High power ultrasonic technology can currently count on a number of industrial applications. Ultrasonic welding, which is standard joining technique in many applications plastics, has few but well established metal applications, such as copper wires, pipes and connectors or, considering spot welding aluminium thin sheets, attractive for the automotive industry field, where it could represent possible cost effective alternative to resistance clinching or self‐pierce riveting. The present...

A new extrusion-based additive manufacturing technique is described in this paper together with the main components of machine capable carrying out process. Innovative characteristics are fixed extrusion head and workpiece moving thanks to a 5-axis parallel kinematics handling system, allowing capability inclining part during material deposition consequently avoiding support structures. The nozzle have been designed order be able extrude high viscosity mixtures low polymeric content....

Understanding the micro milling phenomena involved in process is critical and difficult through physical experiments. This study presents a 3D finite element modeling (3D FEM) approach for end-milling on Al6082-T6. The proposed model employs Lagrangian explicit formulation to perform coupled thermo-mechanical transient analyses. FE simulations were performed at different cutting conditions obtain realistic numerical predictions of chip formation, temperature distribution, forces by...

This work investigates the micro-milling machinability of Ti-6Al-4V alloy produced by a Laser Engineered Net Shaping (LENS) additive manufacturing (AM) process with specific focus on surface quality, cutting forces and burr formation. The effects deposition parameters are also investigated since material thermal history during processing can affect porosity mechanical behavior samples, giving different milling performances. characterization samples is done through micrographies, hardness...

Ti-6Al-4 V titanium alloy is a popular material in industrial applications (e.g. aerospace, oil & gas, medical) due to its superior mechanical properties, although low thermal conductivity and high chemical reactivity with other materials make it hard-to-cut material. A finite element model (FEM) was developed the present investigation simulate dry cryogenic orthogonal cutting of by using TiAlN coated carbide inserts. Numerical prediction effect cooling on chip formation, thrust forces were...

The effects of the main operational machining parameters on material removal rate (MRR) in abrasive waterjet turning (AWJT) are presented this paper using a statistical approach. five most common such as water pressure, mass flow rate, cutting head traverse speed, workpiece rotational and depth cut have been put into five-level central composite rotatable experimental design (CCRD). interaction among them were analyzed by means analysis variance (ANOVA) response surfaces for MRR obtained...

The design of a new additive manufacturing (AM) system based on extrusion and 3D deposition mixture metal (or advanced ceramic) powder polymeric binder is described in this paper. proposed totally innovative terms combination deposited work material, (head nozzle), table, which 5-axes parallel kinematics machine (PKM). head nozzle have been designed order to be able extrude high viscosity mixtures with low content. PKM aimed at obtaining good surface quality the reducing need for supports...

Injection compression molding (ICM) provides enhanced optical performances of molded polymer optics in terms birefringence and transmission light compared to (IM). Nevertheless, ICM requires case-dedicated process optimization ensure that the required high accuracy geometrical replication is achieved, particularly especially case surface micro-features. In this study, two factorial designs experiments (DOE) were carried out investigate capability IM on a micro structured Fresnel lens. A...

Abstract In the growing Industry 4.0 market, there is strong need to implement automatic inspection methods support manufacturing processes. Tool wear in turning one of biggest concerns that most expert operators are able indirectly infer through analysis removed chips. Automatising this operation would enable developing more efficient cutting processes turns easier process planning management toward Zero Defect Manufacturing paradigm. This paper presents a deep learning approach, based on...

Abstract The application of additive manufacturing (AM) for tooling in the mould and die industry brings a disruptive potential process performance, design flexibility product enhancements. Maturing existing AM technologies emerging such as metal-fused filament fabrication (metal FFF) can further support applicability polymer profile extrusion. This study provides complete characterization metal FFF 17–4 PH stainless-steel inserts evaluates their extrusion chain. presented experimental...

The present paper reports the second part of a research carried out by authors on application ultrasonic metal spot welding to lap joints made AA 6022‐T4 thin sheets. In particular, starting from findings Part 1, tensile–shear fatigue experiments are ultrasonically welded both in single and double configurations. analysis consequent failure causes modes traditional approaches for assessment resistance allow then effectively predicting experimental evidences. Furthermore, an optimisation...

Abstract Binder jetting is a versatile additive manufacturing technique suitable to produce alloys that are difficult obtain by powder bed fusion techniques, such as precious metals, due their high reflectivity and thermal conductivity. In this study, 18K 5N gold alloy was employed in the printing process. Different heat treatments densification processes were achieve final-stage sintering remove residual porosity, whilst controlling evolution of copper oxides reduction with hydrogen...

The evaluation of micromilled parts quality requires detailed assessments both geometry and surface topography. However, in many cases, the reduced accessibility caused by complex part makes it impossible to perform direct measurements. This problem can be solved adopting replica molding technology. method consists obtaining a feature that is inaccessible for standard measurement devices performing its indirect measurement. paper examines performance commercial replication media applied...

Complex shaped stainless steel tubes are often required for special purpose biomedical equipment. Nevertheless, traditional manufacturing technologies, such as extrusion, lack the ability to compete in a market of customized complex components because associated expenses towards tooling and extrusion presses. To rapid manufacture few with low cost high precision, new Extrusion based Additive Manufacturing (EAM) process, is proposed this paper, an example, short 316L sectioned were prepared...