the resultant powder heated at 600-900~ to remove unreacted carbon. The fine aluminum nitride powder is also useful as a raw material for providing a sintered body having a high purity and a high density such as at least 2.9 g / c m 3 and for alpha-Sialon, beta-Sialon and AIN poly-types, as an addition aid in various ceramics. N. Kuramoto, H. Taniguchi, and Tokuyama Soda KK. 11 Apr. 1984, Patent no. GB2127390A (UK), 19 Sept. 1983. 54-0689 S i l i c o n Nitride Ceramic Bodies. Silicon nitride compact bodies are sintered using one or more sintering aids selected from the group comprising the oxides of magnesium, yttrium, chromium, molybdenum, iron, manganese, tungsten, cobalt, vanadium, uranium, nickel, titanium, hafnium, zirconium, niobium and tantalum. The method of the invention includes the nitriding of silicon using such sintering aids. J.W. Cotton, R. Swindells, and British Ceramic Research Assoc. 23 May 1984, Patent no. GB2129788A (UK), 30 Sept. 1953. 54-0690 F o r m i n g C o a t i n g s b y H o t I s o s t a t i c C o m p a c t i o n . A thermal barrier coating consists of a composite material of oxide particles of low thermal conductivity in a binder, densified and bonded to a surface of a component by hot isostatic pressing of the powders. The coating may be an oxide such as zirconia in a metal binder such as an alloy of chromium, aluminium and yttrium with cobalt a n d / o r nickel (MCrAIY) or an oxide such as zirconia in a ceramic binder such as zirconium silicate which is ductile at elevated temperature. A metallic interlayer of an MCrAIY type of alloy may be used. The ceramic particles are preferably hollow spheres for a thermal barrier coating or where light weight is necessary. Other coatings described are abrasive, abradable or lightweight shrouds on rotor blade tips. R.I. Conolly, R.G. Ubank, and Roils R o y c e Ltd. 31 May 1984, Patent no. GB2130244A (UK), 4 Mar. 1983.
J. APPLIED METALWORKING
54-0691 Tantalum Powder Composition. An ingot derived agglomerated Ta powder composition is disclosed. It comprises granular tantalum powder less than t 0 microns in size and including 20-40% by weight of a flaked tantalum powder formed by deforming a granular tantalum provided. M.F. Getz, M.J. Maggio, B.F. Hitch, and Cabot Corp, 31 May 1984, Patent no. GB2130246A (UK), 3 Nov. 1983. 54-0692 A Method for Eliminating or Minimising the E f f e c t s o f Defects in M a t e r i a l s . In an example, a rotor disc for a gas turbine engine is formed to an approximate shape by stacking together "sticks" of metallic material in an evacuated container and bonding them together by a hot isostatic pressing process. The "sticks" are produced by extruding a starting body, for example, of metal powder material, to produce an elongation of up to twenty times and then cutting them to the appropriate length. By this means any non-metallic inclusions in the powder are broken up, inspection of the sticks and rejection of defective ones becomes easier, and the sticks can be oriented so that the effects of any remaining defects can be minimised. R.I. Conolly, and Roils Royce Ltd, 31 May 1984, Patent no. GB2130509A (UK), 16 Nov. 1982.
54-0693
High Density Boron Nitride-Containing Sintered Body for
from steel powders in approximately one hour. The process forms part of an effort by the Ministry of International Trade and Industry of Japan, to develop flexible manufacturing systems (FMS) for low-volume production of complex shapes requiring the minimum amount of final m a c h i n i n g , - - A A Met. Powder Rep., Jan, 1984, 39, (1), 23-25, [in English]. ISSN 0026-0657. 54-0701 A u t o m a t e d P M Parts Conveying System. Highly automated Dyna-Slide systems are described for the conveyance of relatively fragile green compacts from press to furnace. The systems do not have moving belts, but shift the parts by vibrating a surface carrying bristles angled in the direction of desired movement. An additional advantage in PM applications is that parts vibration removes excess metal powder.--T,W. Met. Powder Rep., Jan. 1984, 39, (t), 26-27, [in English]. ISSN 0026-0657. 54-0702 H o t I s o a t a U c P r e s s i n g - - E q u i p m e n t and Applications. Research- and commercial-scale installation layouts and performances are very briefly reviewed, with some emphasis on fast-cooling systems. Important new applications in ceramics and composite structures are briefly d e s c r i b e d . - - T . W . P.E. Price. Met. PowderRep., Jan. 1984, 39, (1), 28-29, [in English]. ISSN 00260657.
C u t t i n g T o o l a n d a M e t h o d o f Producing the Same. A high density boron nitride-containing sintered body is disclosed consisting of 60-95 vol.% high density boron nitride and 40-50 vol.% of metal alone or in admixture with ceramic. The high density boron nitride consists of 60-95 vol.% cubic system boron nitride and 40-50 vol.% wurtzite-structured boron nitride, and the cubic system boron nitride has an average particle size of at least 5 times that of the wurtzite-structured boron nitride, has high cutting performance and is suitable as a cutting tool for chilled roll, ultra-heat resisting alloy, cast iron, and the like. T. Akashi, M. Araki, and Nippon Oils and Fats. 6 June 1984, Patent no. GB2130604A (UK), 30 Sept. 1983.
genban to control and monitor the functions of powder compacting presses is described. The microprocessor system allows the production of consistent quality metal powder compacts, and at the same time ensures that the powder press and tooling operate at maximum efficiency. This system should, therefore, improve the productivity of the powder pressing operations in PM part and cutting tool insert plants.--AA W. Trapp. Met. PowderRep., Jan. 1984, 39, (1), 32-33, [in English]. ISSN 00260657.
54-0694 M e t a l l i c P a r t i c l e Generation Device. A device for producing metallic particles, such as stainless steel shot for peening, utilizes the Coanda effect to draw one stream of gas toward another stream of gas flowing over a foil. Molten metal is introduced between the two gas streams, and the resulting interaction breaks up the molten metal flow into particles of appropriate size, shape, composition, and the like. E.N. Stuck, K.D. Pidney, H. Gifford, and Teledyne Industries. 6 June 1984, Patent no. GB2130605A (UK), 23 Nov. 1982.
54-0704 P M S t a i n l e s s S t e e l Seamless Tubes by H o t E x t r u s i o n . A new plant is described in which seamless stainless steel and Ni-alloy tubes are produced, having good mechanical and corrosion-resistant properties. The process includes inert gas atomization of melted scrap to give spherical powders with homogeneous distributions of alloying elements; cold isostatic pressing to produce billets; and hot extrusion of tubes from the compacted billets.--T.W. B. Williams. Met. PowderRep., Jan. 1984, 39, (1), 34-36, [in English]. ISSN 00260657.
54-0695 Dispersion Strengthening and S o l i d S o l u t i o n Strengthening o f Nickel Base Alloys With TaC and TiC Additions, Using Powder M e t a l l u r g i c a l T e c h n i q u e s . Ni can be substantially strengthened by additions of Ta, W, Mo and Nb, and Ni base alloys by TaC and TiC, the mechanical properties depending directly on the amount of carbide present and its grain size. Room temperature hardness, tensile strength, hot hardness, stress-rupture and oxidation resistance were correlated with microstructure. N i - - C r - - W - - M o - - T i C alloys in particular were found to have properties suitable for high temperature uses.--D.P. R.P.H Fleming. Bull. Cercle Etud. ME,taux, June 1983, 15, (2), 2.1-2.31, [in English and French]. ISSN 0366-4104.
54-0705 R a p i d S o l i d i f i c a t i o n Produces New Generation of Aerospace Alloys. The production of RSR 185 Ni-based superalloy powders and their use for turbine blade construction are briefly reviewed. Recent developments in the preparation of Ti alloy p o w d e r s by rapid s o l i d i f i c a t i o n rate techniques are also discussed.--T.W. Met. Powder Rep., Jan. 1984, 39, (t), 47-48, [in English]. ISSN 0026-0657.
M e c h a n i c s o f F r a c t u r e in H o t R o l l e d A I - - 7 M g Alloy Prepared From Rapdily Solidified Powder. A I - - 7 M g rapidly solidified powders were pro54-0696
cessed by extrusion to prepare billets for rolling. The billets were rolled at temperatures between 300 and 500~ and tested in tension. The fracture surfaces were examined and it was found that in the absence of larger precipitates the fracture mechanism is dependent upon oxide content and morphology inherent in the air atomized powders. When larger particles are present (1-3 #m), the fracture is initiated and propagated by the particles; the oxide does not feature in the fracture process. Some billets were rolled in multipasses and it is shown that a maximum of about 40% reduction may be obtained before the oxide particles cause exfoliation by fracture at prior particle boundaries. It is concluded that the thermomechanical process route for the production of engineering materials must pay particular attention to the distribution of the oxide film and to maintaining the thermal stability of the atomized p o w d e r s . - - A A T. Sheppard, and M.A. Zaidi. Met. Sci., May 1984, 18, (5), 236-240, [in English]. ISSN 0306-3453. 54-0698 I n j e c t i o n M o u l d i n g Produces Complex PM Parts. Metal injection moulding (MIM) is a new cost-efficient and productive PM manufacturing technology with many advantages over conventional P M Low capital investment and operating costs, the absence of material waste, environmental safety and above all, the virtually unrestricted freedom to plastically shape intricate geometries into isotropic and near-full density metal parts with, in most cases, little if any secondary operations, make this technology very attractive in many areas of application. The process is d e s c r i b e d . - - A A R. Billiet. Met. Powder Rep., Jan. 1984, 39, (1), 13-16, [in English]. ISSN 00260657. 54-0699 N e w A p p l i c a t i o n s o f C o l d Isostatic Pressing in Powder M e t a l l u r g y . Cold isostatic wet bag pressing usually is a low production rate process, since filling, demoulding, and maintenance of the rubber moulds call for relatively much manual labour, and the cycle times of available equipment often allow 'gnly a few compactions per hour. Therefore it is absolutely necessary to find typical applications in which special advantages outweight these drawbacks of the process. Several new applications of wet bag pressing of metal powders are discussed, indicating the decisive benefit in each c a s e . - - A A J. Getswa, R. Ohiig, and P. Beiss. Met. PowderRep., Jan. 1984, 39, (1), 17-22, [in English], ISSN 0026-0657. 54-0700 H I P [ H o t Isostatic Pressing] Technology for F l e x i b l e Manufacturing Systems. Kobe Steel Ltd of Kobe, Japan has developed a hot isostatic pressing process which has the capability to produce large preforms
J. APPLIED METALWORKING
54-0703 Electronic Control and Monitoring Devices on Powder Presses. The "Press Controller" system developed by Dorst-Maschinen und Anla-
54-0708 M a t r i x Tungsten Electrodes for Flash Lamp Applications by P / M T e c h n i q u e s . Porous tungsten electrodes with up to 40% porosity were prepared from metal powders. The powder was mixed with 1% w a x solution of CCI4, dired, compacted at 20 tsi, dewaxed at 400~ presintered at 9 0 0 ~ and sintered at 1350-1400~ in hydrogen atmosphere for 2 h. Electrodes with lower porosity (15-24%) would require addition of Pd (0.01%) as chloride to the powder and a high sintering temperature (1800~ Flash lamps were subsequently constructed using porous electrodes infiltrated with B a g which reduced to Ba atoms on vaporisation in the chamber to provide a peak current. Tests are in progress relating the life of lamps with the porosity of the sintered eleetrode.--B.C. B.B. Trivedi et aL PMAI NewsL, Sept. 1983, 9, (4), 17-20, [in English]. 54-0709
Application
of
P/M
Technique
to
High
Speed
Steel
Production. High productivity demands high performance from cutting tools. Conventional high speed steel tools cannot meet the challenges posed by new alloys such as superalloys, Powder metallurgy techniques have been applied to produce HSS and other grades having better performance. The paper reviews the various P / M techniques used in the production of HSS and other tools including the AseaStora and the Powdrex processes. The work on evaluation tests of P / M and conventional tools is compared. Studies on the effect of variables such as powder characteristics, consolidation procedures and the heat treatment on the P / M tool life and performance are also presented. Chemical and physical vapour deposition techniques used for coating the tool steels are discussed and the effect of coating on the P / M tool performance is reviewed. 57 r e f . - - A A M.K.B. Nair, and C.V. Gokularatnam. PMAINews/., Sept. 1983, g, (4), 21-33, [in English]. 54-O712 M e t h o d o f Making Products From Powders of Tool Steels. A method of making products from powders of tool steels comprises charging a powder into a capsule, sealing the capsule, heating and then extruding the capsule with the powder contained therein, wherein the heating of the sealed capsule is carried out in two steps wherein sealed capsule is first heated up to a temp. of 700-tO00~ whereupon it is then depressurized and heated up to a temp. of 1050-1200 ~C. A.K. Petrov et al. Off. Gaz,, 24 Jan. 1984, Patent no. US4427626 (USA), 13 Feb. 1980. ISSN 0360-5132, 54-0713 Process for Producing Metallic Chromium Plates and Sheets. A process for producing metallic Cr sheets from metallic Cr powders comprises: rolling metallic Cr powders; sintering rolled sheets in a temp. range 900-1400~ rerolling the sintered sheets with a reduction ranging from 5-50%; and annealing the rerolled sheets. Y. Masuda, R. Watanabe, S. Imura, K. Sakiyama, and Toyo Soda Manufacturing Co Ltd. Off. Gaz., 31 Jan. 1984, Patent no. US4428778 (USA), 28 Sept. 1981. ISSN 0360-5132.
VOL. 4, NO. 1, JULY 1985
107
54-0~16
Rapid Solidification Processing of A l - - C u - - L i - - M g
Alloys.
Aluminum alloys containing up to 3 wt.% Li and additions of Cu and Mg were rapidly solidified by melt spinning. Their composition was derived from a ternary A I - C u - - M g reference alloy comparable with 2024, and was obtained by increasing the Li content and decreasing the Cu content. A modified melt spinning technique in which the ribbons are cut into pieces immediately, whereafter the pieces are hot extruded without previous cold compaction and handling of the particulate in vacuum or inert gas was used. A modified heat treatment based on the assumption that the precipitation sequence in A I - - C u - - L i - - M g alloys consists of independent precipitation of A, (AI--Li) and S' (AI--Cu--Mg) was designed. Existence of these independent precipitation sequences is confirmed by transmission electron microscopy; interaction between these precipitation reactions is observed by differential scanning calorimetry.--NTIS B. Vanderbrandt, P.J. Vanderbrink, H.F. Dejong, L. Katgerman, H, Kleinjan, and Technische Hogeschool (Netherlands), N84- t 9560, Mar, 1983, Pp 15, [in English]. 54-0717 Shock Compaction of Molybdenum Powder. Shock recovery experiments which were carried out in the 9-12 GPa range on 1.4 distension Mo and appear adequate to compact to full-density (45 (a)m) powders were examined. The stress levels, however, are below those calculated to be from 100 to 22 GPa which a frictional heating model predicts are required to consolidate 10-50 (a)m particles. The model predicts that powders that have a distension of m = 1.6 shock pressures of 14-72 GPa are required to consolidate Mo powders in the 50-10 (~)m range.--NTIS T.J. Ahrens, D. Kostka, T. Vreeland, Jr., R.B. Schwarz, P. Kasiraj, and California Institute of Technology. N84-17369, Sept. 1983, Pp 5, [in English].
54-0719 Synthesis and Properties of Elevated-Temperature P / M Aluminum Alloys. High-temp. alloys, to maintain their strength during long-time exposure at high temp., must have stable microstructures. The dispersed phase coarsening rates in the A I - - 7 , 5 F e - - 3 . 5 C e and A 1 - - t O F e - - 1 , 5 M o - - 1 V alloys, developed for high-temp, applications, were compared at 475 and 575~ The dispersed particles in the A 1- - l O F e - - 1.5Mo-- 1V alloy coarsen faster at both temp. than the particles in the A t - - 7 , 5 F e - - 3 . 5 C e , showing that the latter alloy is more stable at these temp. Since the diffusion in diffusion-controlled coarsening usually occurs by a vacancy mechanism, plastic deformation should increase the rate of particle coarsening since plastic deformation increases the vacancy concentration. This has been confirmed in combined creep and coarsening studies with the A 1 - - 7 . 5 F e - - 3 . 5 C e alloy.--NTIS M.E. Fine, J.R. Weertman, and Northwestern University. AD-At35956, 29 Nov. 1983, Pp 47, [in English].
54-0720
Study of Fatigue Crack Propagation in Powder M e t a l l u r g y H o t I s o s t a t i c a l l y P r e s s e d N i c k e l - B a s e A l l o y . Initial efforts were addressed at the preparation of powders that would result in the development of HIP'd logs possessing s large range of grain sizes and grain size distributions. After several trials, it was determined that the widest range of alloy grain size could be obtained using different HIPing temp. in conjunction with different solution treatments (ST). The following treatments and grain sizes are identified: (1107 C HIP + 1121 C ST (ASTM No. 13)); (1107 C HIP + 1149 C ST (Duplex size ASTM average 8-9)); (1107 C HIP + 1177 C ST (ASTM No, 6-6.5)); (1246 C HiP + 1149 C ST (ASTM No. 4)), Further aging treatments are planned at 650 and 800~ to obtain fine and coarse 3' precipitate sizes, respectively. Initial fatigue crack propagation tests were completed with both material and computercontrolled test system performing in a well-behaved manner. Crack closure measurements were obtained.--NTIS R,W. Hertzberg, and Lehigh University. AD-A139290, 31 Jan. 1984, Pp 11, [in English]. 54-0723
An A s s e s s m e n t o f P o w d e r M e t a l l u r g y Today and Its F u t u r e
P o t e n t i a l . ( P a m p h l e t ) . The present level of technology is briefly reviewed in four areas of powder metallurgy: hot forging/forming (P/F), cold forging of sintered preforms, injection molding and sintering of metal powder/plastic mixtures and high-temp, sintering. Some historical background on the factors that have slowed the market acceptance of P/F are reviewed as a guide to understanding future growth. Several examples of current commercially produced parts (4620, N i - - M o steel, 316L, stainless steel) are cited for each technical area. 55 r e f . - - A A L.F. Pease, II1. Passenger Car Meeting [Proc. Conf.], Dearborn, Mich., U.S.A., 6-9 June 1983, SAE, 400 Commonwealth Dr., Warrendale, Pa. 15096, U.S.A., 1983, SAE Tech. Paper Series No. 831042, Pp 17, [in English]. W h a t Automotive Design Engineers Require From the P / M Industry. ( P a m p h l e t ) . A case is presented for revision and augmentation of P / M specifications and standards. It focuses upon the unique properties of these materials and how they ere currently treated. Using an example comparison between P / M steels (4815) and cast iron, some of the major problems encountered by designers are illustrated. Recommendations for needed changes and additions to existing specifications end standards for P/M steels are made. 12 r e f . - - A A S.M. Kaufman, and S. Mocarski. Passenger Car Meeting [Proc. Conf.], Dearborn, Mich., U.S.A., 6-9 June 1983, SAE, 400 Commonwealth Dr., Warrendale, Pa, 15098, U.S.A., 1963, SAE Tech. Paper Series No. 831032, Pp 9, [in English]. 54-0724
54-0725
Powdered M e t a l Gears. ( P a m p h l e t ) . The powder metallurgy process for producing gears is one of the most flexible metalworking techniques available. By adding elemental powders to the base powdered material (Fe in this case), the chemistry can be tailored to achieve mechanical properties ranging in strengths from 20 000 to 160 000 Ib/in 2. The process is capable of producing close tolerance gears in high volume at extremely economical p r i c e s . - - A A D.W. Pantano. International Off-Highway Meeting [Proc, Conf.], Milwaukee, Wis., U.S.A., 12-15 Sept. 1963, SAE, 400 Commonwealth Dr., Warrendale, Pa, 15096, U.S.A., 1983, SAE Tech. Paper Series No. 831265, Pp 5, [in English]. 54-0728
Superalloys for Aerospace by Powder M e t a l l u r g y . The trends in superalloys from the early days of the gas turbine engine to the present are outlined, indicating where powder metallurgy has been involved. The current develop-
108
VOL. 4, NO. 1, JULY 1985
ments and uses are summarized and comments are made regarding possible future trends. Stress rupture properties of several Ni-base superalloys, including Udimet 500, Nimonic 105 and 115, Incoloy alloy MA956, MAR-M200 IN853 and their chemical compositions are cited. 7 r e f . - - A A V,A. Tracey, and S,N. Ansnt Narayan, Trans. Powder Metall. Assoc. India, Sept. 1983, 10, 1-7, [in English]. 54-O731
Development
of Silver/Nickel
Contact Materials by P/M
Technique. The electrical contact material is a very vital part of the electrical transmission and electronic equipment. Most of these materials are made of precious metal and have involved sophisticated production and fabrication technologies. The various parameters involved in the production of Ag and Ag/Ni contact material (Ag--10Ni, A g - - 2 0 N i and Ag--30Ni) by powder metallurgy techniques are outlined. The various parameters for the production of A9 and Ag/Ni contact materials, such as characteristics of powder particles, compacting pressure, sintering and annealing temp., etc., were studied and their influence on the properties of the finished product are discussed. The physical and mechanical properties of the product were evaluated for their suitability for strategic applications.--AA V.A. Altekar, R.K, Dubey, S.K. Chaudhury, S,P. Chakraborty, and P.K. Dey. Trans. PowderMetall. Assoc. India, Sept. 1983, 10, 68-73, [in English].
54-0732 E v a l u a t i o n o f the Performance o f a M e c h a n i c a l A t t r i t o r for Size Reduction of Cast Iron Swarf. The performance characteristics of a mechanical attritor were evaluated for the size reduction of gray cast iron machined swart. The effect of such variables as speed of impeller, time of grinding, ratio of ball weight to charge weight and the use of mixed-size balls on the cumulative weight percent of various size fines and the specific surface area produced was examined. Based on the results of an optimum impeller speed of ~ 550 rpm and an optimum grinding time of ~ 1 h were arrived at for the production o f - - 8 0 mesh fines. The mechanical attritor generated ~ 20 times more specific surface area than that generated by a conventional ball mill operating for the same milling time of 1 h under optimum conditions. The rate of production of the fines was considerably higher than by conventional ball milling.--AA V.M. Pathare, S.L. Palkar, V. Gopinathan, and P. Ramakrishnan. Trans. Powder Metal/. Assoc. India, Sept. 1983, 10, 74-78, [in English]. 54-0734 M e t a l s Handbook, Ninth Edition. VoI. 7. Powder Metallurgy. (Book). This authoritative handbook, prepared with the help and guidance of the ASM Powder Metallurgy Committee, with over 250 authors and reviewers contributing their expert knowledge and practical experience, packs a tremendous amount of information into the most comprehensive single volume available today about powder metallurgy. Discussion is divided into articles that cover basic production processes of current importance and articles that cover the production of individual powders from ferrous and nonferrous metals. The topics of characterization and testing are divided into three main areas: methods for taking a representative sample; methods for determining particle size, shape, chemistry and porosity; and specific tests for determining the processing behavior of metal powders. The fundamentals of compaction are discussed in articles that explain the behavior of metal powders under pressure. Other articles cover sintering atmospheres, sintering furnaces, sintering procedures for specific P/M materials. Practical and informative articles cover P / M applications that have achieved, or that are expected to achieve, production status. Reasons why powder metallurgy was selected for the application, part processing steps, design considerations, material requirements and cost savings are discussed. Numerous ref.--J.A.M. K. Mills. American Society for Metals, Metals Park, Ohio 44073, U.S.A., 1984, (Met.A, 8410-72-0645) Pp 897, [in English].
54-0735 P / M Refractory Metals and A l l o y s . I I . - - P r o p e r t i e s and A p p l i c a t i o n s . The following trends in applications of refractory metals are considered: improved properties, such as high strength, high melting point, corrosion and wear resistance or special absorptive or emissive properties which can be obtained by coating refractory metal or coating other metals with refractory metals. Superalloys are competing with refractory metals at elevatedtemp, in many applications, although refractory metals can better cope with long-term demand, and new functions for refractory metals are being developed. Tungsten alloys, heavy metal alloys, W - - C r alloy system, composites systems, W - - R e alloys, Mo, Nb and Ta are discussed. 144 ref.--C.M.L.S. A.J. Aller. Int. J. Refract. Hard Met., June 1984, 3, (2), 89-78, [in English]. 54-0736 F a c t o r s I n f l u e n c i n g D u c t i l i t y and Fracture Strength in Tungsten Heavy A l l o y s . The mechanical properties of W - - N i - - F e heavy alloys have been investigated with respect to several processing and composition variables. Variations in the tungsten powder, sintering conditions, post-sintering heat treatments and tungsten content are reported. The alloys contained 95 or 97.5% W, with a constant Ni:Fe ratio of 7:3, Sintering of three different W powders was conducted at either 1480 or 1520~ for 1 h, Post-sintering heat treatments at 1000~ were used to improve as-sintered properties, using variations in atmosphere and cooling rate. The results show the nature of the W/W and W/matrix interfaces control mechanical properties in fully densified material. A hierarchy of factors which must be controlled to optimize the mechanical properties of heavy alloys is proposed. 29 r e f . - - A A M.R. Eisenmann, and M. German. Int. J. Refract, HardMet., June 1984, 3, (2), 8691, [in English].
Properties and Production of Powder Metallurgical PVD Sources. To achieve an optimum combination of target properties for sputtering 54-0737
or ion plating, such as homogeneous composition, low level of detrimental impurities, low gas content, high density and rain. formation of flakes, powder metallurgy methods are specially favorable, offering necessary properties and economy of production, Using Mo as an example, the typical powder metallurgy production by powder treatment, compaction and sintering of target materials is discussed. Relevant properties of MolSi, Cr, CrNi, CrFe, tungsten, Re, Wf0Ti, Ta, Nb and TaNb for target materials are discussed.--AA R. Eck, H. Eiter, and P, R0dhammer. Int. J, Refract, HardMeL, June 1984, 3, (2), 92-95, [in English].
J. APPLIED METALWORKING
54-0739
Transparent AIN C e r a m i c s . Three kinds of transparent AIN have been fabricated at Fujisawa Research Laboratory, Takayama Soda Co., Ltd., Japan, by hol pressing under a pressure of 200 kgcm - 2 at 2000~ for 3 h in 1 arm nitrogen without an additive; by hot pressing under the same conditions with 0.5 wt.% CaO added; and by pressureless sintering of an isostatically pressed disk (at 2000 kgcm - 2 ) with 0.5 wt.% CaO at 1900~ for 3 h in 1 arm N. 7 ref. --J.L.B. N. Kuramoto, and H. Taniguchi. ,1. Mater. Sci. Lett., June 1984, 3, (6), 471-474, [in English]. ISSN 0261-8028. 54-0740
Ceramic Component Development for Automotive Power
Plants. Components for internal combustion engines are being developed from nonoxide and oxide ceramic materials. The properties of the most promising materials, the process technology and the design methods of the components are discussed. The present development work concentrates on components for gas turbines, turbochargers and diesel engines. The advantages of ceramics in these applications are deducted and the present state of Volkswagenwerk's component development is reported. Materials discussed are: Si3N4, SiC, ZrO 2 and mixture of AI203--TiO 2. - - A A M. Langer, P. Walzer, and J.E. Siebels. Materials and Processes, Vol. 2 [Proc. ConL], Monteux, Switzerland, 12-14 June 1984, Society for the Advancement of Materials and Process Engineering, P.O. Box 2459, Azusa, Calif. 91722, U.S.A., 1984, (Met.A., 8410-72-0649) Pp 12, [in English]. 54-0741
Local
Microstructural
Modification
in
Dynamically
Consolidated Metal Powders. Powders of 4330V steel, A I - - 6 % Si and Cu have been dynamically consolidated under well-characterized conditions using shock waves. Different regions in the final microstructures correlate well with the shock conditions during compaction, demonstrating the importance of the shock history in determining the final microstructure. Martensite is observed to form locally at powder particle surfaces in compacts of 4330V steel and interparficle melting and rapid resolidification are observed in compacts of A I - - 6 % Si. Microprobe analyses of locally melted regions in the AI alloy indicate a homogeneous distribution of 6% Si, well above the max. equilibrium solid solubility. Comparison with the structure of "splat caps", found in the starting powder, suggests that locally melted regions experience a cooling rate comparable to that obtained in splat quenching. The extent of martensite formation and local melting are in good agreement with current models for energy deposition at powder particle surfaces during consolidation. The general implications of the analysis and observations are discussed. 28 ret.--AA W.H. Gourdin. Metal/, Trans. A, Sept. 1984, 15A, (9), 1653-1664, [in English]. ISSN 0360-2133.
54-0742
Study of the Process o f C o m p a c t i n g A m o r p h o u s M e t a l l i c Alloys. ( T r a n s l a t i o n ) . See Met. A., 8311-54-1078. E.Ya. Malinochka, A.M. Durachenko, and V.T. Borisov. Russ. Meta/L, 1983, (1), 118-120, [in English]. ISSN 0036-0295. 54-0747 F u n d a m e n t a l S t u d y o f P / M Processed E l e v a t e d T e m p e r a t u r e Aluminum A l l o y s . Aluminum alloys exhibiting high strength and improved creep resistance at elevated temp. offer the potential for lower weight and reduced cost in aerospace components. Powder processing, involving controlled atomization and hot consolidation, provides a means for fabricating candidate alloys; the microstructure consists of a stable fine-scale uniform dispersion of intermetallics in the AI matrix. Retention of elevated-temp, strength has been demonstrated in a P/ M A I - - F e - - N i alloy. Atomized powder is characterized by a duplex microatructure of fine and coarse regions of FeNiAI9 (Vf ~ = 0.3) in the AI matrix. The fine microstructure is harder than the coarse microstructure and is stable up to 360~ above which its hardness decreases rapidly. There is a gradual coarsening and decrease in hardness of the initially coarse regions with increasing temp. The duplex microstructure is carried over into the hot pressed and extruded material. Changes in microstructure and hardness of the extruded material during elevated-temp, exposure are similar to those occurring in the powder form. Hot tensile test data (up to 400~ indicate that the extruded material retains ~ 60% of its ambient strength up to ~ 250~ with ductility approaching 10%. This reflects a promising level of structural stability.--NTIS A. Lawley, M.J. Koczak, and Drexel University. AD-A136154, Mar. 1983, Pp 25, [in English].
Processing, Microstructure and Property R e l a t i o n s h i p s in a Powder Metallurgy T o o l Steel. A detailed microstructural examination has
54-0748
been made of T16 high-speed tool steel processed from gas atomized powder with associated strength, toughness and hardness evaluated at elevated temp. Powders were screened into selected size fractions to include the rapid solidification regime, hot isostatically pressed and heat treated. Two HIPing temp., two austenitizing temp. and three tempering temp. were included in the study. A segregated network structure is present in the atomized powder independent of the particle size, with MC and M2C carbides present primarily at cell boundaries. After HIPing, MC, i 6 C and M2306 carbides are present in the form of individual particles in a ferritic matrix. At a given HIPing temp. the carbide size distribution for MC and M6C carbides is dependent marginally on prior particle size fraction, being broader for the coarser size fractions. Prior austenite grain size is influenced by the HIPing and austenitizing temp. and the intermediate hot forging step. MC and M6C carbide size distributions in the fully heat-treated material are influenced primarily by the HIPing temp. and to a lesser extent by the intermediate hot forging step. Strength and toughness are enhanced by hot forging. Hardness retention at elevated temp. is superior to that of commercial material. (DA8405283).--AA K.S. Kumar, and Drexel University. Dies. Abstr. Int., May 1984, 44, (11), Pp 268, [in English]. ISSN 0419-4217.
54-0751
Method o f M a k i n g M u l t i b o n d e d S i l v e r - - C a d m i u m Oxide Material. A method of manufacturing a Ag--cadmium oxide product comprises: superimposing one over another at least two layers of a Ag--cadmium oxide strip material which has an internal cadmium oxide-depleted zone; bonding the superimposed layers by hot rolling them under pressure to reduce the thickness of the combined layers and form a strip of bonded material; superimposing one over an-
J. APPLIED METALWORKING
other at least two layers of the bonded material; bonding the superimposed layers of bonded material by hot rolling under pressure to reduce the thickness to obtain product having throughout a substantially uniform distribution of cadmium oxide. L.J. Gould, Y.-S. Shah, and Engelhard Corp. Off. Gaz., 14 Feb. 1984, Patent no. US4431462 (USA), 7 June 1982. ISSN 0360-5132.
54-0767 How Furnace Zoning Can O p t i m i z e Atmosphere Efficiency. Conveyer-based processes are considered as involving a sequence of real or nominal furnace zones, with each zone requiring a particular type of atmosphere. Examples taken from sintering, brazing and heat treatment processes show how zoned atmospheres can greatly improve process economics, particularly when synthetic N2-based atmospheres are used. 12 ref.--T.W. H.S. Nayar, and D. Schaeffer. Met. PowderRep., Feb. 1984, 39, (2), 82-84, [in English]. ISSN 0026-0657. 54-0768 E n e r g y S a v i n g in the Production of PM P a r t s . With recent increases in energy costs, energy saving has become the most important factor in reducing the cost of producing ferrous-base PM components. Some 75% of energy consumed in a typical PM plant is used in sintering furnaces, carburising and steam treatment. Techniques introduced at some Japanese plants which have resulted in energy savings of more than 25% are described. These activities have also brought improved productivity in the PM part production process as well as improved quality.--AA M. Onoda, and T. Terada. Met. Powder Rap., Feb. 1984, 39, (21, 86-67, [in English]. ISSN 0026-0657.
54-0769 Energy Efficiency and Productivity of Vacuum Sintering Furnaces. Recently introduced vacuum combination cycle furnaces offer significant improvements over previous furnaces in the sintering of most grades of carbides and other PM products. Further refinements in vacuum furnace design are presently being incorporated to offer even greater control and performance. Fully automatic control using microprocessors simplifies the operation considerably and eliminates the risk of operator error. Energy input is controlled by thyristors which are more efficient than transducers. Recent innovations introduced by Degussa AG of West Germany into their vacuum furnaces to improve energy efficiency and productivity of the sintering process are d e s c r i b e d . - - A A R. Bauer. Met. Powder Re/)., Feb. 1984, 39, (2), 88-91, [in English]. ISSN 00260657. 54-0770 High Temperature W a l k i n g B e a m Furnace for the Sintering Industry. The operation of a typical walking-beam furnace when used for sintering processes is briefly described. This method is used instead of conventional conveyor furnaces when temp. in excess of 1100~ are required. Typical applications include the sintering of UO 2 pellets, Mo bars, and automobile spark plug bodies. --T.W. J. Francis. Met. Powder Rap., Feb. 1984, 39, (2), 92-94, [in English]. ISSN 00260657.
54-0783 Structures and Properties of Rapidly S o l i d i f i e d 9 C r - - l M o Steel. Irradiation-induced shifts of the DBTT and possible hydrogen embrittlement of ferritic steels are considered major problems for CTR applications. Rapid solidification and, in particular, liquid dynamic compaction (LDC) has been studied in developing 9 C r - - t M o steel as a candidate first-wall material. Structural refinements, such as reduction of segregation, fine grain size and fine size of secondphase particles, are retained in this process and this will have a favorable effect on fracture properties. LDC also has the potential of preparing first-wall components directly from the melt and this would have an economic advantage over conventional ingot technology. 9 r e f . - - A A J. Megusar, E. Laverhia, P. Domalavage, O.K. Harling, and N.J. Grant. Fusion Reactor Materials [Proc. Conf.], Albuquerque, N. Mex., U.S.A.. 1g.22 Sept. 1983, J. Nucl. Mater., May (11) 1984, 122, (1-3), 789-793, [in English]. ISSN 0022-3115.
54-0786 S t r e s s ~ S t r a i n State of Powder Being Rolled in the Densiflcation Z o n e . - - I I . (Translation). See Met. A., 6409-54-0625. V.P. Katashinskii, and M.B. Shtern. Sov. Powder Metal/. Met. Ceram., Dec. 1963, 22, (12), 972-976, [in English]. ISSN 0038-5735.
54-0787 Effect of Surface Roughness of Roils and Relative Density of Powder on the Strip Thickness and Density. (Translation). See Met. A , 6409-54-0626. O.A. Katrus, and A.K. Radchenko. Soy. Powder Metal/. Met. Ceram., Dec. 1983, 22, (12), 976-978, [in English]. ISSN 0038-5735.
54-0792 Effect of a Method of Preparation of a Nickel--Phosphorus M a s t e r Alloy on the Structure and Properties o f a C h r o m i u m Carbide Alloy Cemented With 15% o f a B i n d e r B a s e d on T h i s A l l o y . ( T r a n s l a t i o n ) . See Met. A., 8409-54-0631. V.A. Maslyuk. Sov. Powder Metal/. Met. Ceram., Dec. 1983, 22, (12), 1003-1006, [in English]. ISSN 0038-5735.
54-0799
Progress of Powder Metallurgy in North A m e r i c a . Economic recovery of the PIM industry parallels automotive recovery, promising 10%lyear growth by 1985 as recognition of its unique advantages sparks process and proparty improvements. Automotive applications and developments are discussed. Forging, isostatic pressing, rapid solidification and injection molding are described, noting 50% P/M forging savings, Ni-base 626 alloy powdi~r superior to 4130 for well head components, tripled fatigue life for P/M 7091 AI alloy over 7075 ingot and small, complex injection molded 316L stainless, Ni, Fe and tool steel parts. Industry influences described are the development campaign and new standard No. 35.--J.V.R. K.H. Roll, and P.K. Johnson. Int. J. PowderMetall. Powder Technol., July 1984, 20, (3), 185-186, 168-190, 192, [in English]. ISSN 0361-3488.
VOL. 4, NO. 1, JULY 1985
109
54-0800
Powder Metallurgy in the Federal Republic of Germany.
P o w d e r metallurgy has an important and growing role in Germany, aided by societies promoting cooperation, training, R & D and standardization. Detailed R & D activities include basic mechanisms, ceramics, high-strength sinterecl steels, cemented carbides, biphase system properties, materials and explosive compaction. Companies involved in structural parts, cemented carbides, refractories, magnetic, electrical and special applications and powder manufacture are noted, Processes, product lines and latest developments are covered.--J,V.R, F. Thummler, and R. Oberacker. Int. J. PowderMetall. Powder TechnoL, July 1984, 20, (3), 193-197, 199-202, 204, [in English], ISSN 0361-3488. 54-0801 P r e s e n t S t a t u s o f Powder Metallurgy in France. French P / M production, 1 / 2 5 U.S., involving six firms besides carbide manufacturers, remains stable while competition depresses prices. Production types are tabled and locations are mapped. Research has produced high tensile steels, friction materials, AI alloys, N i - - M o and N i - - C r automotive steels, magnets and Mo and heavy metal products. Manufacturing developments, now mostly automation and computerization, are outlined and P / M organizations are listed.--J.V.R. M. Eudier. Int. J. PowderMetall. Powder TechnoL, July 1984, 20, (3), 205-207, [in English]. ISSN 0361-3488.
54-0802
Powder Metallurgy in Scandinavia. Sweden manufactures ferrous and hard metal powders and products, hot pressed steel blanks, semifinished steel products, wear resistant coatings and P/M equipment; Finland, extra-fine Co powders, cemented carbides and hard metal tire studs; Denmark, P / M parts and cemented carbides. All pursue P / M R & D, including Norway. Companies involved are listed and products and processes are described,--J,V.R. P.G. Arbstedt, Int. J. PowderMetall. Powder Technol., July 1984, 20, (3), 209-211, 213-214, 216-217, [in English]. ISSN 0361-3488. 54-0803
Present S t a t u s o f Powder Metallurgy in I n d i a . The Indian P / M in-
54-0817 Evaluation for Force and Kinematic Parameters in the Compression of Sintered Porous Blanks. (Translation). See Met. A., 840954-0639. I.D. Radomysel'skii, G.A. Baglyuk, G.E. Mazharova, and G.G. Serdyuk. Soy. Powder Metal/. Met. Ceram., Nov. 1983, 22, (11), 874-877, [in English]. ISSN 00385735.
54-0818 Continuous Shaping of Tubes From Metal Powders. (Translation). See Met. A., 8409-54-0640. A.V. Stepanenko, L,A. Isaevich, and A.A. Veremeichik. Soy. Powder MetalL Met. Ceram., Nov. 1983, 22, (11), 878-882, ]in English]. ISSN 0038-5735. Stressed--Strained S t a t e o f Powder Being Rolled in the Densification Zone. I . - - M a t h e m a t i c a l Model of Rolling in the Densification Zone. (Translation). See Met. A., 8409-54-0641. 54-O819
V.P. Katashinskii, and M.B. Shtern. Soy. Powder Metal/. Met. Ceram., Nov. 1983, 22, (11), 882-885, [in English]. ISSN 0038-5735.
54-0820 Computer Modeling and Investigation of the Process o f Rolling of Porous Materials. (Translation). See Met. A., 8409-54-0642. G.Ya. Gun, S.A. Stabunov, D.Yu, Ganelin, and A.A. Frolov. Soy. Powder MetalL Met, Ceram,, Nov. 1983, 22, (11), 886-890, [in English]. ISSN 0038-5735.
Production and Properties of Reinforced Laminated Materials for Filtration. (Translation). See Met. A., 8409-54-0646, 54-0824
V.K. Sorokin, and G.F. Tikhonov. Sov. PowderMetalL Met. Ceram., Nov. 1983, 22, (11), 916-918, [in English]. ISSN 0038-5735.
54-0827 Effects of Dynamic and Isostatic Compaction on the Microstructure and Mechanical Behavior o f AIN, T i B 2 a n d TiC. Preliminary
dustry is growing moderately and covers products for automotive, electrical, nuclear and aerospace applications. History is outlined and current hard metal, structural, high-speed tool steel and specialized P / M production figures are given. Automotive manufacturing is detailed and 1976-1982 production is tabled. P / M parts for bicycles, sewing machines, household, business, factory and farm applications have growth potential. R & D, training and associations are described. --J.V.R. P. Ramakrishnan. Int. J. Powder MetalL Powder TechnoL, July 1984, 20, (3), 219223, [in English]. ISSN 0361-3488.
comparative studies have been made of AIN, TiB 2 and TiC powders subjected to isostatic a n d / o r plane shock loading in the pressure range 1-5.5 GPa. The microstructural differences between the two modes of loading are discussed in terms of observations made through use of X-ray diffraction, SEM and thermal annealing. 7 r e f . - - A A M. Akaishi et al. High Pressure in Science and Technology, IIl.--General Topics [Proc. Conf.], Albany, N.Y., U.S,A,, 24-29 July 1983, Elsevier Science Publishing Co., Inc., 52 Vanderbilt Ave., New York, N.Y. 10017, U.S.A., 1984, (Met.A. 841172-0701) 159-162, [in English].
54-0804 P r e s e n t S t a t u s o f Powder Metallurgy in Japan. The fastest growing Japanese metal forming sector (P/M), covers powder production, production equipment and machine, automotive, electrical, magnetic, friction and hard alloy parts. Metalforming 1969-1982 growth rates are graphed and production of six metal powders are described, and 1972-1983 production is tabled. Equipment and processes are outlined. Product description covers Fe and bronze bearings, ferrous alloy machine parts, Cu-base friction materials, tungsten, W-Cu/Ag, Mo, Cu and Fe electrical products, hard and soft territe magnets, sintered carbides and cermets. Research and new developments are covered.--J,V.R. T. Watanabe, and T. Sakurai. Int. J. Powder Metall. Powder TechnoL, July 1984, 20, (3), 225-229, [in English]. ISSN 0361-3488.
54-0828
54-0805 Titanium Diboride/Graphite Composites. A process for manufacturing a C/TiB 2 composite article comprises blending coke, a first carbonizable binder and a first TiB2 forming reactant to form a dispersion, shaping the article, baking to carbonize binder, impregnating the article under alternate cycles of vacuum and pressure at least once with a second TiB2-forming reactant in liquid form and heating to a TiB2-forming temp, to form C / T i B 2 composite article. L.A. Joo, K.W. Tucker, F.E. McCown, Jr., and Great Lakes Carbon Corp. Off. Gaz., 27 Mar. 1984, Patent no, US4439382 (USA), 27 July 1981. ISSN 0360-5132. 54-0806 Metallurgically Bonded Diamond/Metal Composite Sintered Materials and Method of Making Same. A metallurgically bonded, sintered, diamond/metal composite is comprised of a matrix consisting of a metal selected from the group consisting of Ni, Co and mixture, diamond powder uniformly dispersed in the matrix and particles of hard, brittle, intermetallic compound uniformly dispersed in matrix, the composite having been prepared by mixing powder of the matrix metal, the diamond powder and powder of substance capable of combining with the matrix metal to form the intermetallic compound, the substance being selected from the group consisting of Sn, Sb, Zn and mixture thereof, the amount of the substance being from 5-40 wt.%, then sintering until the intermetallic compound is formed, S, Kuminitsu, I. Hayakawa, S. Kitatani, A. Emura, and Mitaui Mining and Smelting Co Ltd. Off, Gaz., 27 Mar. 1984, Patent no. US4439237 (USA), 27 June 1978. ISSN 0360-5132. 54-O814 Engineering Applications o f S i a l o n s . The acronym "Si-AI-O-N" describes new ceramic alloys that are derived from silicon nitride by the simultaneous replacement of Si and nitrogen by AI and oxygen. Commercially developed "Sialon" is fabricated using the normal shaping techniques for oxide ceramics and then fully densified by pressureless sintering. It promises to be an outstanding material for engine components and is already highly successful as a cutting tool for machining metals. Other applications are in welding and extrusion, in molten metal handling and for seals, bearings and wear parts. Analogous replacement of O by N in vitreous silicates gives stronger and more refractory g l a s s e s . - - A A K.H. Jack. Materials Engineering [Proc. Conf.], Leeds, U.K., 10-12 July 1984, Institution of Metallurgists, The Hub, Emson Close, Saffron Walden, Essex CB10 1HL, 1984, (Met.A., 8411-72-0697) 65-72, [in English]. A t t r i t o r M i l l i n g o f T i t a n i u m Carbide and Titanium N i t r i d e Produced by Self-Propagating High-Temperature Synthesis. (Translation). See Met. A., 8409-54-0637, 54-0815
R.A. Andrievskii, A.Zh. Dzneladze, L.N. Petrov, and S.V. Yudin. Soy. Powder Metall. Met. Ceram., Nov. 1983, 22, (11), 867-869, [in English]. ISSN 0038-5735.
110
VOL. 4, NO. 1, JULY 1985
Thermodynamics of Shock Compression of Porous Materials.
Investigation of shock compression thermodynamics is of interest for understanding the processes of detonation initiation, explosive compaction of different materials and for studying behavior of materials in a wide range of the P - - T diagram. Experimental data obtained using the thermal e.m.f, method are discussed. The dependence of the nonequilibrium temp. of particle interfaces on pressure magnitude and fraction size and energy distribution between the components of the porous mixtures as determined by the ratios of the particle sizes have been revealed. A method for obtaining supercooled melts and a method for generating high-temp, states by shock compression of porous materials is proposed. Cited materials include Cu, Ni, tungsten, Ge, Si, InAs and C u / B N powder mixture. 14 ref. --AA V.F. Nesterenko. High Pressure in Science and Technology. IIl.--Generai Topics [Proc. Conf.], Albany, N.Y., U.S.A., 24-29 July 1983, Elsevier Science Publishing Co., Inc., 52 Vanderbilt Ave., New York, N.Y. 10017, U.S.A., 1984, (Met.A., 841172-0701) 195-198, [in English].
54-0830 Powder Metallurgy Science. ( B o o k ) . Among the various metalworking technologies, powder metallurgy is the most diverse manufacturing approach. An introduction is provided to the basic scientific principles behind powder metallurgy technology. The following topics are covered: physical characterization of metal powders; fabrication of powders by mechanical comminution, electrodeposition, chemical reduction, precipitation and atomizing; precompaction powder handling; compaction and sintering; full density processing; compact characterization and applications. Most frequently cited materials are Fe, Cu and prealloyed steels. Numerous r e f . - - A A R.M. German. Metal Powder Industries Federation, 105 College Rd. E., Princeton, N.J. 08540, U.S.A., 1984, (Met.A. 8411-72-0704) Pp 279, [in English]. 54-0836 Engine Cylinder Liners Based o n A l u m i n i u m Alloys and Intermetallic Compounds. Engine cylinder liners containing a matrix based on AI alloys with high mechanical strength obtained by powder metallurgy, and possibly other elements, also contain a dispersion of grains of at least one intermetallic compound, apart from the dispersion of such compounds as may exist in the alloy, the melting point of which is over 700~ The liners are obtained by extruding or sintering a mixture of powders. They may be used particularly in the automobile industry and in any kind of industry where liner--piston unit of good compatibility have to be obtained from aluminium alloys. M. Eudier, N. Huret, J. Meunier, and Cegedur Soci~t(~ de Transformation de I'Aluminium Pechiney. 20 June 1984, Patent no. GB2131457A (UK), 8 Dec. 1983.
54-0838 Process for Improving the High Temperature F l e x u r a l Strength of Titanium D i b o r i d e - - B o r o n Nitride Intermetallic Compositions. There is disclosed a process for improving the high temperature flexural strength of TiB2--BN intermetallic compositions which comprises reheating hot pressed TiB2--BN stock to a temperature of between 1600 to 2200~ in an inert atmosphere for a time sufficient to vapourize the bond phase of the hot pressed body. L.C. Montgomery, and Union Carbide Corp. 4 July 1984, Patent no. GB2132227A (UK), 21 Dec. 1983. S i l i c o n Carbide Sintered Article and Process for Its Production. A silicon carbide sintered article composed essentially of elongated 54-0841
and/or plate-like grains of a S i C - - A I N solid solution consisting essentially of 2 to
J. APPLIED METALWORKING
20 wt.% AI, from 0.2 to tO wt.% N, from 0.2 to 5 wt.% O, from 0 to 15 wt.% of a Group nla element, the rest being substantially Si and C. Sintering of the green body is carried out in a non-oxidizing atmosphere at 1900 to 2300~ K. Suzuki, and Asahi Glass Co Ltd. 18 July 1984, Patent no. GB2133042A (UK), 7 Dec. 1983.
54-0842
Method of Making W e a r Resistant Ferrous Based Parts. A
method is disclosed for making wear resistant, ferrous based parts by molding a uniform mixture of ferrous based powder and binder material into a compacted shape, heating the compacted shape to remove the binder and to partially sinter the mixture to a strength of 1000-8000 psi, while maintaining a porosity of 20-40% at least along the outer region of the part, depositing a fluid suspension of wear resistant particles onto a surface zone of the shape, and heating the coated shape to bond the particles to the surface and fully sinter the part. V. Durga, N. Rao, and Ford Motor Co. 18 July 1984, Patent no. GB2133043A (UK), t0 June 1982.
54-0846
A Special C a s e of Metal Forming. Powder metallurgy, as it is known today, is a young technology for forming metal powders into articles using the advantages of mass production. It is economic both in finance and energy since the products require little or no machining before being put into use and wasteage of material is kept to a minimum. In general, a powdered metal is compacted in a press in a specially designed toolset. The compact, which has almost the final required shape, is then sintered in a furnace under a controlled atmosphere. The materials that are presently available range from irons, steels and a variety of non-ferrous alloys including AI, brass and bronze. The basics of powder metallurgy of ferrous and non-ferrous structural components are described. Powder metallurgy products and their properties are also described for the purpose of increasing the understanding essential for the successful use of PM. 21 r e f . - - A A P. Blaine. S. Aft. Mech. Eng., Feb. 1984, 34, (2), 49-55, [in English]. ISSN 00382442. 54-0847
Shock Consolidation of a Rapidly Solidified Steel Powder.
Rapidly solidified AIS19310 steel powders were consolidated by shock waves produced from the impact of high-velocity f l y e r s Dependence of themicrehardness and the ultimate tensile strength of the compacts on the initial shock pressure (from 3 6 to 1 7 9 GPa) a n d t h e m a x , shock pressure (from 6 to 37 GPa) w a s m e a sured for an initial powder density 0.6 of the bulk density and shock duration of 23 #s. Photomicrographs and SEM fractographs were used to study the interparticle bonding in the compacts. Results show that for initial shock pressures 4 GPa, the compacts have negligible strength. However, above this threshold the strength of the compact rises rapidly untila max. value of 1.3 + 0,1 G P a i s reached for an initial shock pressure of 12,4 GPa. The strength then remains constant before decreasing at the highest initial shock pressure. In marked contrast with increasing shock pressure, the diamond pyramid hardness increases very gradually from a value of ~ 340 for the powder to ~ 500 at the highest shock pressure. The m a x strength obtained correlates reasonably well with the strength expected from microhardness measurements, 23 r e f . - - A A P Kasiraj, T. Vreeland, J r , RB. Sehwarz, and T.J. Ahrens. Acta Metal/., Aug. 1984, 32, (8), 1235-1241, [in English] ISSN0001-6160,
54-0848
A Theory for the S h o c k - W a v e Consolidation of Powders. A
model for the shock consolidation of powders is developed w~',ch predicts, for a given powder density, the regimes of shock pressure P and ",lock duration t d expected to yield fully densified compacts of near optimum strungth. Most of the densification work is assumed deposited near particle boundaries, leading to partial melting. The model gives an upper bound to the amount of melt. The condition that the melt between particles must exceed a critical thickness and must solidify within the duration of the shocked state leads to necessary conditions for P and t a. These requirements are presented in "maps of shock consolidation", using normalized parameters. The model predicts that for a shock energy (normalized to that required to heat Fe to the melting point) of 0.7, a min. shock duration of 2 #s is required to consolidate 60 /~m dia. Fe-based powder. 26 r e f . - - A A R.B. Schwarz, P. Kasiraj, T. Vreeland, Jr., and T.J. Ahrens. Acta MetalL, Aug. 1984, 32, (8), 1243-1252, [in English]. ISSN 0001-6160.
54-0851
Influence of the Stress Mode on the Plasticity of Compacted
G r a n u l a t e d A l u m i n u m A l l o y s . ( T r a n s l a t i o n ) . See Met. A., 8405-54-0312. A.I. Kolpashnikov, A.P. Petrov, A.S. Kirilyanchik, V.M. Fedorov, and P.A. MasIovskii. Russ. Meta/l., 1983, (3), 92-94, [in English]. ISSN 0036-0295.
54-0852 Investigating the Straightening o f C a s t A l u m i n u m Containing Refractory Titanium Compounds. ( T r a n s l a t i o n ) . See Met. A., 8405-54-0313. N.L. Baturinskaya, N.A. Kalchuk, M.G. Servetskaya, and V.G. Chernyi. Russ. Metal/., 1983, (3), 150-153, ]in English]. ISSN 0036-0295. 54-O855
Titanium P / M Comes of Age. Recent developments have demonstrated that the prealloyed powder-metal technique allows production of highintegrity, large and complex shapes which are cost effective. Mechanical properties of P / M alloy T i - - 6 A I - - 4 V , shapemaking processes used, parts and processes now in production and cost reduction are considered. Future developments are suggested. 15 r e f . - - C M . L . S . L. Parsons, J. Bruce, J. Lane, and F.H. Frees. Met. Prog., Sept. 1984, 126, (4), 8384, 86, 89, 91, 93-94, [in English]. ISSN 0026-0665. 54-0858
The C r u s h a b i l i t y o f T i t a n i u m S p o n g e . ( T r a n s l a t i o n ) . See A4et. A., 8405-54-0338. V.A. Pavlov, S N . Kokorkin, and Zh.G. Volchok. Sov. Non-Ferrous Met. Res., 1983, 11, (4), 325-327, [in English]. ISSN 0307-7349. 54-0878 Containerless HIP'ing of P / M Parts: Technology, Markets and Economics. Hot isostatic processing of materials represents a multibillion dollar market, growing at an estimated real compound growth rate of 20-25%/year. Fueling the huge past and projected growth are the successful applications of HIP to
J. APPLIED METALWORKING
repair and rejuvenate castings, fully density sintered carbides and ceramics, produce P / M forgings and extrusion preforms and net and near net shape P / M turbine disks. Potentially profitable markets and applications of containerless (sinter/HIP) HIP'ing of closed porosity sintered P / M parts are identified and discussed. The technology of containerless HIP is discussed, along with the economics of HIP'ing for various types of HIP cycles. A historical overview of the present successful applications of HIP is also p r e s e n t e d . - - A A A.C. Nyce. Progress in Powder Metallurgy 1983, Vol. 39 [Prec. Conf.], New Orleans, La., U.S.A., t-4 May 1983, Metal Powder Industries Federation, 105 College Rd. E., Princeton, N.J. 08540, U.S.A., 1984, (Met.A., 8 4 i 2 - 7 2 - 0 7 3 4 ) 13-36, [in English].
54-0879
S i n t e r / H I P Equipment for the P o w d e r Metal Process. Recent advances in equipment and process technologies make it possible to form powder metal parts by a variety of techniques. The newest technique of combining sintering and HIPing equipment and its potential for processing materials are described. Sinter/HIP production capacities are discussed and processing costs are analyzed (for the case of WC production). 13 r e f . - - A A F.X. Zimmerman, and C.W. Smith. Progress in Powder Metallurgy 1983, Vol. 39 [Prec. Conf.], New Orleans, La., U.S.A., 1-4 May 1983, Metal Powder Industries Federation, 105 College Rd. E., Princeton, N.J. 08540, U.S.A., 1984, (Met.A., 8412-72-0734) 37-52, [in English]. 54-0880 Consolidation to Full Density Under Pseudoisostatic Conditions Using Conventional Presses. Several processes are emerging as alternatives to hot isostatic pressing (HIP). The patented Ceracon Process, which utilizes a ceramic grain as the medium for consolidating porous preforms, is discussed. Preforms are heated, charged into heated grain, then subjected to pressure using a conventional press. Pressurization of the grain due to the axial load leads to densification and deformation of the preform. Analysis of these results is presented, leading to preform design guidelines. Materials amenable to Ceracon processing are 1000, 2000 and 4600 grade steels, 420 stainless steel, IN-IO0, AI alloys, Ti alloys, Cu alloys, Me and t u n g s t e n . - - A A H.A. Kuhn, B.L. Ferguson, and O.D. Smith. Progress in Powder Metallurgy 1983, Vol. 39 [Prec. Conf.], New Orleans, La., U.S.A., t-4 May 1983, Metal Powder Industries Federation, 105 College Rd. E., Princeton, N.J. 08540, U.S.A., 1984, (Met.A., 8412-72-0734) 59-71, [in English].
54-O881
Microstructure and Properties o f a P / M High-Chromium Iron A l l o y . Microstructure--property relations have been developed for a powderprocessed high-Cr Fe alloy ( F e - - 2 0 % C r - - 1 . 5 % M o - - 2 . 5 % C), with particular interest vested in the possible effects of rapid solidification of the powder on final properties. The alloy was gas atomized, screened into three size fractions (119 to 213 ~m; 74 to 107 #m; < 44 /~m), hot i s o s t a t i c a l l y p r e s s e d (HIP'ed) to full density and heat-treated (HT) to give a structure consisting of i 7 C 3 carbides in tempered martensite. Microstructures were characterized in the powder form, after HIP'ing and HIP + HT. Properties evaluated were hot hardness, hot compressive strength, fracture toughness and abrasive and adhesive wear. Comparisons were made with a chill cast alloy of similar composition. Each of the properties was relatively insensitive to powder particle size. The strength and temp. dependence of strength of the powder-processed and cast forms were similar but there were significant differences in fracture toughness and w e a r resistance between the powder-processed and cast forms of the alloy. 18 r e f . - - A A S. Mohan, A. Lawley, L.R. Woodyatt, and K.S. Brosius. Progress in Powder Metallurgy 1983, Vol. 39 [Prec. Conf.], New Orleans, La., U.S.A., 1-4 May 1983, Metal Powder Industries Federation, 105 College Rd. E., Princeton, N.J. 08540, U.SA., 1984, (Met.A. 8412-72-0734) 73-99, [in English]. 54-0884 C o m p u t e r S i m u l a t i o n o f P / M G e a r Forging. The finite slab analysis method d e v e l o p e d in this research can be successfully utilized for the computer-simulated upsetting of a cylinder and forging of a gear, for both fully dense and porous materials. Excellent agreement (1% or less error) with the analytical solution was obtained with fully dense cylinder upsetting. A higher coefficient of friction constrained the outward flow of metal for the cylinder upsetting and gear forging of porous preforms and produced a higher final density level. The simulation predicts a sudden jump to a lower axial stress at the base of the gear tooth due to a change in boundary conditions which can lead to lower relative densities at that location. 11 r e f . - - A A R.W. Herian, G.W. Halldin, and T.H. Tsai. Progress in Powder Metallurgy 1983, Vol. 39 [Prec. Conf.], New Orleans, La., U.S.A., 1-4 May 1983, Metal Powder Industries Federation, 105 College Rd. E., Princeton, N.J. 08540, U.S.A., 1984, (Met.A, 8412-72-0734) 139-151, [in English]. 54-0885 P o w d e r M e t a l l u r g y ( P / M ) Process Selection of Ferrous Alloy for High-Cycle Fatigue Applications. An attempt was made to find a powder metallurgy process and heat treatment for manufacturing components with enhanced high-cycle fatigue strength. An accelerated fatigue testing technique has also been developed. Powder metallurgy samples manufactured from the conventional P / M process and injection molding process (I/M) were tested for high-cycle fatigue strength for different case depths. All the samples were case-hardened in an endogas atmosphere with minute amounts of NH 3. It was found that a case depth of ~ 14% of the sample thickness (one side of case depth along the direction in which force is applied) maximizes the fatigue strength of I / M steel. Higher case depths actually embrittle the material and thus reduce the fatigue strength. Injection molded Ni steel with 2% Ni and a 5% case depth offers at least a 40% higher fatigue strength than cased sintered iron (by a conventional P / M process) with the same case d e p t h . - - A A P.C. Chen, and C.K. Lim. Progress in Powder Metallurgy 1983, Vol. 39 [Prec. ConL], New Orleans, La., U.S.A., 1-4 May 1983, Metal Powder Industries Federation, 105 College Rd. E., Princeton, N.J. 08540, U.S.A., 1984, (Met,A., 8412-720734) 153-161, [in English].
54-0889
The Effects of Hydrogen on Sulfur in Ferrous Compacts. High hydrogen-containing atmospheres, such as endothermio gas and dissociated ammonia, effectively remove much of the sulfur that is added to ferrous compacts for
VOL. 4, NO. 1, JULY 1985
111
machinab!lity. Sulfur loss was found to decrease with lower H concentrations in the atmosphei'e. The high hydrogen sulfide concentrations present with high H airedspheres will reduce the life expectancy of the metal components in the furnace. Low H concentrations in the atmosphere produce little hydrogen sulfide and expected belt and muffle life will significantly increase. Additions of water to the sintering atmosphere did not appear to have a significant effect on the S content of the c o m p a c t s . - - A A J.J. Kaiser, A.T. Sibley, and J.G. Marsden. Progress in Powder Metallurgy 1983, Vol. 39 [Prec. Conf.], New Orleans, La., U.S.A., 1-4 May 1983, Metal Powder Industries Federation, 105 College Rd. E., Princeton, N.J. 08540, U.S.A, 1984, (Met.A., 8412-72-0734) 231-241, [in English].
54-'0892
Welding o f 3 1 6 L P / M Stainless S t e e l . With the exception of friction welding, all of the welding processes studied can be successfully used with P / M 316L stainless steel material over the full range of densities. The ease of welding and the weld strength increase with increasing density, although the forged material tended to have the lowest weld efficiencies. Over-all, the GMAW process seemed to give the best properties, while the intermediate density samples for each process tended to have the best weld efficiencies. 12 r e f . - - A A G.W. Halldin, S N . Patel, and G.A. Duchon. Progress in Powder Metallurgy 1983, Vol. 39 [Prec. Conf.]. New Orleans, La., U.S.A., 1-4 May 1983, Metal Powder Industries Federation, 105 College Rd. E , Princeton, N.J. 08540, U.S.A., 1984, (Met.A, 8412-72-0734) 267-280, [in English]. 54-0893 Microstructure and Quality Control of P / M Parts Heat Treated Under Various Atmospheres. Several steel P / M parts (4500 N i - - M o steel) were sintered under endothermic and nitrogen-based atmospheres subsequently heat treated in endo, N/methanol (Endomix), natural g a s / w a t e r and N - - n a t u r a l gas atmospheres. Quality control during both sintering and heat treatment is examined. The results for various atmospheres on the physical properties and microstructures are presented, then used to compare the different processes for part quality and uniformity, process control and usability. The N-based sintering atmosphere is seen to produce a more uniform microstructure and resultant part properties. This greater uniformity in the sintered part carries through the subsequent heat treatment. Although all heat treat atmospheres used produced 'acceptable results, parts sintered in a N-based atmosphere had better uniformity after heat treatment. 7 r e f . - - A A P. Johnson, H.S. Nayar, and W.Q. Judge. Progress in Powder Metallurgy 1983, Vol. 39 [Prec. Conf.], New Orleans, La., U.S.A., 1-4 May 1983, Metal Powder Industries Federation, 105 College Rd. E., Princeton, N.J. 08540, US.A., 1984, (Met.A., 8412-72-0734) 281-306, [in English].
54-0894
Tailored Coatings for Hardfacing. An update on Conforma Clad coatings is provided. The major advantage is the ability to offer selective-area coatings in a wide range of thicknesses and material choices while retaining dimensional and edge control of the coating. Complex geometries can be coated with a high materials utilization and with coating properties tailored to the end application. Porosity and bond strength values can match or exceed those seen with the best commercially available thermal sprayed coatings. The ability of the process to balance abrasion resistance and toughness requirements for a specific wear mode is illustrated by microstructural control of the size, shape and density of WC carbide particles contained in the Ni-base coating. Dry sand abrasive test data are provided on Conforma Clad coatings and competitive processes. Ongoing developments of nonturnace fusion techniques, such as laser cladding, are presented and the microstructures are compared with those obtained with conventional coating processes. Commercial applications for these coatings are highlighted with some typical examples. 10 r e f . - - A A M . R Dustoor, and L.N. Moskowitz. Progress in Powder Metallurgy 1983, Vol. 39 [Prec. Conf.], New Orleans, La., U.S.A., t-4 May 1983, Metal Powder Industries Federation, 105 College Rd. E., Princeton, N.J. 08540, U.S.A., 1984, (Met.A., 8412-72-O734) 307-321, [in English]. 54-0895
Quality Assurance Procedures for P o w d e r Forged Materials.
The fatigue performance of powder forged parts of N i - - M o steels can be better than that of similar components which have been cast or drop forged. To achieve such properties, close control must be exercised over the powders from which the parts are fabricated and also over the process used to consolidate them. Some of the property requirements for powders intended for forging applications are discussed. Consideration is given to both the physical and chemical characteristics of the powders, with emphasis on powder cleanliness and an automated image analysis technique for nonmetallic inclusion assessment. Process control requirements during preform compaction and powder forging are also covered and a magnetic bridge sorting technique for assessing the microstructural integrity of the forgings is outlined. 16 r e f . - - A A W.B. James. Progress in Powder Metallurgy 1983, Vet. 39 [Prec. Conf.], New erieans, La., U.S.A., 1-4 May 1983, Metal Powder Industries Federation, 105 College Rd. E., Princeton, N.J. 08540, U.S.A., 1984, (Met.A, 8412-72-0734) 333-348, [in English].
54-0896 The Benefits in Application of Statistical Process Controls on Quality in the P o w d e r e d Metal Industry. Ferro Manufacturing Corp. is a supplier of electromechanical body component hardware to the automotive industry and uses several powdered metal components, specifically gears, in their assemblies. These gears affect the functional characteristics of the product and improving uniformity will play a major role in improving the smoothness and reliability of these gears in operation. Application of statistical process controls will allow improved uniformity to be achieved, allowing the parts to be manufactured to tighter specifications with greater reliability without relying on t 0 0 % inspection or AOQL methods to sort good lots from bad. The application of statistical process controls, the methods of application and the anticipated benefits are d i s c u s s e d . - - A A D.J. Bickerstaff. Progress in Powder Metallurgy 1983, Vol. 39 ]Prec. ConL], New Orleans, La., U.S.A., 1-4 May 1983, Metal Powder Industries Federation, 105 College Rd. E., Princeton, N.J. 08540, U.S.A., 1984, (Met.A., 8412-72-0734) 349-366, [in English].
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VOL. 4, NO. 1, JULY 1985
54-0897 F r e e - F r e e R e s o n a n t F r e q u e n c y Testing of P o w d e r Metal Alloys to Determine Elastic Moduli. Elastic meduli of solids are of interest both as fundamental data needed in the calculation of many solid-state properties and as engineering data. For most engineering work it is assumed that the material is elastically isotropic; then it is necessary to define only two elastic constants to completely describe the material elastically. These two constants are Young's modulus, E - (normal stress/normal strain), and the shear modulus, G = (shear stress/shear strain). A third elastic constant, Poisson's ratio, u, which represents a lateral effect, the fact that a stress in one direction is accompanied by a strain in the perpendicular direction can easily be obtained from E and G. The purpose of this work is to determine Poisson's ratio, u, which is needed in many engineering design equations, for powder metal alloys. 12 r e f . - - A A R.R. Phillips, and W. Franciscovich. Progress in Powder Metallurgy 1983, Vol. 39 ]Prec. Conf.], New Orleans, La., U.S.A., 1-4 May 1983, Metal Powder Industries Federation, 105 College Rd. E., Princeton, N.J. 08540, U.S.A., 1984, (Met.A., 8412-72-0734) 369-390, [in English].
54-0900 R e l a t i o n s h i p s B e t w e e n P r o c e s s i n g , M i c r o s t r u c t u r e and Properties o f a C o - - C r - - M o A l l o y . Stellite alloy No. 21 was produced by rapid solidification processing (RSP) in a variety of particulate morphologies (coarse and fine powder, flakes, fibers, ribbons). The various RSP forms showed similar, fine microstructures with only a slight difference in the scale of the microstructural features. These RSP particulates were consolidated by extrusion, dynamic compaction and rapid omnidirectional compaction (ROC) at two processing temp. (1077 and 1121 ~ Dynamic compaction proved to be unacceptable. A plot of elongation vs. yield strength depicted two yield strength/ductility relationships for the C o - - C r - - M o type alloys. As-ROC'd samples had a low yield strength/ductility relationship. However, after hot forging, the relationship shifted to a level comparable to similar material processed by conventional extruding and forging operations. Atomized powder size also affected the strength/ductility relationships of the extruded products. 20 r e f . - - A A V. Anand et aL Progress in Powder Metallurgy 1983, Vol. 39 [Proc. Conf.], New Orleans, La., U S A . , 1-4 May 1983, Metal Powder Industries Federation, t05 College Rd. E., Princeton, N.J. 08540, U.S.A., 1984, (Met.A., 8412-72-0734) 445-490, [in English].
54-0901
Refractory Metals in Ordnance. The effective use of explosives in ordnance applications with their associated high temp. and high stresses requires the use of refractory metals such as Me and Cr for strengthening and toughening steels used to contain and control burning propellant and explosives. In extreme conditions of erosion caused by hot gases at high velocity, Cr plating is an effective barrier; additional protection may be afforded, e.g. by titanium dioxide powder placed to encase the propellant charge. As a protection of last resort, T a - - N b alIoys are effective, but costly. For energy transfer modes such as kinetic energy penetration, high-density materials are essential to give low aerodynamic loss in flight and high-energy density at impact. Tungsten alloyed with N i - - F e meets these general requirements. When treated by combinations of cold work and heat treatment after fabrication by powder metallurgy, very effective penetration and fragmentation devices result. Zirconium with its inherent pyrophoricity is very effective as a target marker and in incendiary d e v i c e s . - - A A T.W. Penrice. Progress in Powder Metallurgy 1983, Vol. 39 ]Prec. Conf], New Orleans, La., U.S.A., 1-4 May 1983, Metal Powder Industries Federation, 105 College Rd. E., Princeton, N.J. 08540, U.S.A., 1984, (Met.A, 8412-72-0734) 507-513, [in English]. 54-0903 Mechanical Properti.es of HIP Niobium C - 1 0 3 A l l o y . Progress in studying the feasibility of producing near net shape components of Nb C-103 via powder metallurgy and hot isostatic pressing (HIP) is presented. The effect of powder particle size, shape and purity, and of HIP conditions on the room-temp. and 3000~ properties and on welding are presented and the results are explained by microstructural, fractographic and Auger analyses. In general, the HIP product compares favorably wilh commercial wrought material.--AA C. Himmelblau eta/. Progress in Powder Metallurgy 1983, Vol. 39 [Prec. Conf.], New Orleans, La., U.S.A., 1-4 May 1983, Metal Powder Industries Federation, 105 College Rd. E., Princeton. N.J. 08540, U.S.A., 1984, (Met.A., 8412-72-0734) 525542, [in English]. 54-0904
Designing P / M Parts for W e a r and W e a r C o m p a t i b i l i t y . In busihess equipment, particularly in the area of mailing machines and postage meters, the mechanical components in the force transfer mechanism often slide against each other. Their fatigue and wear life are often expected to be well over 8M cycles. To meet this challenge, wear and wear compatibility become as critical as mechanical properties when a P / M part is designed. The preliminary experimental results on four widely used commercial m a t e r i a l s - - F e - - 6 C u - - 0 . 6 C , R3755 HS PJ M, Fe--O.3C, AIS14620--are presented. They represent four density levels ranging from 6.3 g/c.c, to full density. Special emphases were placed on the wear behavior change when a wrought component is replaced with P / M - - A A Y.T. Chen, B. Cuttitta, and P. Zovas. Progress in Powder Metallurgy 1983, Vol. 39 [Prec. Conf.], New Orleans, La., U.S.A., 1-4 May 1983, Metal Powder Industries Federation, 105 College Rd. E., Princeton, N.J. 08540, US.A., 1984, (Met.A, 8412-72-0734) 559-587, [in English]. 54-0905 New Nickel-Base Alloy With High Strength and Corrosion Resistance Made Via Rapid Solidification Technology. A new Ni-base alloy (Markomet 1119) with high strength combined with excellent aqueous corrosion resistance prepared by rapid solidification powder metallurgy is reported. The alloy was prepared as powders by the method of melt spinning and consolidated by hot extrusion. The consolidated alloy exhibited superior tensile strength properties compared to commercial Ni-base alloys. Its corrosion resistance in various acids, e.g. sulfuric, nitric, hydrochloric, phosphoric, was found to be excellent. --AA V. Panchanathan, and R. Ray. Progress in Powder Metallurgy 1983, Vol. 39 [Prec. Conf.], New Orleans, La., U.S.A., 1-4 May 1983, Metal Powder Industries Federation, 105 College Rd. E., Princeton, N.J. 08540, U.S.A., 1984, (Met.A., 8412-720734) 589-602, [in English].
J. APPLIED METALWORKING
54-0906
Developments in Titanium Powder Metallurgy. Powder metallurgy has become a viable method for producing full density, net-shape Ti alloy components. By compaction of prealloyed powder, it is now possible to routinely produce compacts with mechanical properties at least equivalent to those of components fabricated from Ti ingot. The alternate blended elemental approach, while exhibiting lower fatigue behavior, allows a viable low-cost approach for less demanding applications. Very recently, a new aspect of Ti P / M has been receiving increased attention: rapid solidification of both conventional alloys and alloys not possible using the ingot metallurgy (I/M) approach. The over-all Ti P / M scenario ( T i - - 6 A I - - 4 V alloy) is discussed and some thoughts are presented on where this technology is headed. 3 0 r e f . - - A A S. Krishnamurthy, R.G. Vogt, D Eylon, and F.H. Froes. Progress in Powder Metallurgy 1983. Vol. 39 [Proc. ConL], New Orleans, La., U S A . , 1-4 May 1963, Metal Powder Industries Federation, 105 College Rd. E., Princeton, N J . 08540, U.S.A., 1984, (Met A., 8412-72-0734) 603-623, [in English]. 54-0907 Microstructure and Properties of P / M Tool S t e e l s . A detailed microstructural examination has been made of T15 and Rex 25 high-speed tool steels processed from rapidly solidified gas atomized powders and associated strength and toughness were evaluated. Powders were screened into selected size fractions, hot isostatically pressed to full density and heat treated. After HIP'ing, MC, MsC and M2306 carbides are present in the form of individual particles in a ferritic matrix. Independent of prior particle size fraction, the carbide size distribution after HIP'ing is skewed to larger carbide sizes with increasing HIP'ing temp., but with no significant change in volume fraction of carbides. M23C6 goes into solution during austenitizing if the temp. is high enough and il does not reprecipitale on tempering. Austenite grain size and the volume fraction and size distribution of MC and MsC carbides are controlled primarily by the prior HIP'ing and austenitizing temp.; the trends observed after HIP'ing are maintained after heat treatment, Strength and toughness are enhanced by hot forging after HIP'ing but prior to heat treatment. 9 r e f . - - A A S. Kumar, A Fareed, M.J. Koczak, andA. Lawley. Progressin Powder Metallurgy 1983, V o l 39 [Proc. Conf], New Orleans, La., US.A., 1-4 May 1983, Metal Powder Industries Federation, 105 College Rd. E., Princeton, N,J. 08540, U.S.A., 1984, (MetA. 8412-72-0734) 627-652, [in English]. 54-0908 Cold S i n t e r i n g - - a New Powder Consolidation Process. The plastic delormation of powder particles in a high-pressure gradient at ambient temp results in green densities close to theoretical. Physical contact of freshly formed oxide-free surfaces leads to strong particle/particle bonding; this phenomenon is called "cold sintering". High strength levels can be obtained in metals, alloys. composites, ionic and ionic-covalent solids by cold sintering Subsequent heat treatment of cold sintered material, at temp, significantly lower than those used in conventional sintering, results in excellent combinations of strength and ductility Thus, cold sintering offers the potential for retaining metastable constituents, fine-scale microstructures and small precipitates in rapidly solidified powders Interface reactions or dissolution of phases in metal matrix composites can a~so be reduced or eliminated. Details of the compacting response, microstructure and mechanical properties of cold sintered and heat treated high-speed tool steel (T15, M2) and superalloy powders (Nimonic 80A) are presented. 32 r e f . - - A A E.Y. Gutmanas, and A. Lawley. Progress in Powder Metallurgy 1983, Vol. 39 [Proc. Conl], New Orleans, La., U S A . , 1-4 May 1983, Metal Powder Industries Federation, 105 College R d E , Princeton, N.J. 08540, U S A . , 1984, (Met.A, 8412-720734) 653-667, [in English]. 54-0909 Microstructure and Mechanical Properties of Cold Sintered P / M Aluminum Alloys. Air atomized A I - - F e - - N i (6.2% Ni, 5.9% Fe) and A I - F e - - N i - - C o alloy (4% Ni, 4% Pe, 4% Co) powders have been cold sintered at ambient temp. under axia; pressures up to 3 GPa. The consolidated alloys exhibited high strength levels at compacting pressures - ~ 2.5 GPa. Cold sintering has also been used in the preparation of thin foils for transmission electron microscopy, thereby allowing for the investigation of microstructure in as-atomized powder and following heat treatment at temp. lower than those normally used in P / M hot consolidation or hot working. The compressive and bend properties of the cold sinfeted AI alloys have been investigated as a function of heat treatment and excellent combinations of strength and ductility have been achieved. Mechanical properties are compared with those of hot pressed and hot extruded material. Cold sintering is discussed in the context of processing viability for P / M AI alloys. 19 r e f . - - A A E.Y. Gufmanas, M, Premkumar, and A. Lawley. Progress in Powder Metallurgy 1983, VoI. 39 [Proc. ConL], New Orleans, L a , U.S.A., 1-4 May 1983, Metal Powder Industries Federation, 105 College R d E., Princeton, N . J 08540, U.S.A, 1984, (Met.A., 8412-72-0734) 669-682, [in English].
54-O913 Improving the Corrosion S t a b i l i t y o f Parts Based on Iron Powders. A method for depositing oxide films on Fe powder compacts is proposed whereby a corrosion-resistant film of Fe304 is obtained, both on the surface of a part and inside the voids, by treating the part with superheated steam under pressure. The film formed during the steam oxidation treatment is 5-10 /~m thick; it is evenly distributed over the surface of the part and strongly adheres to the base metal It is shown that oxide films with optimum corrosion-protection properties are obtained after 60 m i n a t 5 5 0 - 5 6 0 ~ B.F. Minailov. Prib. Sist. Upr., June 1984, (6), 37-38, [in Russian]. ISSN 0032-8154. 54-O916
Development of Nitrogen Ceramics. Nitrogen ceramics of silicon
nitride (Si3N4) and aluminum nitride (AIN) have been investigated for over ten years. High strength Si3N 4 ceramics using yttria (Y203) and alumina (AI203) additives and densified AIN with rare earth oxides or alkali earth oxides were developed. Si3N4 powder with high ~-phase and homogeneous shape and size was "synthesized by the silica reduction method. 17 r e f . - - A A K. Komeya. Am Ceram. Soc. Bull., Sept. 1984, 63, (9), 1158-1159, 1164, [in English]. ISSN 0002-7812.
5 4 - 0 9 18 Demonstration o f a Silicon Nitride Attrition Mill for Production o f Fine Pure Silicon and Si3N 4 Powders. To avoid metallic impurities normally introduced by milling ceramic powders in conventional steel hardware, an attrition
J. APPLIED METALWORKING.
mill (high-energy stirred ball mill) was constructed with the wearing parts (mill body, stirring arms and media) made from silicon nitride. Commercial Si and Si3N4 powders were milled to fine uniform particles with only minimal c o n t a m i n a t i o n - primarily from wear of the sintered Si3N 4 media. 7 r e f . - - A A T.P. Herbell, T.K. Glasgow, and N.W. Orth. Am. Ceram. Soc. Bull., Sept. 1984, 63, (9). 1176-1178, [in English]. ISSN 0002-7812.
54-0919 Kobe Steel System for Fine Ceramics. A new hot isostatic pressure system announced by Kobe Steel Ltd. for the production of super-hard alloys, superalloys, and fine flaw-free ceramics comprises vastly improved cooling arrangements which reduce the process time by 75%,--J.R. New Mater./Jpn., 1984, 1, (5), 7, [in English]. 54-0923
Explosive Powder Consolidation of Cermets. Cermets were pre-
pared by the explosive compaction of a mixture of alumina and magnesia p o w d e r s with 5 or 25% AI powder binder. Direct compaction using a collapsing mild steel cylinder produced compacts of low porosity and high green strength and density. Attempts to produce compacted discs indirectly in a piston/block assembly were less successful. Hardness data and micrographs are presented.--T.W. A Szecket, S. Nadiv, and I.J. Lin. Materials Engineering Conference, 1981 [Proc. Conf.], Haifa, Israel, 20-22 Dec. 1981, Freund Publishing House, P.O. Box 35010, Tel Aviv, Israel, 1981, (Met.A, 8412-72-0764) 14-16, [in English]. 54-0924
Cold Sintering as a Possible Industrial Process. The literature on the cold compaction of metal powders and powder composites is briefly reviewed, and advantages and disadvantages of this type of process are discussed relative to potential industrial applications. 14 ref.--T.W. E.Y. Gutmanas. Materials Engineering Conference, 1981 [Proc. Conf.], Haifa, Israel, 20-22 Dec. 1981, Freund Publishing House, P.O. Box 35010, Tel Aviv, Israel, 1981, (Met.A., 8412-72-0764) 42-45, [in English]. 5 4 - 0 9 2 5 High Density Tungsten Alloys. W - - N i - - F e and W - - N i - - C u alloys containing 80-98% W have densities of 15-18.8 g/ml. Typical powder metallurgy methods of preparation of these alloys are briefly described, and microstructual, fracture, tensile, and deformation properties are reported.--T.W. R. Gero, and D. Chaiat. Materials Engineering Conference, 1981 [Proc. Conf.]. Haifa, Israel, 20-22 Dec. 1981, Freund Publishing House, P.O. Box 35010, Tel Aviv, Israel, 1981, (Met.A., 8412-72-0764) 46-50, [in English]. 54-0926
Recovery of Heavy Metal for Powder Metallurgy Applications.
A new process for reclaiming machining chips of heavy metal alloys is described. The process involves oxidation of the chips in air at 850-1000~ milling the oxidised chips, and reduction to metallic powders in H 2 at 500-900~ Typical powder properties are reported for reclaimed 9 4 W - - 4 N i - - 2 F e Chips.--T.W. D. Chaiat, R. Gero, and S, N a d i v Materials Engineering Conference, 1981 [Proc Conf.], Haifa, Israel, 20-22 Dec. 1981, Freund Publishing House, P.O. B o x 35010. Tel Avlv, Israel, 1981, (Met.A.. 8412-72-0764) 51-55, [in English].
54-0927 High Pressure Compaction and Cold Sintering of Aluminium Alloys. Specimens were prepared from water-atomized 7123 AI powder, wateratomized pure AI powder, gas-atomized A I - - 1 2 S i eutectic alloy powder, and centrifugally atomized A I - - 7 F e - - 1Cr powder. Compaction pressures ranged up to 30 Kbar. Compaction curves (density vs. pressure), compressive s t r e s s - - s t r a i n curves, transverse rupture test curves, and electron micrographs of fracture surfaces are presented. 9 ref.--T.W. E.Y, Gutmanas, and D. Schechtman. Materials Engineering Conference, 1981 [Proc. ConL], Haifa, Israel. 20-22 Dec. 1981, Freund Publishing House, P.O. Box 35010, Tel Aviv, Israel, 1981. (Met.A., 8412-72-0764) 78-80, [in English].
54-0928 Cold Sintering and Mechanical P r o p e r t i e s of F e r r o u s Powders. (Abstract Only). High pressure compaction up to P = 4.0 GPa of various ferrous powders was investigated. Experiments were conducted on iron powders of various purity, diffusion alloyed iron powders and some prealloyed steel powders. Mechanical properties in compression, shear, three point bending as well as hardness and microhardness were checked after high pressure compaction followed by heat treatments. Pressed and fracture faces were investigated using optical microscopy and SEM. It was found that for powders with a high compressibility density, close to theoretical and good bonding of powder particles may be obtained when P .~ 2.5 GPa, at room temp., providing cold sintering of powder. Heat treatments at T -- 8 0 0 ~ (1 hour) result in high strength accompanied by high ductility. Such temperatures are appreciably lower than those used for sintering of ferrous powders. Additional alloying and proper heat treatments provide mechanical properties, noticeably exceeding those of (hot) sintered samples with the same or nearly the same c o m p o s i t i o n . - - A A Y. Schefer, and E.Y. Gutmanas. Materials Engineering Conference, 1981 [Proc. ConL], Haifa, Israel, 20-22 Dec. 1981, Freund Publishing House, P.O. Box 35010, Tel Aviv, Israel, 1981, (Met.A, 8412-72-0764) 81, [in English].
54-0929 High Pressure Compaction of Powders in One and Two Component Systems. {Abstract Only). The compaction of p o w d e r s at room temp. under high pressure up to P = 4.0 GPa may be used for cold sintering of powders into solid bodies with high mechanical strength. The last depends on properties of powders and on relative density that is obtained after high pressure compaction. High pressure compaction of two or multicomponent Systems may be used for additional alloying that is obtained during heat treatments, following compaction. The present work reports on study of influence of size, shape, purity, methods of preparation and hardness (mechanical properties) of powders on relative density and mechanical properties of c o m p a c t s Iron, stainless steels 304L and 434L, F e - - C r - - C o , Fe--graphite, F e - - W and F e - - W C were investigated. It was shown that p r e s s u r e - - d e n s i t y curves may be obtained from the l o a d - - t i m e curves on the Instron testing machine. Mechanical tests in compression and three point bending were performed. Pressed and fracture faces were investigated using optical microscopy and SEM. Heat treaments were conducted at a temp. to provide diffusion alloying in high pressure compacted samples. These temperatures are noticeably lower than those used for sintering of the same or similar s y s t e m s
VOL. 4, NO. l, JULY 1985
113
High mechanical properties were obtained for a number of systems. The results obtained may be used for design and preparation of other one and two component systems using the method of cold sintering.--AA D. Zak, and E_Y. Gutmanas. Materials Engineering Conference, 1981 [Prec. Conf.], Haifa, Israel, 20-22 Dec. 1981, Freund Publishing House, P.O. Box 35010, Tel Aviv, Israel, 1981, (Met.A., 8412-72-0764) 82, [in English].
54-0930
High Pressure Compaction of W - - C u Composites. (Abstract
O n l y ) , W - - C u composites with up to ~ 30 vol.% Cu are used for heavy duty electrical contacts. Usually, they are oblained by the infiltration of liquid Cu inside a sintered W skeleton. Such composites provided a relatively high electric conductivity, good wear and spark erosion resistance. A report is presented of the investigation of high pressure compaction, mechanical and electrical properties of W - Cu composites. Composites containing 50, 30 and 10 vol.% Cu, as well as pure Cu and W were studied. The 10% Cu composite may be used as a model for high pressure compaction of heavy alloys. Mechanical properties in compression, shear and three point bending, electrical conductivity and microstructure were investigated as a function of compacting pressure, density and heat treatments that follow high pressure compaction. Cold sintering of powder particles was observed for all compositions, mechanicat properties being high for 30 C u - - 7 0 W composite. Tests were performed on samples using a current of high density and mechanical loading close to the working conditions. Temperatures of heat treatments that provide high mechanical and electrical properties are much lower than those that are used in producing such composites by other m e t h o d s . - - A A J. Malek, and E.Y. Gutmanas. Materials Engineering Conference, 1981 [Prec. Conf.], Haifa, Israel, 20-22 Dec. 1981, Freund Publishing House, P.O. Box 35010, Tel Aviv, Israel, 1981, (MetA., 8412-72-0764) 83, (in English].
54-0935 General A s p e c t s for the Optimization of Pressing and Sintering Conditions of Copper Compacts. Solid state sintering of compacts made from dendritic copper powder and its dependence on compacting pressure and sintering temp. have been studied by means of dilatometrical measurements. With regard to high density in the sintered state these parameters must be suitably chosen in order to avoid a decrease in density by an overlapping swelling effect. Within the range of the compacting pressure of P = 500 MPa up to P = 800 MPa and sintering temp. of T s > 1010K a decrease in density was always observed even in the case of stepwise sintering. With P = 400 MPa and T s = 1123K, however, a continuous increase in density of the compacts was obtained. The microstructure of high pressed copper compacts showed intensive pore coalescence after sintering; at the lower compacting pressure rounded, single pores with considerably lower total volume are d o m i n a n t . - - A A H. Schreiner, and R. Tusche. Sintering--Theory and Practice [Prec. ConL], Portoroz, Yugoslavia, 7-10 Sept. 1981, Elsevier Scientific Publishing Co., P.O. Box 211, t000AE Amsterdam, The Netherlands, 1982, (Met.A., 8412-72-0779) 45-51, [in English].
number of cases, it seems likely to prove technologically useful. But fundamentally, and especially at the particulate level, it still is not a very well understood process. The challenge now seems clear: sintering theorists and expermentalists may be uniquely prepared by b a c k g r o u n d - - a n d inclination--to deal with the science of particulate systems during densification. A more complete knowledge is required of the complex processes and relationships involved in dynamic compaction of sinterable powders. 29 r e f . - - A A H Palmour, V.D. Linse, and R.M. Spriggs. Sintering--Theory and Practice [Prec. Conf.], Portoroz, Yugoslavia, 7-10 Sept. 1981, Elsevier Scientific Publishing Co., P.O. Box 211, 1000AE Amsterdam, The Netherlands, 1982, (Met.A. 8412-720779) 611-618, [in English].
54-0958 The Kinetics of Densification of Binary Titanium--Chromium Diboride With C o p p e r ~ N i c k e l Binder. An experimental study was carried out of densification kinetics for powder mixtures of titanium--chromium diboride with copper--nickel binder during hot pressing. As a result of the analysis of the kinetics above in the framework of volume viscous flow theory the porous solid densification is shown to be affected by non linear steady-state creep with dependence of solid flow rate on quadrate of stress. Activation energy was evaluated regularly decreasing from 2.8 to 2.0 eV as binder content rising in alloys of titanium-chromium diboride. The mechanism is discussed briefly. 11 r e L - - A A M.S. Koval'chenko, and L.F. Ochkas. S i n t e r i n g - - T h e o r y and Practice [Prec. ConL], Portoroz, Yugoslavia, 7-10 Sept. 1981, Elsevier Scientific Publishing Co., P.O. Box 211, 1000AE Amsterdam, The Netherlands, 1982, (Met.A, 8412-720779) 619-624, [in English].
54-0959 Formation of Properties of Powdered Carbide Steels Under Quasi-lsostaUc Pressing. The method of quasi-isostatic hot pressing with the pressure applied on a compacting part through intervening media provides for high efficiency densification of porous materials during compaction. High pressure compaction and shear deformations in material make it possible to produce high density parts with fine structure and improved physical and mechanical properties. This method is believed to produce best results when applied to high density billets production from poorly compactable materials including hard alloys and carbide s t e e l s . - - A A V.M. Gorokhov, M.M. Dechko, E A . Doroshkevich, and O.V. Roman. Sintering-Theory and Practice [Prec. ConL], Portoroz, Yugoslavia, 7-10 Sept. 1981, Elsevier Scientific ~ublishing Co., P.O. Box 211, 1000AE Amsterdam, The Netherlands, 1982, (Met.A., 8412-72-0779) 625-629, [in English].
54-0967 Characteristics of Inflammability and Explosion Hazard of Powders of Ferroalloys. (Translation: BISI 22754). See Met A, 8408-540533. I.V. Babaitsev et al. Stal', Jan. 1984, (t), 34-37, [in English]. ISSN 0038-920X. 54-0972
54-0937 Some Magnetological Insights in the Consolidation of Metal Powders. Coercivity, retentivity, conductivity and X-ray diffraction measurements were performed on cobalt green compacts in the pressure range 0-660 MPa. Well pronounced property anisotropy, respectively directions parallel and normal to the pressing action direction, is discussed. Mean internal stresses in compacts, assessed from magnetomery data, reach 400 MPa at highest pressure applied and are in reasonable agreement with stress values computed by using X-ray diffraction data. Crystallite size data and stacking fault probabilities are also considered. 18 r e f . - - A A D. Dutevid, A. Kirin, and A. Bonefa(~i(~. Sintering--Theory and Practice [Prec. Conf.], Portoroz, Yugoslavia, 7-10 Sept. 1981, Elsevier Scientific Publishing Co., P.O. Box 211, IO00AE Amsterdam, The Netherlands, 1982, (Met.A., 8412-720779) 85-90, [in English].
54-0950 Preparation of Fine Grained T h e r m o e l e c t r i c Alloys by Vacuum Hot Pressing. N-type Silicon Germanium alloy compacts of the composition Si63.5 Ge365 and with a grain size (L) in the range 10 . L ~ 25/~m, 5 .~ L 9 10 /~m and 9 5 /Jm have been prepared by vacuum hot press sintering at temp. close to the alloy solidus temp. (1200~ and at pressures of ~ 200 MPa. The compacts were better than 98% dense compared to equivalent single crystal material and little if any grain growth has occurred. Initial measurements of the thermoelectric transport properties confirm the theoretical prediction that the lattice thermal conductivity decreases with a reduction in grain size At room temp. the lattice thermal conductivity of the "single crystal" starting material is equal to 4.31 W m--~K--1 and falls to 3.10 W m ,K--1 in the compact with a grain size ,. 5 #m, a reduction of ~ 28%. Within experimental error the Seebeck Coefficient and Electrical Resistivity do not change with a reduction in grain size. It is concluded that the thermoelectric conversion efficiency o1 the alloy would be significantly improved through the use of fine-grained material. 18 r e f . - - A A D.M. Rowe. Sintering--Theory and Practice [Prec. ConL], Portoroz, Yugoslavia, 710 Sept. 1981, Elsevier Scientific Publishing Co., P.O. Box 211, IO00AE Amsterdam, The Netherlands, 1982, (Met.A., 8412-72-0779) 487-495, [in English].
5 4 - 0 9 5 1 Effect of Thermal Treatment on Microstructure of Nickel Base PM Superalloys. APK-1, APK-4 and APK-7 superalloy powders were characterized by scanning electron microscopy as well as X-ray analysis, and then submitted to the identical powder metallurgy route of compact production (hot pressing and subsequent heat treatment). Speciat attention was paid to the microstructure development (precipitation of -~' phase and carbides distribution), during the different stages of sample t r e a t m e n t . - - A A M. Mitkov, M. Gligi6, and D. Nikovi6. Sintering--Theory and Practice [Prec. ConL], Portoroz, Yugoslavia, 7-10 Sept. 1981, Elsevier Scientific Publishing Co., P.O. Box 211, 1000AE Amsterdam. The Netherlands, 1982, (Met.A. 8412-72-0779) 527532, [in English].
54-0957 Recent Trends in Understanding Dynamic Compaction of Powders. In direct and indirect applications, the dynamic compaction of powders holds obvious promise for a number of existing or proposed materials processing schemes. Rightly or wrongly, it is being (or will be) attempted, and in a significant
114
VOL. 4, NO. 1, JULY 1985
An Assessment of Powder Metallurgy Today and Its Future
P o t e n U a l . - - I I . In Part I of this review the current status of hot and cold forging of sintered prelerms in North America was described and examples were given of parts in commercial production. Part II covers trends in the manufacture of powder metallurgy components by injection moulding and high temperature sintering. 55 ref - - A A L . F Pease. Met. Powder Rap, Aug 1983, 38, (8), 423-427. ]in English] ISSN 0026-0657.
54-0973
Design of Powder Metallurgy Gears. The advantages in producing gears by the powder metallurgy process are both economic and technical. The economic advantages derive from excellent material utilisation, low labour intensity, and high machine toolutitisation Technical advantages relate to shape capability for combined functions, p a r t - t o - p a r t uniformity, c o n t r o l l e d material properties, and inherent surface finish. The design procedure for powder metallurgy gears, is also discussed.--AA S.W. McGee. Met. Powder Rap., Aug. 1983, 38, (8), 429-431, [in English] ISSN 0026-0657.
54-0974 Design and Introduction of Powder Metallurgy Parts in the Automotive Industry. A new powder metallurgy part is created due to one of three reasons: (1) cost savings over a manufacturing method tar a current part (2) cost savings over an alternative method to manufacture a new part or (3) it is the only practical way to manufacture the part. In today's quality conscious atmosphere suppliers of powder metallurgy parts should be aware of their responsibilities in producing a powder metallurgy part to required standards. How the producer must become involved in early feasibility issues, prove process capability and maintain capability on a ongoing basis is d i s c u s s e d - - A A L.A. Winquist. Met. Powder Rep., Aug. 1983, 38, (8), 436-438, [in English]. ISSN 0026-0657.
54-0975
Forgeability Evaluation of Steel Powder Preforms. Results of systematic investigation on the influence of Cr and Me addition on the densification, forgeability and strength of low carbon steel powder preforms under varying compacting pressures are presented The work has also been carried out on a steel powder preform of composition En 3 5 1 / 3 5 3 produced from a mixture of elemental powders. 14 ref - - A A H.N Tewari, and R. Sharon Met. Powder Rep., A u g 1983, 38, (8), 441-443. [in English]. ISSN 0026-0657. 54-0976
Hot Powder Metallurgy Forging Technology and Application.
Hot forging sintered preforms presented companies entering this new area of powder metallurgy technology in the early 1970s with considerable production problems before the process could become a viable proposition. These problems are discussed along with how company production experience has resulted in a number of powder forgings in regular commercial production.--AA A.C Alves. Met. Powder Rap., Aug. 1983, 38, (8), 444-446, [in English]. ISSN 0026-0657
J. APPLIED METALWORKING
54-0001 Competing Near Net Part Processes Compared. Report is made on a special workshop conducted by the International Powder Metallurgy Conference and Exhibit. Fine blanking, die casting, powder metallurgy and plastic molding are discussed. Cost c o m p a r i s o n is made for the processes, including production of a transfer geneva pinion by Fe P / M vs. plastic molding. Growth rates for P / M in various markets are projected as follows: a u t o m o t i v e - - 8 to 9%; a p p l i a n c e s - - 6 to 8%; power t o o l s - - 7 to 9%; business m a c h i n e s - - 7 to 8%; consumer p r o d u c t s - - 6 to 7%.--C.M.L.S. Mod. Met., Sept. 1984, 40, (8), 58, 60, 82, 64, [in English]. ISSN 0028-8127. 54-0002 Fabrication and Mechanical Properties of ODS Ferritic Alloys Canning Tubes for Fast Reactor Fuel Pins. The ODS alloys are made through powder metallurgy methods and a matrix was first selected. It contains 13% Cr, 1.5% Me and 2-3% Ti which gives the alloy much improved high-temp, strength because of a x-phase precipitation. The carbon content is kept very low to avoid the formation of titanium carbides. TiO 2 or Y203 were chosen as oxide additions. Tensile test results are given as a function of temp. and axial creep data at 500 to 700~ are presented. From these tests, the Y203 containing alloys appear to be slightly superior; both alloys are comparable to AISI 318 at 700~ they are better at low stresses and at lower temp. A shallow min. of ductility appears between 400 and 500~ but elongation remains always > 7% in tensile tests. Creep rupture ductility is - 5% and does not depend strongly on stress level (or time-to-rupture). Biaxial creep tests made by internally pressurizing the tubes are also presented. 15 r e f . - - A A J.-J. Huet et al. Topical Conference on Ferritic Alloys for Use in Nuclear Energy Technologies [Prec. ConL], Snowbird, Utah, US.A,, 19-23 June 1983, The Metallurgical Society/AIME, 420 Commonwealth Dr., Warrendale, Pa. 15086, U S . A _ 1984, (Met.A, 8501-72-0004) 329-334, [in English].
54-0003 High Strength A I - - F e - - V Alloys at Elevated Temperatures Produced by Rapid Quenching From the Melt. The microstructure, hardness and tensile properties of high-strength A I - - F e - - V alloys (8-14 wt.% Fe, 1.03.5 wt.% V) produced by rapid solidification are reported. A series of A I - - F e - - V ternary alloys were prepared from cast ribbon which was ground into powder and then compacted and extruded into rectangular bar. While room-temp, strength requirements (UTS of 500 MPa) were generally met, the attainment of elevatedtemp. strength and ductility requirements could only be achieved with a dispersoid volume fraction of 35 to 40o/,,.--G.P.K. D.J. Skinner. and K. Okazaki, Scr. Metall., Sept. 1984, 18, (9), 905-909, [in English]. ISSN 0036-9748.
54-0004 AI--Fe--Zr A l l o y s for H i g h - T e m p e r a t u r e A p p l i c a t i o n s Produced by Rapid Quenching From the Melt. The results of a program to optimize the mechanical properties of A I - - F e - - Z r ternary alloys (6-13 wt.O/o Fe, 1.5-6 wt.U/c,Zr) produced by rapid solidification are described. Alloy bars were obtained from the extrusion Of compacted powder which has been ground from rapidly quenched cast ribbon. Most desirable mechanical properties (tensile strength and hardness) were achieved with a dispersoid volume fraction of 27 to 30%. 9 ref. --G.P.K K. Okazaki, and D.J. Skinner. Scr Metall., Sept. 1984, 18, (9), 911-916, [in English], tSSN 0 0 3 6 - 9 7 4 8
54-0009 Structure of High-Speed Steel With High Solidification Rates. (Translation). See Met. A., 8 4 0 9 - 5 4 - 0 6 7 4 A.D Ozerskii, Kh. Fishmayster, L. Olsson, and G.A. Panova. Met. Sci. Heat Treat. (USSR), Mar.-Apr 1984, 26, (3-4), 204-209, [in English]. ISSN 0026-0673.
D.R. Chang, D.D. Krueger, and R.A. Sprague. Superalloys 1984 [Prec. ConL]. Champion, Pa,, U.S.A., 7-11 Oct. 1984, The Metallurgical Society/AIME, 420 Commonwealth Dr., Warrendale, Pa. 15086, U.S.A., 1984, (Met.A., 8501-72-0013) 245273, [in English].
54-0015
High-Temperature Deformation Behavior of P / M Rend 9 5 . The
deformation behavior of P / M Rend 95 at 1107~ as a function of strain rate and prior thermomechanical processing is described. Data were obtained by carrying out constant true strain rate tensile tests at 1107~ and at strain rates ranging from 0.01 to 30 min--1 p / M Ren~ 95 consolidated f r o m - - 1 5 0 mesh powder was studied in the HIP-consolidated, extrusion-consolidated and HIP plus isothermally forged conditions. The data define the regimes of superplastic and nonsuperpiastic deformation for Rend 95 at 1107~ and show that the superplastic region shifts to lower strain rates with increasing grain size. The implications of the data with respect to current isothermal forging practice and starting stock of P / M Ren~ 95 are discussed. 13 r e f . - - A A T.E. Howson, W.H. Couts, Jr., and J.E. Coyne. Superalloys 1984 [Prec. ConL]. Champion, Pa., U.S.A., 7-11 Oct. 1984, The Metallurgical Society/AIME, 420 Commonwealth Dr., Warrendale, Pa. 15086, U.S.A., 1984, (Mef.A., 8501-72-0013) 275284, [in English].
54-0016 Influence of Powder Particle Size Distribution and Pressure on the Kinetics of Hot Isostatic Pressing (HIP) Consolidation of P / M Superalloy Rend 95. A study is made of the modes and the kinetics of deformation between powder particles during HIP consolidation of superalloy powders. The kinetics of powder densification and the powder morphological changes occurring during HIP were determined as a function of applied pressure, temp. and initial powder particle size distribution for the Ni-base superalloy Rend 95. It is found, for example, that at 1120~ and 103 MPa, consolidation occurs rapidly (full density is reached within 5 min) mainly by instantaneous plastic flow instead of by local creep deformation. It is also found that noncreep deformation a n d / o r a full distribution of particle sizes can result in a greater number of undeformed particles in the consolidates. 10 r e f . - - A A R.D. Kissinger, S.V. Nair, and J.K. Tien. Superalloys 1984 [Prec. ConL], Champion, Pa., U.S.A., 7-11 Oct. 1984, The Metallurgical Society/AIME, 420 Commonwealth Dr., Warrendale, Pa. 15086, U.S.A., 1984, (Met.A., 8501-72-0013) 285-294, [in English].
54-0017 The Effect of Microstructure, T e m p e r a t u r e and Hold-Time on Low-Cycle Fatigue of As-HIP P / M Rene 9 5 . The effects of microstructure, temp., plastic strain range and hold time on the low-cycle fatigue (LCF) life were studied for Ren~ 95, a superalloy used in jet engine disks. It was shown that the life could be varied by approx, an order of magnitude at elevated temp. by simple heat treatments. The life was largest for the microstructure that promoted the most homogeneous deformation mode. The results are explained using the concept of a synergistic interaction between the deformation mode and boundary oxidation. 10 r e f . - - A A S. Bashir, and S.T. Antolovich. Superalloys 1984 [Prec. Conf.], Champion, Pa., U.S.A., 7-11 Oct. 1984, The Metallurgical Society/AIME, 420 Commonwealth Dr., Warrendale, Pa. 15086, U.S.A., 1984, (Met.A., 8501-72-0013) 295-307, [in English].
54-OO18 The Influence of Hold Times on LCF and FCG Behavior in a P / M Nickel-Base Superalloy. The relative importance of creep and environmental
interactions in high-temp, fatigue behavior has been investigated for as-HIP Rene 95. Strain-controlled low-cycle fatigue and load-controlled fatigue crack growth tests were performed at elevated temp. in Ar, followed by fractographic analyses 54-0010 Influence of Carbon on the Phase Composition, Structure and of the fracture surfaces by scanning electron microscopy. Fatigue lives were drastically reduced and crack growth rates increased 100-fold as a result of superpoP r o p e r t i e s of T y p e R 6 M 5 P o w d e r M e t a l l u r g y H i g h - S p e e d S t e e l . sition of hold times on continuous cycling. A change in fracture mode with hold time ( T r a n s l a t i o n ) . See Met. A., 8409-54-0675. S ~, Gorchakova. Met Sci Heat Treat. (USSR), Mar.-Apr. 1984, 26, (3-4), 210- also was noted. Chromium oxide was detected on the fracture surface by Auger electron spectroscopy, 13 r e f . - - A A 212, [in English]. ISSN 0026-0673. S.J. Choe, S.V. Golwalkar, D.J. Duquette, and N.S. Stoloff. Superalloys 1984 54-0Oll P r o p e r t i e s of I O R 6 M 5 - M P S t e e l P r o d u c e d by R o l l i n g . [Prec. ConL], Champion, Pa., U.S.A., 7-11 Oct. 1984, The Metallurgical Society/ AIME, 420 Commonwealth Dr., Warrendale, Pa. 15086, U.S.A., 1984, (Met.A, ( T r a n s l a t i o n ) . See Met A,8409-54-0676 8501-72-0013) 309-318, ]in English]. M N Goryushina, V . M Panovko, S . V Dubrovskii, Yu.F. Tarasevich, and V.S. Yusupov. Met. Scf. Heat Treat. (USSR), Mar.-Apr. 1984, 26, (3-4), 212-214, [in En54-0019 Long-Term Mechanical Behavior of S o m e O D S Alloys. One of glish] ISSN 0026-0673. the major attributes of oxide dispersion strengthened lOPS) alloys is that they can retain useful strengths up to a relatively high fraction of their melting points. More54-O012 Processes of Interaction on the Interface o f a B i m e t a l B i l l e t Produced by the Method of Rolling Unsintered Powder. ( T r a n s l a t i o n ) . over, at the higher operating temp. characteristic of advanced gas turbine engines, t h e s e alloys display long-term strengths beyond the c a p a b i l i t i e s of See Met. A, 8409-54-0677. conventional superalloys. Determination of the long-term mechanical properties V D Karner, M.N. Goryushina, and L.A. Sychuzhnikova. Met. Sci. Heat Treat. and related microstructures of ODS alloys, such as Inconel alloy MA 6000, has (USSR), Mar -Apr. 1984, 26, (3-4), 214-217, [in English]. ISSN 0026-0673. identified some unique stress rupture behavior characteristics, particularly the existence of two distinct regions of the rupture stress vs. time curves that predict 54-0013 S t r u c t u r e and Properties of Materials ZhGr0.8 and ZhGrO.SKh higher design stresses for long-time service than could be predicted from onty Depending on Sintering Time and Heat Treatment. ( T r a n s l a t i o n ) . See Met. short-term data. This behavior and the advantages for industrial applications are A , 8409-54-0678. discussed. 7 ref. AA S I Borodukhov, S.S. Kiparisov, and V.I. Rudakov Met. Sci. Heat Treat. (USSR), R,C. Benn, and S.K. Kang. Superalloys 1984 [Prec. ConL], Champion, Pa., U.S.A., Mar. A p r 1984, 26, (3-4), 221-224, [in English]. lSSN 0025-0673 7-11 Oct. 1984, The Metallurgical Society/AIME, 420 Commonwealth Dr., Warrendale, Pa. 15086, U S A . , 1984, (Met.A., 8501-72-0013) 319-326, [in English]. 54-0014 Superalloy Powder Processing, Properties and Turbine Disk C r e e p and F r a c t u r e of I n c o n e l MA 7 5 4 at E l e v a t e d Applications. The characteristics of inclusions resulting from various consolida- 5 4 - 0 0 2 0 tion techniques and their effects on the fatigue properties of a typical high- T e m p e r a t u r e s . The high-temp, longitudinal creep and fracture properties of the 3trength PM superalloy, Rene 95 are discussed The nature, origin and size range mechanically alloyed oxide dispersion strengthened alloy Inconel MA 754 have of defects found in HIP, HIP + isothermally forged, extruded + isothermally been examined. Two distinct regions of deformation have been observe~: a highforged material are described and their influence on LCF behavior is analyzed. stress, high-stress exponent regime wherein plastic flow is homogeneous and Thermomechanical processing improves the LCF life considerably. The improve- fracture is transgranular, and a low-stress, low-stress exponent regime wherein ment is attributed to the dispersion of large defects. The LCF life of forged mate- cavitation occurs and fracture is intergranular. The cavitated transverse grain rial is also benefited by a greater tendency toward internal fatigue initiation at boundaries have been examined in an effort to understand the mechanisms of incrystallographic origins or initiated at smaller defects. The effects of heat treat- tergranular fracture of MA 754. 8 r e f . - - A A ment on the m e c h a n i c a l p r o p e r t i e s and microstructural features of J.J. Stephens, and W.D. Nix. Superalloys 1964 [Prec. Conf.], Champion, Pa., extruded + isothermally forged materials are also investigated. 17 r e f . - - A A U.S.A., 7-11 Oct, 1984, The Metallurgical Society/AIME, 420 Commonwealth Dr.,
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Warrendale, Pa. 15086, U.S.A., 1984, (Met.A, 8501-72-0013) 327-334, [in English].
Warrendale, Pa. 15086, U.S.A., 1984, (Met.A, 8501-72-0013) 387-396, [in English].
54-0021 The Development of Preferred Orientation in N i - - M o - - A I - - X and N i - - C r - - A I - - X Superalloys. The development of preferred crystallographic orientation was studied in advanced Ni based superalloys 185 and 116 of the type N i - - M o - - A I - - X and N i - - C r - - A I - - X . Principal variables of interest were mode of deformation (e.g. extrusion, rolling), deformation temp. and reduction and
54-0028 Mechanical Properties and Microstructure of Melt-Spun Superalloy Ribbons. Rapid solidification is expected to produce fine-grained su-
effect of initial texture. Textures developed in the N i - - M o - - A I - - X alloys were typical of moderately high stacking fault energy (SFE) f.c.c, metals, while textures for the N i - - C r - - A I - - X alloys were typical of low SFE-f.c.c. alloys. 25 r e f . - - A A H A . Chin, and A.M. Adair. Superalloys 1984 [Prec. ConL], Champion, Pa., U.S.A., 7-11 Oct. 1984, The Metallurgical Society/AIME, 420 Commonwealth Dr., Warrendale, Pa. 15086, U.S.A., 1984, (Met.A., 8501-72-0013) 335-345, [in English].
54-0022 Thermomechanical Processing of P / M Alloy 7 1 8 . This study was undertaken to investigate the structural changes and mechanical property behavior induced in P / M Alloy 718 by thermomechanical processing. Argon atomized p o w d e r was consolidated via the consolidation by atmospheric pressure (CAP) process and subjected to various hot working procedures and heat treatments. Tensile and stress-rupture testing and optical and electron microscopy and X-ray analysis were used to evaluate the heat treated material. It was found that P / M alloy 718 exhibits the same phases as its conventionally cast and wrought counterpart after similar solution treatments; however, both precipitate and secondphase particles are finer and more uniformly dispersed in the powder material. The recrystallized structure of P / M Alloy 718 maintains a finer grain size at a given solution temp., i.e. grain coarsening does not occur as readily as in wrought Alloy 718. Finally, P / M Alloy 718 demonstrates equivalent mechanical properties to the conventional material, indicating that a useful product with a fine uniform structure can be produced through powder metallurgy techniques. 7 r e f . - - A A J.F. Radavich, and D.J. Meyers. Superalloys 1984 [Prec. Conf,], Champion, Pa., U.S.A., 7-11 Oct. 1984, The Metallurgical Society/AIME, 420 Commonwealth Dr., Warrendale, Pa. 15086, U.S.A., 1984, (Met.A., 8501-72-0013) 347-356, [in English]. 54-0023 Attractive Dislocation and Particle Interactions in O D S Superalloys and Implications. For the oxide dispersion strengthened (ODS) alloys, dislocation~particle interactions is generally believed to be repulsive since the elastic constants of the oxide dispersoids are believed to be greater than those of the matrix. High-temp. strengthening is thought of in terms of a dislocation climb modified Orowan-type bowing mechanism between the particles. Dislocation escape occurs when the stress is sufficient to cause the dislocation to bow to a critical configuration. Contrary to this general belief, through detailed TEM micros* copy study of crept and hot tensile tested Inconel MA 754, it was found that the interaction between dislocations and oxide dispersoid is in fact attractive, with the high-temp, properties of ODS alloys stemming from this unexpected attractive interaction. In particular, the characteristic and important threshold behavior of ODS alloys during creep at high temp. is discussed, 15 r e f . - - A A A . H Cooper, V.C, Nardone, and J.K. Tien. Superalloys 1984 [Prec. Conf.], Champion, Pa., U.S.A., 7-11 Oct. 1984, The Metallurgical Society/AIME, 420 Commonwea!th Dr., Warrendale, Pa. 15086, U.S.A,, 1984, (Met.A., 8501-72-0013) 357366, [in English].
54-0024 The E f f e c t o f Grain Shape on Stress R u p t u r e o f the Oxide Dispersion Strengthened Superalloy Inconel MA 6000. Creep specimens of Inconel MA 6000 with different grain aspect ratios (GAR) ranging from ~ 4 to 60 were tested at 9 5 0 ~ at a stress of 230 MPa. The resulting rupture times show a pronounced dependence on the GAR below a value of ~ 20, where fracture is mainly iotergranular. At higher GAB values, the rupture time becomes less sensitive to grain shape, and fracture is predominantly transgranular, These results are interpreted in the light of the hypothesis that sliding of the elongated grains along longitudinal grain boundaries, which is a necessary accommodation mechanism, controls the rate of creep damage accumulation on boundaries perpendicular to the applied stress. A quantitative model for the coupling between the two processes is presented. 17 r e f . - - A A E. Arzt, and R.F. Singer. Superalloys 1984 [Prec. ConL], Champion, Pa., U.S.A., 711 Oct. 1984, The Metallurgical Society/AIME, 420 Commonwealth Dr., Warrendale, Pa. 15086, U.S.A., 1984, (Met.A., 8501-72-0013) 367-376, [in English].
54-OO25
Fabricated RSR Vane Manufacturing Technology. The objective of the programs is to develop a vane alloy and component design which affords a 250~ increase in turbine inlet temp. or a 6-10X increase in turbine durability over existing F100 performance standards. To achieve the goal, a technology required to produce a multipieee, first-stage, fabricated turbine vane has been developed. The fabricated vane consists of two PWA 1123 single-crystal airfoils and two PWA 1480 single-crystal platforms assembled as a doublet. Details of the powder atomization, consolidation, directional recrystallizatien, brazing and machining processes are presented. 9 r e f . - - A A S.A. Baker, W.J. Gostic, and R.J. Ondercin. Superalloys 1984 [Prec. ConL], Champion, Pa., U.S.A., 7-11 Oct. 1984, The Metallurgical Society/AIME, 420 Commonwealth Dr., Warrendale, Pa. 15086, U.S.A., 1984, (Met.A, 8501-72-0013) 377385, [in English]. 54-0026 E f f e c t o f Oxygen on Creep Crack Growth in P M / H I P N i c k e l B a s e SuperaUoys. The creep crack growth rates (CCGR) of four PM/HIP Nibase superalloys were measured in a range of CCGB from 10 - 9 to 10 - 5 m/s, The alloys tested were low-carbon Astroloy, Merl-76, Iow-C IN- 100 and Rend 95. Crack growth rates were measured in air and 99.999% pure Ar at 704~ Creep crack growth tests were performed on single-edge notched specimens and the crack length was measured using the d.c. potential drop technique. The curve of crack growth vs. the stress intensity factor exhibits three ranges which are dependent upon the initial value of the stress intensity factor. Region I is characterized by slow crack growth followed by Region II where the crack growth has a power law dependency on the stress intensity factor and Region nl of fast fracture which is limited by the Kic value of the material. 22 r e f . - - A A K.R. Bain, and R.M. Pelloux. Superalloys 1984 [Prec. Conf.], Champion, Pa., US.A., 7-11 Oct. 1984, The Metallurgical Society/AIME, 420 Commonwealth Dr.,
116
VOL. 4, NO. 1, JULY 1985
peralloys displaying enhanced mechanical properties. The production of melt-spun ribbons of two Ni-base superalloys (Ren~ 80 and IN738LC) and a Co-base superalIoy (FSX414) is described. Their microstruetures have been characterized by met a l l o g r a p h i c techniques, e l e c t r i c a l r e s i s t i v i t y c h a n g e s and hardness measurements. Tensile properties were determined at ambient and elevated temp., where values of the strain rate sensitivity indicate that micrograin superplasticity may be occurring,--AA K Yasuda, M. Tsuchiya, T. Kuroda, and M. Suwa. Superaltoys 1984 [Prec. Conf.], Champion, Pa., US.A., 7-11 Oct, 1984, The Metallurgical Society/AIME, 420 Commonwealth Dr., Warrendale, Pa. 15086, U.S.A., 1984, (Met.A., 8501-72-0013) 477486. [in English].
5 4 - 0 0 2 9 Rapid Solidification and Dynamic Compaction of Nickel-Base Superalloy Powders. A Ni-base superalloy containing 13o/,) A I - - 9 % M o - - 2 % Ta (in at,~/n) has been characterized in both the rapidly solidified condition and after dynamic compaction. Dynamically compacted specimens were examined in the as-compacted condition and observations related to current theories of interparticle bonding. In addition, the recrystallization behavior of the compacted material at relatively low temp. ( ~ 0.5-0,75 Tin) was investigated. 8 r e f . - - A A R.0, Field, S.J. Hales, W.O, Powers, and H,L, Fraser. Superalloys t984 [Prec. Conf.], Champion, Pa., U.S.A, 7-11 Oct, 1984, The Metallurgical Society/AIME, 420 Commonwealth Dr., Warrendale, Pa. 15086, U.S,A., 1984, (Met.A. 8501-720013) 487-496, [in English],
5 4 - 0 0 3 0 Corrosion-Resistant Alloy Products for Oil and Gas Industries by the HIP C l a d P r o c e s s . The use of cladding in the development of corrosionresistant equipment for sour gas well drilling is examined, Alloy 625 powder is clad onto the inside of an alloy steel forging using hot isostatic pressing (HIP); the clad product is then quenched, tempered and machined. Test results for HIP625 are presented for sulfide stress cracking tests, chloride stress corrosion tests, pitting and corrosion tests, and anodic stress cracking tests, HIP625 is compared to wrought 625. Mechanical properties of HIP625 are compared to API Type 3 Requirements and 4130 low-alloy steel,--C.M,L,S, M. Bishop. lad, Heat., Oct, 1984, 51, (10), 18-19, [in English] ISSN 0019-8374,
54-O031
Titanium Powder Rolling Technology: Current State of
Development. A blended elemental P / M T i - - 6 A I - - 4 V material is studied; the influence of green density, unique sintered microstructure, influence of sintering temp., influence of sintered density on mechanical behaviors, welded microstructure and thermocbemical effects are considered. Tensile properties for various process conditions are listed. The sintering cycle of 1093~ and 4 h is determined to be the optimum sintering condition for 99% sintereddensity, appropriate micrestructure, cost-effectiveness and tensile properties close to MIL-T-gO46H --C.M.L.S. J.S, Park, D.H. Re, and E N Aqua, Ind. Heat., Oct. 1984, 51, (10), 24, 26-27, [in English]. ISSN 0019-8374. 54-0032
Tantalum Powder Composition. An ingot-derived agglomerated Ta powder composition comprises a granular Ta powder having a particle size 10 #m and including ~ 20-40% of a flaked Ta powder having a BET surface area of ~ 0.20-0.40 m2/gm produced by deforming a granular Ta powder having a particle size ranging from ~ 10-44 ,um. The composition has an oxygen content of - ~ 1900 ppm. a Scott Density 9 ~ 25 g / i n 3, (1500 kg/m3), a crush strength of an unsinteredpellet, pressed at 6.0 g / c c , . ~ 15 I b ( 6 7 N) and an anode c a p a c i t a n c e , p r e s s e d at 6.0 g / c c and sintered at 1600~ of 7500 C V / g M.F. Getz, M.J. Maggie, B.F. Hitch, and Cabot Corp. OfL Gaz., 10 Apr. 1984, Patent no. US4441927 (USA), 16 N o v 1982. ISSN 0360-5132. 54-0033
Method for Manufacturing Tubes by Sintering. A method of manufacturing tubes comprises: forming an inner tube wall layer of sinterable metallic powder on a mandrel; forming an outer tube wall layer of sinterable metallic powder on the inner layer, the grain size of the powders formed as the inner and outer layers being unequal; providing a forming surface for the layer of fine-grained powder while sintering the tube wall and infiltrating therein an infiltratable material which is liquid or liquifiable at the sintering temp. and is capable of wetting the metal powder particles and which solidifies at temp. below the sintering temp. and forms a bond of infiltrable material between fine-grained and coarse-grained particles, the infiltration being carried out in a direction from the layer of coarsegrained powder towards and into the layer of fine-grained powder. L.M. Bruce, and Uddeholms AB. Off. Gaz., 8 May 1984, Patent no. US4447389 (USA), 11 June 1980. ISSN 0360-5132. 54-0034 Process for the Production of Silicon Carbide Composite. A process for preparing a bonded composite comprises: blending diamond crystals and carbon black to permit an even coating of diamond crystal surfaces; forming a first dispersion of blended diamond crystals and C black in paraffin; forming a second dispersion of C fiber, C black and filler in paraffin; compacting one of the dispersions to produce a physically stable intermediate compact; recompacting the intermediate compact with the remaining dispersion to produce a binary compact; subjecting binary compact to a vacuum for a period of time at a temp. sufficient to vaporize essentially all of the paraffin; infiltrating binary compact with liquid Si; and sintering the binary compact containing infiltrated Si under conditions sufficient to produce a ~ silicon carbide binder uniting the composite, elemental Si forming ~ 3-6% of the first dispersion after sintering. J.M. Ohno, and General Electric Co. OfL Gaz., 12 June 1984, Patent no. US445395f (USA), 22 Jan. 1981. ISSN 0360-5132. 54-0036
Powder Rolling Finds Some Niches. Polential savings by rolling strip from metal powder initiated many attempts but only a few succeeded. Three
J. APPLIED METALWORKING
successful specialized operations are described--specialty Ni, Co and AI-base alloys. New powders include C u - - 15Ni--8Sn and A I - - 8 . S P b - - 4 S i - - 1.5Sn-- 1Cu. High-tensile Cr strip with adequate ductility, Cu strip from cuprous oxide powder with good strength, elongation and electrical conductivity and Ti from sponge fines are r e p o r t e d . - J.V.R. R.R. Irving. Iron Age, Met. Prod., 3 Sept. 1984, 227, (17), 57-60, [in English]. ISSN 0164-5137.
M. Ward, and Lucas Ind plc. 30 Aug. 1984, Patent no. GB2135411A (UK), 16 Feb. 1984.
54-0070 S t r u c t u r e of Fe40Ni40P14B 6 A m o r p h o u s P o w d e r M a t e r i a l C o m p a c t e d by Explosion Pressing. (Translation). See Met. A., 8405-540323. O.V. Roman etal. Phys. Chem. Mater. Treat. (USSR), July-Aug. 1983, 17, (4), 424428, [in English]. ISSN 0264-729X.
54-0040
Pressing and Sintering of Nickel Powders. Data on pressed and sintered Ni powders Type -123, 287 and 255 are sparse. Available published data together with some new data necessary to confirm trends are presented. The published and new data have been analyzed from the aspect of production of porous and dense materials by pressing and sintering. The data have been summarized by plotting the compaction characteristics and the densification that takes place over a wide range of porosities when sintering between 700 and 1100~ It also shows the sintered strength trends with porosities for materials pressed at low compacting pressures ( 100 M P a ) . - - A A V.A Tracey. Int. J. PowderMetall. Powder TechnoL, Oct. 1984, 20, (4), 281-282, 284-285, [in English]. ISSN 0361-3488. 54-0048 Isostatic Pressing of Metals. The technologies of cold isostatic and hot isostatic pressing of metal powders are described. Both processes offer a competitive and economical means of fabricating materials that are otherwise difficult or uneconomic to fabricate by more traditional means. Cold isostatic pressing is being applied increasingly to bulk manufacture of precision parts of complex geometry, while hot isostatic pressing provides an economical route for consolidating high-alloy powder systems to full theoretical density, and to nearnet-shape configurations. 18 r e f . - - A A P.J. James. Perspectives in Metallurgical Development [Proc. ConL], Sheffield, England, 16-18 July 1984, The Metals Society, 1 Carlton House Terrace, London SWtY 5DB, England, 1984, (Met.A, 8501-72-0044) 243-247, [in English]. 54-0052
HIP-Tool Materials. Representative alloys for the cold and hot work field as well as for the stellites are investigated to demonstrate that alloys produced by the HIP-PM route offer strength and toughness properties at least to those of conventional alloys, even before forging after HIP. Based on these results, the fabrication of near-net-shapes in the tool materials area is made possible by HIP-technology. Thus, the initial goals of the HIP-technology, namely to minimize material and energy consumption as well as finishing efforts, can be considered accomplished for this application area. 7 r e f . - - A A E. Bayer. Powder MetalL Int., May 1984, 16, (3), 117-120, [in English]. ISSN 00485012. 54-0059
Manufacture and Properties of PM Aluminium A I I o y s . - - I I I . In
part III of this paper on the properties of PM aluminium alloys, the following properties are examined: effect of structure on quench sensitivity; properties versus ageing time at 165~ fraclure toughness versus density; ultimate elongation of A I - AI203 powder materials versus mass fraction of AI203; wear resistance of AI powder materials; hardness versus total porosity: hot hardness of extruded dispersion strengthened AI compared with pure aluminium versus temperature; hardness retention of extruded dispersion strengthened At-3 w t . % - - a f t e r annealing at various temperatures for 1 hour; resistivity of sintered aluminium powder compacts versus relative density. Finally, the many applications of aluminium powder are listed. 139 ref--R S A J AIler Fernandez Aluminium, July 1984, 60, (7), 510-515, [in English]. ISSN 0002-6689
54-0061 Relationship B e t w e e n Compacting Pressure, Green Density, and Green Strength of C o p p e r Powder Compacts. The dependence of green strength on green density and on compacting pressure was investigated for the bidirectional die pressed and isostatically pressed Cu powder compacts. The breaking strength of the pressed Cu compact was found to increase with green density and also with compacting pressure. The green strength seemed to be directly proportional to the contact area between powder particles. A theoretical equation for the relationship between green density and contact area was derived from a geometrical consideration, and agreed welt with experimental findings. 8 ref--AA t -H Moon, and K - H Kim. Powder Metall., 1984, 27, (2), 80-84, [in English]. ISSN 0032-5899.
54-0066
E f f e c t s of A r g o n Contamination
in PM Hot Isostatically
Pressed Nickel Base Superalloy. The effects were studied of argon contamination in PM MERL 7 8 h o t isostatically pressedat 103.4MPa ( 1 5 k s i ) and 193.1 MPa (28 k s i ) Microstructures were characterized and mechanical properties at 704~ ( 1 3 0 0 ~ were determined for material containing 59 ppm argon (by weight) in the powder container. Baseline hipped PM MERL 76 was also evaluate d The argon contamination resulted in a significant level of porosity in the final material. Contaminated PM MERL 76 hipped at 103.4 MPa (15 ksi) was 97.6% dense, and that hipped at 193.1 MPa (28 ksi) was 98.7% dense, in both cases after heat treatment. Porosity due to argon adversely affected the notch stress rupture life and tensile properties of the alloy. The creep crack growth resistance was only slightly degraded by argon contamination and the resultant distributed pores. 17 r e f . - - A A J Prybytowski, R.M Pelloux, and P. Price. PowderMetall., 1984, 27, (2), 107-111, [in English]. ISSN 0032-5899. 54-0069
Friction E l e m e n t and Method of Manufacture Thereof. To produce a sintered metal-type brake friction on a backing plate which beds in quickly and which has a "feel" similar to a resin-based element, powdered metallic friction material is subjected to a resistance sintering or furnace sintering operation, so as to produce a sintered substrate and an unsintered or partly sintered surface layer which has less wear resistance than the substrate but friction properties which are not substantially less than the substrate. The surface layer may be formed of the same or different material as the substrate layer, depending upon the sintering technique chosen. Friction materials typically employed include copper with optional alloying additives.
J. APPLIED METALWORKING
54-0073 Structure of Aluminium S h e e t s Produced by the E l e c t r i c Bursting Method. (Translation). See Met. A., 8408-54-0622. V.Yu. Zelinskii, N.A. Yavorovskii, L.T. Proskurovskaya, and V.I. Davidovich. Phys. Chem. Mater. Treat. (USSR), Jan.-Feb. 1984, 18, (1), 50-53, [in English]. ISSN 0264-729X.
54-0077 Microstructure and Deformation in a Dynamically C o m p a c t e d C o p p e r Powder. Dynamic (shock wave) compaction of a spherical Cu powder having a narrow size distribution yields a distinctive directional microstructure. Powder particles are smooth and convex on the upstream side of the shock propagation direction and sharply peaked on the downstream side, This structure results from differences in material speeds which occur because of release at free surfaces adjacent to voids. The filling of voids thus occurs faster than the deformation of surrounding particles. The structure becomes less apparent as the pow* der size distribution broadens, An oxide film is observed between powder particles following densification. The possible effects caused by this film are discussed. --AA W.H. Gourdin. Mater. Sci. Eng., Nov. 1984, 67, (2), 179-184, [in English]. ISSN 0025-5416.
54-0078 The Structure and Properties of a Rapidly Solidified HighSulfur Stainless Steel. A 0.54 wt.% sulfur stainless steel corresponding to an ultralow carbon grade of AtSI 316 stainless steel was rapidly solidified using a twin-roller technique. As-cast flakes were characterized by a number of methods and it was found that not all the S had remained in solid solution despite an estimated cooling rate of at least 105K - 1 , which is a typical value for the twin-roller technique of rapid solidification. Some S precipitated, primarily as chromium sulfide of size 0.02-0.05 pro, in a well-defined hexagonal pattern within a dendritic cell. After high-temp, annealing had been carried out, the nature of these sulfide particles changed in that the sulfides then contained Mn, Fe, Cr and Ni. The ascast flakes were consolidated by cold compaction followed by hot extrusion at 1448K. After extrusion the sulfide volume fraction was ~ 2.5 vol.%. The extruded bar was given a variety of thermomechanical treatments. Tensile tests showed that the alloy had an excellent combination of tensile strength and ductility. 15 ref. --AA G. Rai, and N.J. Grant. Mater. ScL Eng., Nov. 1984, 67, (2), 197-205, [in English]. ISSN 0025-5416.
54-0079
Nondestructive Evaluation of Powder Metallurgy Materials.
Ultrasonic velocity and resonant frequency measurements have proven to be valuable tools for nondestructively evaluating the processing and properties of powder metallurgy ( P / M ) materials. Measured values of ultrasonic velocity and resonant frequency increase with increasing P / M part density, time and temp, of sintering and part strength. Although these nondestructive methods are sensitive to the pore structure of P / M materials, which strongly affects properties, they are less sensitive to the matrix microstructure and composition which also affects the strength. In tests employing P / M stainless steel production parts, ultrasonic velocity measurements have proven capable of discriminating well*sintered parts with satisfactory microstructures and high crushing strength from identically appearing parts sintered in a contaminated atmosphere with resulting unsatisfactory microstructures and low crushing s t r e n g t h . - - A A B.R Patterson, K.L. Miljus, and W.V. Knopp. Nondestructive Evaluation: Application to Materials Processing [Proc. Conf.], Philadelphia, Pa., U.S.A., 3-4 Oct. 1983, American Society for Metals, Metals Park, Ohio 44073, U.S.A., 1984, (Met.A., 8502-72-0060) 109-t 19, [in English].
54-0083 Near Net Shapes: Closing in on Materials W a s t e . Near net shape manufacturing techniques currently in use in the powder metallurgy industry are reviewed. Processes described include hot isostatic pressing, cold isostatic pressing, pressure-assisted sintering and injection molding. Rapid solidification plasma deposition is being used to produce near net shapes of thin-wall design difficult to obtain by conventional methods. The capabilities of the various near net shape techniques for parts of tool steels, Ni alloys and Ti alloys are compared. --G.P.K. R.R. Irving. Iron Age, Met. Prod., 5 Nov. 1984, 227, (21), 31-32, 34, 39-41, 43, 46, [in English]. ISSN 0164-5137. 54.0086 Method of Manufacturing Bodies of Silicon Nitride. A method of manufacturing a body of silicon nitride having improved strength at elevated temp. and substantially the same strength in all directions comprises enclosing a quantity of silicon nitride material in the form of a powder or a product preformed from such powder in a gas-tight casing comprising glass that is yielding at the temp. used for sintering silicon nitride, and thereafter heating the casing with the silicon nitride material encased to at least 1600~ and subjecting the casing and thereby the silicon nitride material to isostatic pressing at a pressure of at least 100 MPa using a gaseous pressure medium to form silicon nitride body within the casing. J. Alderborn, H. Larker, and ASEA AB. Off. Gaz., 19 June 1984, Patent no. US4455275 (USA), 11 Nov. 1974. ISSN 0360-5132. 54-0088 Method of Strengthening Silicon Nitride C e r a m i c s . A method of fabricating an improved Si3N 4 structural ceramic comprises: providing a mixture of SizN 4 powder and a sufficient quantily of a densification aid to cause rapid densification due to the formation of a liquid glassy phase during sintering; sintering the mixture to form a dense Si3N 4 ceramic; providing SiO 2 on the surface of the Si3N 4 ceramic; heating the Si3N 4 ceramic and SiO2 at a temp. sufficient to cause diffusion of impurities and additive cations from silicates in glassy phase into the SiO2; and grinding the Si3N 4 ceramic to a depth sufficient to remove surface pits formed during heating step.
VOL. 4, NO. 1, JULY 1985
117
F.F. Lange, D.R. Clarke, and Rockwell International. Off. Gaz., 3 July 1984, Patent no. US4457958 (USA), 22 May 1981. ISSN 0360-5132.
54-0116 Influence of Porosity on the Tribological Properties of IronBase Powder Metallurgy Materials. (Translation). See Met. A., 8412-54-
54-0092
0872. I.M. Fedorchenko et al. Sov. PowderMetall. Met. Ceram., May 1984, 23, (5), 394396, [in English]. ISSN 0038-5735.
HIPing o f SiC. The effects of high temp. (up to 2100~ and high pressure (up to 207 MPa) on the density and strength of sintered SiC are discussed. Both containerless and clad processes are used. Statistically designed experiments are employed to study the influence of several HIP parameters on the repair of damage caused by machining o p e r a t i o n s . - - A A T.J. Whalen. Ceram. Eng. ScL Proc., May-June 1984, 5, (5-6), 341-349, [in English]. ISSN 0196-6219. 54-0097
Powder M e t a l l u r g y - - a Global Perspective. Metal powder consumption, technical developments, and trends in applications are very briefly reviewed for the following countries: U.S.A., Canada, U,K, Italy, W. Germany, and Japan. The importance of the car industry to the consumption of metal powders is emphasised throughout.--T.W. Met. PowderRep., Aug. 1984, 39, (8), 447-450, [in English]. ISSN 0026-0657. 54-0098
Brunswick Makes PM Injection Moulding W o r k . Brunswick Corporation, U.S.A., has developed a process for the high-volume production of PM parts from an injection moulding system. The key part of the process is the debinding and sintering of the green injection moulded part in one vessel, i.e. without an intermediate transfer of parts. The evaporative debinding stages leads to a substantial shrinkage of the part (around 20% linear), and to ensure uniformity of shrinkage the composition of the feedstock powder must be closely controlled. The process is used to produce precision parts in stainless and other steels. --T.W. Met. Powder Rep., Aug. 1984, 39, (8), 463-464, [in English]. ISSN 0026-0657. 54-0099
Fine Metal Powders f o r I n j e c t i o n M o u l d i n g . Pfizer are producing metal powders of standard particle sizes of 10, 20 and 30,urn and special particle sizes down to 5 ,urn. The powders available include Ni alloys, Co alloys, stainless steels, and hardfacing alloys. New particle sizing processes are important in the production of these powders.--T.W. Met. Powder Rep., Aug. 1984, 39, (8), 464, [in English]. ISSN 0026-0657. 54-O101
Kobe Steel Develops Nitrogen-Added PM High-Speed Steels.
Kobe Steel Ltd., Japan, has developed three new PM high-speed steels with improved wear and hardness properties. The new materials are prepared by adding N 2 to the steel powder particles after atomisation, achieving some replacement of carbides by C N - - T . W . Met. PowderRep., Aug. 1984, 39, (8), 471, ]in English]. ISSN 0026-0657.
5 4 - O 1 0 4 Structure of Particles of Very Finely Divided Electrolytic Iron. (Translation). See Met. A., 8412-54-0860. V.V. Myalkovskii, T.M. Shvets, V.P, Vasilenko, and Z,M. Melnichenko. Soy. Powder Metall. Met. Ceram., May 1984, 23, (5), 331-335, [in English]. ISSN 0038-5735.
54-0105 Liquid Classification of Titanium Carbide Micropowders. (Translation). See Met. A., 8412-54-0861. G.M. Kabysh, E.I. Moshkovskii, and L.G. Kabysh. Soy. Powder Meta/I. Met. Ceram., May 1984, 23, (5), 335-338, [in English]. ISSN 0038-5735.
54-O106 Pressing of Amorphous Alloy Powders Under Dynamic Conditions. (Translation). See Met. A., 8412-54-0862. O.V. Roman et al. Soy. Powder Metall. Met. Ceram., May 1984, 23, (5), 345-350, [in English]. ISSN 0038-5735.
54-0109 E x p e r i e n c e in the M a n u f a c t u r e of Tools in CarbideContaining Steels. (Translation). See Met. A., 8412-54-0865. I.D, Bykov, G . L Dubrov, Yu.F. Boky, V.A. Sakhno, and V.T. Zubkova. Soy. Powder Metall. Met. Ceram., May 1984, 23, (5), 365-369, [in English]. ISSN 0038-5735.
54-O1 10 Some Properties of Thin S t e e l - - C o p p e r Bimetal Sheet. (Translation). See Met. A., 8412-54-0866. O.A. Katrus, A,V. Aleshina, V.K. Gribkov, and V.M. Ocheretyanskii. Soy. Powder Metall. Met. Ceram., May 1984, 23, (5), 370-372, [in English]. ISSN 0038-5735.
54-Olll M a g n e t o m e t r i c I n v e s t i g a t i o n of the D e c o m p o s i t i o n o f Residual Austenite in ROM 1OF3 and R2M lOF3K8 High-Speed Steel Powders. (Translation). See Met. A,, 8412-54-0867. B,A. Apaev, B.F. Galkin, and G,E. Titenskaya. Soy. Powder MetalL Met. Ceram., May 1984, 23, (5), 373-376, [in English]. ISSN 0038-5735. P l a s t i c S t r a i n and Fracture Behavior o f E P 7 4 1 N i c k e l Alloy Under Conditions of High-Temperature Deformation. (Translation). See Met, A., 8412-54-0868. L,P. Gerasimova, M A . Godovanets, V.F. Kotov, L.E. Popova, and V.I. Shvarts. Soy. PowderMetall, Met. Ceram., May 1984, 23, (5), 376-381, [in English]. ISSN 00385735, 54-0112
D i s t r i b u t i o n o f P o r o s i t y in Sintered Permeable Materials by an Eddy Current Method. (Translation). See Met. A., 8412-54-0869.
54-01 13
P.A, Vityaz etal. Soy. PowderMetall. Met. Ceram., May 1984, 23, (5), 381-384, [in English]. ISSN 0038-5735. 54-0114 M a c r o s t r e s s e s in Sintered Carbides. ( T r a n s l a t i o n ) . See Met. A., 8412-54-0870. I.l. Deryavko, A.G. Lanin, N.A. Bochkov, and L.I. Kosacheva. Soy. Powder Metal/. Met. Ceram., May 1984, 23, (5), 384-387, [in English]. ISSN 0038-5735.
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Wear Resistance o f S l i d i n g E l e c t r i c C o n t a c t s o f Silver-Base Composite Materials. (Translation). See Met. A., 8412-54-0873. 54-01 17
G,N. Braterskaya, and V.G. Zatovskii. Soy. PowderMetalL Met. Ceram., May 1984, 23, (5), 397-401, [in English]. ISSN 0038-5735.
54-0120 A Machine for Accelerated Tests o f E l e c t r i c a l Contacts. (Translation). See Met. A., 8412-54-0876. V . L Kalikhman, V.N. Babkin, E.P. Gladchenko, A.A. Bogdanov, and N.O, Yashina. Soy, PowderMetall. Met. Ceram., May 1984, 23, (5), 411-413, [in English]. ISSN 0038-5735.
5 4 - 0 1 2 3 Aluminum Powder Metallurgy. A process for making a workpiece suitable for being hot worked to produce a wrought metal product comprises: providing an AI alloy in the form of a powder consisting essentially of particles solidified at a rate of ~ 1000K/s or more; producing a compact by isostatic pressure such that the density of the compact is ~ 60-85% of the theoretical density of the alloy; exposing the compact to a dynamic atmosphere which is essentially devoid of water and gaseous oxidants of the alloy and heating the composite to a temp. of up to ~ 650K to degas the surface films and to remove H20 as H20; while the compact is exposed to the atmosphere, further heating so that its exterior surfaces attain temp. at which ~ 2-20 wt.% of the alloy would be liquid under standard conditions, volatilizing alloying materials from a liquid surface region to form a reduced volatile alloying material surface region of ~ 0.1-1 mm, thereby raising the solidus temp. of the surface region at an equilibrium point causing resolidification of the surface region at the equilibrium point, then cooling so it becomes sinter-sealed. O,R. Singleton, H.M Edwards, and Reynolds Metals Co. Off. Gaz., 17 July 1984, Patent no. US4460541 (USA), 24 Mar. 1983. ISSN 0360-5132. 54-0124 Internal Oxidation Method of Silver Alloys. A method of promoting the internal oxidation of a Ag alloy containing at least 3-15 wt.% Sn for electrical contact materials and the like comprises: adding other solute metals which sublimate from the alloy in the course of the heat treatment held prior to the internal oxidation to the alloy for the production of vacant lattice points in the alloy with their sublimation from the alloy; heat treating the alloy in the presence of a reducing gas or neutron prior to the internal oxidation of the alloy, whereby the alloy absorbs the reduction gas or neutron, thereby producing in the alloy vacant lattice points; and subjecting the alloy to heat in the presence of oxygen to effect the internal oxidation thereof, during which oxidation step the vacant lattice points work as paths of oxygen and as oxidation nuclei about which Sn is diffused and oxidized. A. Shibata, and Chugai Denki Kogyo KK. Off. Gaz., 3 July 1984, Patent no. US4457787 (USA), 21 Sept. 1982. ISSN 0360-5132.
Superplastic Properties of Two Rapidly Solidified Powder Metallurgy Aluminum Alloys. Very fine microstructures resulting from the ultra54-0127
sonic gas atomization of two highly alloyed AI alloys promoted superplastic deformation at selected temp. and strain rates. An A I - - 6 . 7 M g - - 1 . 6 L i alloy (where the composition is given in approx, weight percent) exhibited a max. tensile elongation of 184% at 325~ for an initial strain rate of 10 - 2 s - l and an X7091alloy showed a tensile elongation of 218% at 4 0 0 ~ for an initial strain rate of 9 x 10 - 3 s - 1 . In comparison with conventionally produced ingot alloys, the rapidly solidified powder metallurgy AI alloys show high elongation values at the relatively high strain rate of 10 - ~ s - 1 but do not achieve as high elongation values at the slower strain rates (10--3-10 - 5 s--l). 11 r e f . - - A A Y. Zhang, and N.J. Grant. Mater. Sci. Eng., Dec. 1984, 6 8 , ( 1 ) , 119-124, [in English]. ISSN 0025-5416.
54-0128
Strength Measurements on Rapidly Solidified Metal Particles.
The strength of rapidly-solidified Ni-based superalloy (AP1, produced by Wiggin Alloys Ltd.) powder was measured. One of two test methods was used to determine the contact pressure required to cause deformation of spherical metal particles. It was concluded that, generally speaking, the max. deformation pressure for a metal sphere is ~ 0.7 to 0.8 times its Vickers hardness before deformation. --G.P.K. M.M. Chaudhri, and I.M. Hutchings. J. Mater. Sci. Lett., Jan. 1984, 3, (1), 79-82, [in English]. ISSN 0261-8028.
5 4 - 0 1 3 0 Production of Deep Cylindrical and Square Cups by Ironing o f Sintered Metal Powder Preforms. A powder metallurgy technique is used to facilitate low-volume production of deep cylindrical and square cups. As starting materials, Cu, Fe and AI powders are used instead of sheet metals. A simple device using a cylindrical polyurethane as a pressure medium is used for compacting cups with almost uniform density over the cup wall. The compacted cups are sintered and then the sintered cups are ironed to decrease the porosity and to improve the dimensional accuracy. It is shown that thin and very deep cups can be successfully produced by this process using metal powders as starting materials. The dimensional accuracy, surface finish and ductility of the cups produced are satisfactory and ears are not formed at the edge of the cups, unlike the conventional deep drawing of sheet metals. 9 r e f . - - A A K. Yamaguchi, K. Nosoh, N. Takakura, and M. Fukuda. Advanced Technology of Plasticity, Vol. 1 [Proc. Conf.], Tokyo, Japan, 1984, Japan Society for Technology of Plasticity, 5-2-5 Roppongi, Minato-ku, Tokyo 106, Japan, 1984, (Met.A, 850372-0109) 347-352, [in English]. 54-0136 The Economics of Pressing Grade Copper P o w d e r Production. The article presents parameters on which to base a decision on the choice of the basic technology for making Cu powder for PM purposes, taking into
J. APPLIED METALWORKING
account the raw material available, the domestic industrial environment and the size and the nature of the market to be supplied.--AA M. Baudier: Met. Powder Rep., May 1984, 39, (5), 251-257, [in English]. ISSN 0026-0657.
54-0140 Titanium PM Gyro Components. The paper describes work to d e m o n s t r a t e the feasibility of manufacturing five titanium g y r o s c o p e components--the base, gotcha lock, gimbal ring, inner gimbal and actuator housing, by PM. The programme was undertaken because a cost analysis showed that significant savings could be realised in comparison to machining these components from bar, while retaining or enhancing the properties desired in this application,--AA G. Friedman, and R. Regn. Met. PowderRep., May 1984, 39, (5), 273-281, [in English]. ISSN 0026-0657. 54-0141
Ultra Rapidly Solidified Alloys for Dies, Tools and Wear Parts.
The consolidation of powders of metallic glass into bulk microcrystalline solids is described. The properties are shown to be particularly dependent on consolidation technique. Extrusion produces a high toughness material with an exceptionally high hot hardness that is not lost by repeated exposure to temp. Alloys processed by this route are now commercially available as a result of a recent agreement between Amax Inc. and Allied Corp. 8 r e f . - - A A D. Raybould. Met. Powder Rep., May 1984, 39, (5), 282-266, [in English]. ISSN 0026-0657. 54-0142
New RST Nickel-Base Alloy With High Strength and Corrosion
Resistance. Rapid solidification technology (RST) has been recognised in recent years as having excellent prospects for creation of new engineering alloys with improved service performance characteristics. A new nickel-base alloy made by RST shows both high strength and corrosion resistance.--AA R. Ray. Met. PowderRep., May 1984, 39, (5), 287-289, (in English]. ISSN 00260657. 54-0143 increasing the Speed of Powder Compacting Presses. Manufacturers of sintered metal components are continually seeking ways to improve the productivity of the powder compacting operation. The following article describes some recent developments at PTX-Pentronix Inc. of Lincoln Park, Mich. which has resulted in increased speed of powder compacting presses up to 35 ton.--AA Met. Powder Rep., May 1984, 39, (5), 291-293, [in English]. ISSN 0026-0657.
54-0144 Powder Metallurgy Research at BNF Metals Technology Centre. The BNF Metals Technology Centre at Wantage, Oxf6rdshire, through a long involvement in all aspects of metallurgical industry activities, identified a need for a more positive trust in PM technology to take advantage of some of the recent advances in both PM materials and processing. Consequently, in 1983 e new Powder Technology Programme was initiated. Some of the projects now in progress are outlined.--AA J.E. Bowers. Met. Powder Rep., May 1984, 39, (5), 294-295, [in English]. ISSN 0026-0667.
54-0145 Heavy Alloys or Heavy Currents--Johnson Matthey's Advanced PM A c t i v i t i e s . This report describes the manufacturing activities of Johnson Matthey Metals Ltd. of Wembley, a company specialising in tungstenbased heavy alloys and electrical contact materials.--AA K,J.A. Brookes. Met. Powder Rep., May 1984, 39, (5), 296-298, [in English]. ISSN 0026-0657. 54-0146 PM S u p e r e l i o y T u r b i n e Disks Produced by G a t o r i z i n g . The development of isothermal forging processes for the production of turbine disks from metal powders is very briefly reviewed, with some emphasis on the Gatorizing process developed by Pratt & Whitney and its use in the production of a range of superalloy engine components.--T.W. Met. Powder Rep., May 1984, 39, (5), 300, (in English]. ISSN 0026-0657. 54-0147 C o n t r o l o f Nitrogen Absorption and Surface Oxidation o f A u s t e n i t i c Stainless Steels in H2--N 2 Atmospheres. The composition of protective atmospheres used to process austenitic stainless steels by powder metallurgy has a direct impact on the final properties achieved in the treated product. The implications of using H2--N 2, atmospheres in the sintering of stainless steel compacts are discussed. 14 r e f . - - A A R.H. Shay, T.L. Ellison, and K.R. Berger. Met. Powder Rep., June 1964, 39, (6), 319-326, [in English]. ISSN 0026-0657.
54-0150
Developments in the Use of Tin in Ferrous Powder Metallurgy.
Research at the International Tin Research Institute (ITRI) in Perivare, Greenford continues to explore the potential of tin in ferrous powder metallurgy and the results of some recent studies are summarised. 11 r e f . - - A A M.E. Warwick. Met. Powder Rep., June 1984, 39, (6), 339-342, [in English]. ISSN 0026-0657.
54-0152 Diffusion Bonding Method to Assemble Green Compacts During Sintering. The development of a new method to assemble green ferrousbase compacts during sintering is described. The choice of materials, the bonding strength of assembled compacts and some examples of current applications for assembled sintered components in the business machine sector are also described.--AA K Asaka, and T. Hayasaka. Met. PowderRep., June 1984, 39, (6), 347-350, [in English]. ISSN 0026-0657.
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54-0154 L o n d o n & Scandinavian's Hardmetal Centre. The development and production facilities of London & Scandinavian Metallurgical Company, U.K., are briefly described. Standard powders produced include tungstic oxide, W and Co metals, and the carbides of Ta, W, Ti, V, Cr and Nb, either singly or as standard or custom blends, A recent development has been the production of WTiNbZr quaternary carbide as a substitute material for TaC.--T.W. K.J.A. Brookes. Met. PowderRep., July 1984, 39, (7), 384, 385, 387, [in English]. ISSN 0026-0657.
54-0155
High Strength HSS Components by Powder Metallurgy.
Powdrex Ltd., U.K., have developed new processes for the production of components from tool steels by powder metallurgy. Alloy melts are water atomised to give highly irregular powders which, after annealing, milling and grading, can be processed into tool steel components. High compaction pressures are required, and the sintering cycles use higher than normal temp. The components produced have good hardness and tensile properties, and perform in wear tests to a level comparable with that of conventional parts. The commercial future of these new materials is likely to be in wear-resistant applications, e.g. in the car industry. --T.W. P.R. Brewin. Met. PowderRep., July 1984, 39, (7), 396,397,400-402, [in English]. ISSN 0026-0657.
54-0156
Graphite Furnaces for HIPing Aero Engine Components. Tests were carried out on a new graphite furnace developed by ASEA AB, Sweden, 1o determined its suitabiWity for the hot isostatic pressing of superaIIoy engine components. The effects on inert gas purity and oxide coating of the component were studied, and it was concluded that the graphite furnace was an acceptable and more economic alternative to the conventional molybdenum furnace.--T.W. S. Friborg, Met. PowderRep., July 1984, 39, (7), 413-414, [in English]. ISSN 00260667. 54-0157 IsostaUc Presses for Complex Shapes and Thin Walled Tubes. The priniciples of isostatic pressing are very briefly reviewed, and typical processes are described with reference to isostatic presses developed by Smiths Industries, U.K.--T.W. Met. Powder Rep., July 1984, 39, (7), 415 416, [in English]. ISSN 0026-0657.
54-0158
Kobe Steel Produces Fine Superalloy Powders. Kobe Steel Ltd., Japan, has developed a process for the production of Ni-based superalloy powders of particle size < 40 /~m. The spherical particles have a uniform grain structure due to the rapid cooling achieved by the Ar gas atomisation process. Applications are mainly in the production of aero engine components by HIP processes.--T.W. Met. Powder Rep., July 1984, 39, (7), 417, [in English]. ISSN 0026-0657. 54-0160 Device for Locating and Handling of Loose PM Parts. A new device is described which is capable of locating and picking up parts deposited at random on trays. The microprocessor-controlled unit uses an x - - y table to move the presented tray beneath a TV camera. Once the part is located it is centred under the pick-up head, picked up by an appropriate mechanism, and deposited on a moving belt in the desired orientation.--T.W. Met. Powder Rep., July 1984, 39, (7), 419, [in English]. ISSN 0026-0657. 54-0161 Potential for Rapidly Solidified PM Aluminium Alloys for Aerospace Applications. A major review presented at a recent symposium on rapidly solidified AI alloys for aerospace applications is briefly reviewed. Newer alloys for PM applications include AI--Li, A I - - F e - - C e , and A I - - F e - - M o , and the properties of these alloys are described and related to typical high-stiffness, towdensity, high-temp, aerospace applications.--T.W. Met. PowderRep., July 1984, 39, (7), 420, [in English]. ISSN 0026-0657.
54-0162
New PM Chrome Steel Powder From Hoganas. Hoganas AB, Sweden, has added a new alloy powder to its range of Fe powders prealloyed by diffusion. 'Bondaloy Cr' contains 6% Cr and consists of fine particles of ferrochromium bonded to the base Fe powder by a special technique.--T.W. Met. PowderRep., July 1984, 39, (7), 421, [in English]. ISSN 0026-0657. 54-0164 M e t h o d o f C o n s o l i d a t i n g a M e t a l l i c o r Ceramic Body. A method of consolidating a metallic (especially steel) or ceramic body comprises the steps of forming an article of manufacture from powdered metal; sintering the article so as to increase the strength thereof; providing a bed of heated, generally spheroidal ceramic particles which have been coated with a thermally stable lubricant; and compacting the article of manufacture embedded in the heated bed under pressure to consolidate the article into a dense, desired shape. F.G. Hanejko, R_ Bradt, and Metal Alloys Inc. 5 Dec. 1984, Patent no. GB2 I40825A (UK), 22 Feb. 1984. E x a m i n a t i o n o f the Structure and Contact Fatigue o f a HighSpeed Tool Steel Produced by Hot Isostatic Pressing. (Translation). See 54-0165
Met. A., 8406-54-0389. S. Emmer, A. Havalda, and A. Salak. Met. Mater. (Czech.), Jan.-Feb. 1984, 22, (1), 17 22, [in English]. ISSN 0264-7303.
54-0176 Designing Band-Fastened Dies With SecUonalised Inserts. (Translation: BISI 22085). See Met. A., 8312-54-1263. VJ. Blagin. Poroshk. Metal/., June 1983, (6), 103-105, [in Engiish]. ISSN 00324795.
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