Advances in Material Forming and Joining: 5th International and 26th All India Manufacturing Technology, Design and Research Conference, AIMTDR 2014

385 Pages·2015·12.037 MB·English

by  R. Ganesh Narayanan, Uday Shanker Dixit (eds.)

Topics in Mining, Metallurgy and Materials Engineering
Series Editor: Carlos P. Bergmann
R. Ganesh Narayanan
Uday Shanker Dixit E ditors
Advances in
Material Forming
and Joining
5th International and 26th All India
Manufacturing Technology, Design and
Research Conference, AIMTDR 2014
Topics in Mining, Metallurgy and Materials
Engineering
Series editor
Carlos P. Bergmann, Porto Alegre, Brazil
More information about this series at http://www.springer.com/series/11054
R. Ganesh Narayanan Uday Shanker Dixit
(cid:129)
Editors
Advances in Material
Forming and Joining
5th International and 26th All India
Manufacturing Technology, Design
and Research Conference, AIMTDR 2014
123
Editors
R. Ganesh Narayanan UdayShanker Dixit
Mechanical Engineering Mechanical Engineering
Indian Instituteof TechnologyGuwahati Indian Instituteof TechnologyGuwahati
Guwahati, Assam Guwahati, Assam
India India
ISSN 2364-3293 ISSN 2364-3307 (electronic)
Topicsin Mining,Metallurgy andMaterials Engineering
ISBN 978-81-322-2354-2 ISBN 978-81-322-2355-9 (eBook)
DOI 10.1007/978-81-322-2355-9
LibraryofCongressControlNumber:2015934677
SpringerNewDelhiHeidelbergNewYorkDordrechtLondon
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About the Conference
AIMTDR series of conferences is a highly prestigious biennial event in the field
of mechanical engineering. It has a glorious history. The first conference entitled
All India Machine Tools Design and Research Conference was held at Jadavpur
University, Kolkata. Later on it was renamed as All India Manufacturing
Technology, Design and Research Conference in order to widen its scope.
Itbecameaninternationaleventin2006withthefirstinternationalconferenceheld
at IIT Roorkee. The conference aims to bring together the academicians and
industry professionals working in the field of manufacturing for the exchange of
ideas.
Indian Institute of Technology Guwahati organized 5th International and 26th
AllIndiaManufacturing,Technology,DesignandResearch(AIMTDR)conference
during 12–14 December 2014. The conference was attended by more than 400
delegates from Academia and Industry. Apart from the addresses of Chief Guest
Professor Amitabha Ghosh, former Director of IIT Kharagpur and Mr. P.K.
Borthakur, Former Director (offshore), ONGC, a total of 22 invited lectures were
presented in the conference. Some of the notable speakers from academia were
Prof. Kornel Ehmann, Prof. Shiv G. Kapoor and Prof. Marc Madou from USA,
Prof. Hocheng from Taiwan and Prof. V. Radhakrishnan from India. Some of the
invitedspeakersfromindustry/R&DorganizationswereDr.V.K.SurifromBARC,
Mr. Khongwir from IOCL Bongaigaon, Dr. Sumitesh Das from Tata Steel,
Dr. Sanyal from CSIR and Dr. K. Ramesh from DRDL Hyderabad. Some manu-
facturing organizations also gave presentations on their products.Total423 papers
werepublishedintheproceedingsoftheconferencebyyoungandseniorengineers/
scientists.
Prof.M.RahmanofNationalUniversityofSingaporedeliveredProf.Amitabha
Bhattachraya Memorial Lecture. He advocated sustainable manufacturing that
should not harm the environment. He emphasized the role of revolutionary and
evolutionary innovation to achieve sustainable manufacturing. Overall, The con-
ference was a huge success in terms of the participation of delegates from the
premier educational and research institutions of India and abroad.
v
Preface
MaterialformingandJoiningareamongsttheoldestmanufacturingprocesses,that
areinusetilltodaytofabricatemicrotomacrocomponents.Whilematerialforming
involvesmainlyelasticandplasticdeformationofmaterialstoobtaindesiredchange
inshape,joiningessentiallyisanassemblyprocesstomakelarge-sizedorcomplex
parts. The material and metallurgical properties undergo substantial change during
theseprocesses.Researcherstrytounderstandtheseprocessesbyexperimentaland
computational means. Although experiment-based research is inevitable, there is a
trend to supplement it with computational techniques based on sound theoretical
principles.
The chapters in this book discuss some of the basic and advanced topics in
material forming and joining, including problems on rolling, sheet metal forming,
adhesive bonding, welding operations like submerged arc welding, friction stir
welding, accumulative roll bonding, and magnetic pulse welding. These chapters
are extended versions of peer reviewed manuscripts presented in 5th International
and 26th All India Manufacturing Technology, Design and Research (AIMTDR)
conference held during December 12–14, 2014 at Indian Institute of Technology
Guwahati, India. In total, 53 authors from academia and industry have contributed
to this book. The book will be useful for researchers and practicing engineers.
Thebookcontains18chapters.Theyareonvariedtopics.Chapter“AnEfficient
InverseMethodforDeterminingtheMaterialParametersandCoefficientofFriction
inWarmRollingProcess”dealswithnumericalmodellingofwarmrollingprocess
for predicting the materials behaviour using an efficient inverse method. Chapter
“Incremental Sheet Forming (ISF)” discusses incremental sheet forming. Chapter
“Effect of Yield Strength, Pre-strain and Curvature on Stiffness and Static Dent
ResistanceofFormedPanel”discussestheinfluenceofselectedprocessparameters
on the dent resistance of sheets. Chapter “Formability Prediction and Springback
Evaluation of Adhesive Bonded Steel Sheets” describes how the springback and
formability of base sheets can be controlled by adhesive bonding. Chapter
“Feasibility Study of Thermal Autofrettage Process” proposes a method for
achieving autofrettage that involves creating thermal gradient in the wall of the
cylinder. Chapters “Numerical Analysis of Warm Deep Drawing for Ti–6Al–4V
vii
viii Preface
Alloy”, “Springback and Formability Studies on Friction Stir Welded Sheets”
and “Prediction of Formability of Bi-axial Pre-strained Dual Phase Steel Sheets
Using Stress-based Forming Limit Diagram” present some of the recent research
activities in sheet metal forming. The authors of chapter “Numerical Analysis of
WarmDeepDrawingforTi–6Al–4VAlloy”havepredictedthewarmdeepdrawing
behaviour of a titanium alloy. In chapter “Springback and Formability Studies on
FrictionStirWeldedSheets”controllingspringbackandformabilityofsheetsusing
frictionstirweldinghasbeendiscussed.Thestressbasedforminglimitdiagramhas
been used to predict the formability of dual phase steel in chapter “Prediction of
Formability of Bi-axial Pre-strained Dual Phase Steel Sheets Using Stress Based
FormingLimitDiagram”.Themicroformingofaparticularsheetmaterialhasbeen
discussed in chapter “Size Effect on Mechanical Behaviour of SS304”.
Chapters “Prediction of Weld Induced Angular Distortion of Single Sided and
Double Sided Fillet Joints by SAW Process” and “Optimization of Process
Parameters in Submerged Arc Welding Using Multi-objectives Taguchi Method”
dealwiththeroleofsubmergedarcweldingprocessonthejointdistortionandweld
joint quality. Chapter “Monitoring of Weld Quality in Friction Stir Welding based
on Spindle Speed and Motor Current Signals” presents real-time weld quality
monitoringduringfrictionstirweldingusingspindlespeedandmainmotorcurrent
signals.Thefiniteelementmodellingsimulationofmagneticpulseweldingoftubes
is presented in chapter “Coupled Electromagnetic–Structural Simulation of
Magnetic Pulse Welding”. In chapter “Numerical Analysis of Heat Transfer of
Arc Welded Plate”, finite difference method has been used to provide solution for
moving heat source with Gaussian distribution of heat flux density during sub-
merged arc welding. The micro-friction stir welding of aluminium sheets and the
joint strength and hardness characteristics are described in chapter “Development
and Analysis of Butt and Lap Welds in Micro-friction Stir Welding (µFSW)”.
Chapter “Numerical Modeling of Impact and Solidification of a Molten Alloy
Droplet on a Substrate” discusses the solidification characteristics of an alloy
droplet impacting on a substrate using a two dimensional axisymmetric model.
Plasma assisted friction stir welding, a hybrid system, is described in chapter
“HybridFrictionStirWeldingofSimilarandDissimilarMaterials”withtheaimof
improvingtheweldjointqualityandjointefficiency.Finally,thebasicconceptsof
roll bonding and accumulative roll bonding as applicable to light weight ductile
metalsandtheinfluenceofvariousparametersonthejointstrengtharedescribedin
chapter “Solid-State Joining by Roll Bonding and Accumulative Roll Bonding”.
Authors and editors have taken utmost care in presenting the information and
acknowledging the original source wherever necessary. Editors are thankful to
authors, organizers of AIMTDR and staff of AIMTDR (India) for making the
publicationofthistypeofresearchbookpossible.Readersarerequestedtoprovide
their feedbacks and constructive suggestions to us. We hope that manufacturing
fraternity will welcome this book.
R. Ganesh Narayanan
Uday Shanker Dixit
Editorial Acknowledgments
Theeditorsthankanumberofreviewersinvolvedinreviewingthepaperssubmitted
totheconference.Weacknowledgealltheauthors,invitedspeakers,sponsors,sub-
committee members, members of national advisory committee and members of
scientific advisory committee for successful conduct of the conference. We are
grateful to Prof. Gautam Biswas, Director, Prof. Gautam Barua, former director,
Prof.AnoopK.Dass,HODMechanicalEngineering,andProf.P.Mahanta,former
HOD Mechanical Engineering for their continual motivation to organize such a
huge event, that paved way for this book issue. The assistance extended by our
colleagues and students, beyond their work schedule, needs a special mention and
wethankthemforactiveparticipation.Finally,weacknowledgethestaffmembers
of Springer.
ix
Contents
An Efficient Inverse Method for Determining the Material
Parameters and Coefficient of Friction in Warm Rolling Process. . . . . 1
V. Yadav, A.K. Singh and Uday Shanker Dixit
Incremental Sheet Forming (ISF). . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Yogesh Kumar and Santosh Kumar
Effect of Yield Strength, Pre-strain, and Curvature on Stiffness
and Static Dent Resistance of Formed Panel. . . . . . . . . . . . . . . . . . . . 47
G. Manikandan, Rahul K. Verma, Marcel Lansbergen,
Abhishek Raj and Deepak Deshpande
Formability Prediction and Springback Evaluation
of Adhesive-Bonded Steel Sheets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
V. Satheeshkumar, Avinash Kumar Yadav and R. Ganesh Narayanan
Feasibility Study of Thermal Autofrettage Process . . . . . . . . . . . . . . . 81
S.M. Kamal and Uday Shanker Dixit
Numerical Analysis of Warm Deep Drawing for Ti–6Al–4V Alloy. . . . 109
Nitin Kotkunde, Aditya D. Deole, Amit Kumar Gupta
and Swadesh Kumar Singh
Springback and Formability Studies on Friction Stir
Welded Sheets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Sudhindra Katre, Siddhartha Karidi, B. Durga Rao,
P. Janaki Ramulu and R. Ganesh Narayanan
xi