Strengthening and Joining by Plastic Deformation

259 Pages·2019·10.93 MB·English

by  Uday Shanker Dixit

Lecture Notes on Multidisciplinary Industrial Engineering
Series Editor:
J. Paulo Davim

Uday Shanker Dixit
Editors
R. Ganesh Narayanan
Strengthening
and Joining
by Plastic
Deformation
Select Papers from AIMTDR 2016
Lecture Notes on Multidisciplinary Industrial
Engineering
Series editor
J. Paulo Davim, Department of Mechanical Engineering, University of Aveiro,
Aveiro, Portugal
“Lecture Notes on Multidisciplinary Industrial Engineering” publishes special
volumes of conferences, workshops and symposia in interdisciplinary topics of
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management sciences, computational sciences, mechanical engineering, industrial
engineering, manufacturing, mechatronics, electrical engineering, environmental
and civil engineering, chemical engineering, systems engineering and biomedical
engineering are covered. Selected and peer-reviewed papers from events in these
fields can be considered for publication in this series.
More information about this series at http://www.springer.com/series/15734
Uday Shanker Dixit R. Ganesh Narayanan
(cid:129)
Editors
Strengthening and Joining
by Plastic Deformation
Select Papers from AIMTDR 2016
123
Editors
Uday ShankerDixit R. GaneshNarayanan
Department ofMechanical Engineering Department ofMechanical Engineering
Indian Institute of Technology Guwahati Indian Institute of Technology Guwahati
Guwahati, Assam Guwahati, Assam
India India
ISSN 2522-5022 ISSN 2522-5030 (electronic)
Lecture NotesonMultidisciplinary Industrial Engineering
ISBN978-981-13-0377-7 ISBN978-981-13-0378-4 (eBook)
https://doi.org/10.1007/978-981-13-0378-4
LibraryofCongressControlNumber:2018940420
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Preface
Thisbookfocusesonstrengtheningandjoiningofmaterialsbyplasticdeformation.
Most of the metals strain-harden after plastic deformation. This phenomenon has
been used as an advantage during material processing for improving their
mechanical properties. The strengthening by plastic deformation is prevalent in
automotive, aerospace, construction, household appliance and ship-building
industries. Joining by plastic deformation is also popularly used. In terms of
environmental degradation, this process is superior to commonly employed fusion
welding processes. Moreover, because of plastic deformation, the mechanical
properties improve during joining, resulting in better products. In the era of
increasing importance to sustainable manufacturing, strengthening and joining by
plastic deformation will find more application in industries. These processes will
helptoreducetheweightsoftheproducts,therebyhelpinginreducingthematerial
and energy consumption.
The book includes ten chapters. These are extended versions of peer-reviewed
papers presented at the 6th International and the 27th All India Manufacturing
Technology, Design and Research (AIMTDR) conference held at College of
Engineering Pune (COEP) during December 16–18, 2016. In the area of strength-
ening, the topics covered are autofrettage, cryo-rolling and equal channel angular
processing.Intheareaofjoining,frictionstirwelding,ultrasonicspotweldingand
electromagnetic joining are covered. The book will be useful for final year
under-graduate,post-graduateanddoctoralstudentsofengineering.Itcanalsoserve
as avaluable resource material for industry experts,scientists and policymakers.
Chapter 1 discusses an important method of enhancing the fatigue strength of
thick-walled cylinders by thermal autofrettage in combination with shrink fit.
Theoretical analysis highlights the contribution of autofrettage and shrink fit in
enhancing the fatigue life. Chapter 2 describes cryo-rolling and short-annealing
treatment of an aluminum alloy. The deformation and fracture behavior are ana-
lyzed.Thetensilestrengthofthecryo-rolledsheetwasimprovedconsiderably,and
the sheet was also having good formability.
v
vi Preface
Chapters3–10concentrateonjoiningofmaterialsinvolvingplasticdeformation.
Electromagnetic pulse crimping of aluminum tube on dual phase steel rod is
attempted in Chap. 3. Electromagnetic pulse joining is a sustainable solid-state
joining method. Hardness and pull-out tests were conducted to ascertain the
mechanical strength of the joint. Chapter 4 describes the post-weld heat treatment
processes on the corrosion and mechanical properties offriction stir welded 7xxx
aluminum alloy. Friction stir spot welding of polymer core sandwich sheets is
discussed in Chap. 5. The temperature evolution, hardness distribution, joint for-
mation and static strength of the joints were evaluated to reveal the validity of the
process for joining sandwich sheets. Chapter 6 focuses on the friction stir welding
of thermoplastic polymers. A case study on welding of high-density polyethylene
polymeraimingatstudyingtheeffectofweldingspeedandrotationalspeedonthe
joint mechanical properties was performed. Chapter 7 presents an enhancement of
mechanical properties of friction stir welded portion of Al 6061 by incorporating
additional reinforcing particulates of silicon carbide and aluminum oxide at the
weldinterface.Ultrasonicspotweldingofaluminumandcoppersheetsisdiscussed
in Chap. 8. Mechanical and metallurgical tests confirmed the application of the
welding method for joining of dissimilar metal sheets. Finite element simulations
werealsoconductedtostudythedeformationandstressdistributionduringjoining.
Chapter 9 describes the finite element simulation of magnetic pulse welding for
predicting the distribution of electromagnetic force and magnetic field. Chapter 10
discussesthepotentialofelectromagneticweldingforfabricatingtubularstructures
innuclearpowerindustry.Joiningofgradesofaluminumalloysandstainlesssteel
was experimented, and interesting results have been presented.
Thesechaptershighlightthesignificanceofstrengtheningandjoiningbyplastic
deformation for a variety of materials including metals and polymers. Future
directions for research are also provided. It is expected that the book will be
welcomed by engineers and scientists, particularly those involved in mechanical,
metallurgical,materialscience,manufacturingandindustrialengineeringfields.We
solicit the valuable feedback of the readers.
Guwahati, India Uday Shanker Dixit
R. Ganesh Narayanan
Editorial Acknowledgements
WearethankfultoProfessorB.B.Ahuja,DirectorofCollegeofEngineeringPune
(COEP), who was chairman and organizing secretary of AIMTDR 2016, for
allowing us to publish the book from extending versions of selected papers of the
conference.ThankstoDr.B.Rajiv,HeadofDepartmentofProductionEngineering
and Industrial Management, College of Engineering Pune (COEP), and the orga-
nizing team for their motivation and encouragement provided during conference
organization that led to the publication of this book. We thank all the authors for
contributing their valued research work as extended chapters for this book. The
authors submitted the chapters and responded to the revisions promptly which
could make it possible to publish the book without delay. We sincerely acknowl-
edge the organizers and the National Advisory Committee (NAC) members of
AIMTDR 2016 for their guidance and support. We are grateful to Prof. Amitabha
Ghosh,Prof.V.K.Jain,Prof.V.Radhakrishnan,Prof.M.S.ShunmugamandProf.
P. Radhakrishnan for their encouragement and suggestions.
WeexpressourheartfeltappreciationtoProf.J.PauloDavimfromUniversityof
Aveiro,theSeriesEditorofthisbook,forhisencouragementandguidance.Lastbut
not least, we express our sincere gratitude to the staff members of Springer,
particularly to Ms. Swati Meherishi, Ms. Aparajita Singh, Dr. Mayra Castro and
Ms. Christy, for their dedicated support during publication process of this book.
vii
About the AIMTDR Conference
AIMTDRconferenceisahighlyprestigious,biennialeventorganizedinthefieldof
mechanical and production engineering in India. The conference has a glorious
history of organization since its inception. The first conference entitled ‘All India
Machine Tool Design and Research Conference’ was held at Jadavpur University,
Kolkata,in1967.Inearly90s,itwasthoughtappropriatetowidenthescopeofthe
conference to encompass areas related to different manufacturing process tech-
nologies and systems. Accordingly, it was renamed as ‘All India Manufacturing
Technology, Design and Research’ conference and the 16th in the series was
organized at Central Machine Tool Institute, Bangalore, in 1994. It became an
international event with the first international conference being held at Indian
Institute of Technology Roorkee in 2006. The international conference aimed to
bring together academicians, researchers and industry professionals working
worldwide in the field of manufacturing to exchange and disseminate ideas.
ThesubsequentinternationalAIMTDRconferenceswereheldatIITMadrasand
AndhraUniversity,Visakhapatnam,respectively.JadavpurUniversityhostedsilver
jubilee of the conference and organized 4th International and 25th AIMTDR
conference at Kolkata. The fifth international conference was organized at IIT
GuwahatiinDecember2014,whilethe6thone(AIMTDR2016)wasorganizedby
Department of Production Engineering and Industrial Management, College of
Engineering Pune (COEP), during December 16–18, 2016.
ix
Mission, Vision, Challenges and Direction
of AIMTDR Conference
(Excerpt from the address of Prof. Amitabha Ghosh, the Chief Guest of 26th
AIMTDR conference, held at IIT Guwahati during December 12–14, 2014)
Personally,IhaveacloseassociationwithAIMTDRconferencefromtheveryfirst
one for which I happened to be a humble and young member of the organizing
team. That event was organized jointly by Late Prof. Amitabha Bhattacharyya and
Prof. A. K. De at Jadavpur University in the year 1967. Keeping in view the
growingindustrializationofIndia,theAIMTDRconferencewasplannedalongthe
line of MTDR conference that used to be organized by Profs. Tobias and
Koenigsberger at Cambridge and Birmingham alternately.
India being an emerging economy, the importance of ‘manufacturing’ was well
recognizedandoneoftheprimarygoalsofAIMTDRconferencehasbeentobring
the academicians, researchers and the engineers from the industry to a common
platform for exchanging ideas and developing a deeper mutual understanding
among all concerned. The organizers of the AIMTDR conference in the past were
eminently successful in this regard. With time, this event has gained maturity and
has emerged as one of the most important international and national conferences
held in India for all who are associated with the field of manufacturing.
Since the economic development of any country is very critically linked to the
manufacturing sector, it is only very natural that the current political leadership of
India has taken up ‘Manufacturing in India’ as one of its key objectives. In fact,
xi