Tool design in a multi-stage drawing and ironing process of a rectangular cup with a large aspect ratio using finite element analysis

Tool design is carried out for a multi-stage deep drawing and ironing process of a rectangular cup with the large aspect ratio using the result of the finite element analysis. The analysis incorporates three-dimensional continuum elements for an elasto-plastic finite element method with the explicit time integration scheme using LS-DYNA3D. The analysis simulates the five-stage deep drawing and ironing process with the thickness control of the cup wall. Simulation is performed in order to investigate the failure by tearing during the forming process at the initial state of tool design. The analysis reveals that the difference of the drawing ratio within the cross section induces non-uniform metal flow which causes severe local extension. The irregular contact condition between the blank and the die also induces non-uniform metal flow which causes local wrinkling. This paper identifies such unfavorable mechanism in the rectangular cup drawing with ironing and proposes a new tool design with the guideline for modification in the design of the process and the sequential tool shape. The finite element analysis result with the improved tool design confirms that the proposed design not only reduces the possibility of failure but also improves the quality of a deep-drawn product. The numerical result shows fair coincidence with the experimental result.     

Selective Coating of SnS on the Bio‐Inspired Moth‐Eye Patterned PEDOT:PSS Polymer Films

A new strategy for the selective coating of tin sulfide (SnS) on the surface of moth‐eye patterned (MEP) conducting polymer film is studied by considering the optical properties of the antireflective moth‐eye pattern and flexibility of polymer films. The semiconductor SnS is selectively coated on the surface of MEP microdomes of poly(3,4‐ethylenedioxythiophene) poly(styrene‐sulfonate) (PEDOT:PSS) film. The SnS coated MEP film is obtained by using pore selectively SnS thin layer functionalized polystyrene honeycomb‐patterned porous (HCP) film as a template. Aqueous PEDOT:PSS solution is poured on the SnS functionalized HCP films and detached for the fabrication of SnS coated MEP films. The films show a satisfactory photo‐responsive property under solar stimulated light illumination due to the antireflective MEP structure of PEDOT film and homogenous SnS coating on the surface of the conducting polymer.     

In situ-grown hexagonal silicon nanocrystals in silicon carbide-based films

Silicon nanocrystals (Si-NCs) were grown in situ in carbide-based film using a plasma-enhanced chemical vapor deposition method. High-resolution transmission electron microscopy indicates that these nanocrystallites were embedded in an amorphous silicon carbide-based matrix. Electron diffraction pattern analyses revealed that the crystallites have a hexagonal-wurtzite silicon phase structure. The peak position of the photoluminescence can be controlled within a wavelength of 500 to 650 nm by adjusting the flow rate of the silane gas. We suggest that this phenomenon is attributed to the quantum confinement effect of hexagonal Si-NCs in silicon carbide-based film with a change in the sizes and emission states of the NCs.     

Dieless drawing steel wires using a dielectric heating method and modeling the process dynamics

Modern industries require the production of multi-functional, inorganic, micron-sized metal wires. This study suggests a novel method that could potentially offer a highly efficient dieless drawing technology for manufacturing thin stainless steel fibers. The method is based on a hot-working principle, using microwaves as the heat source and SiC as the susceptor. Experimental trials with a laboratory rig showed that the new system worked effectively for drawing the stainless steel wires and should be able to realize the diameter attenuation with a diameter reduction of up to 21%. The theoretical model describing the deformation behavior of the stainless steel wires in the working zone along with the constitutive equation of Bingham model modified with a power law and Zener–Hollomon parameter turned out to match very good with the actual results of the experiment. The coefficient of variation of the drawn wire diameter increased, as the draw ratio increased, which could be attributed to the occurrence of the narrow necking zone.     

Seismic reliability of non-linear frames with PR connections using systematic RSM

An effective, efficient, and robust reliability analysis algorithm is proposed for non-linear structures, where seismic loading can be applied in the time domain. The method is developed specifically for steel frame structures considering all major sources of non-linearity, including geometry, material, and partially restrained (PR) connections. The non-linearity due to PR connections is modeled by moment-relative rotation curves using the four-parameter Richard model. For seismic excitation, the loading, unloading, and reloading behavior at PR connections is modeled using moment-relative rotation curves and the Masing rule. The proposed algorithm intelligently integrates the response surface method, the finite element method, the first-order reliability method, and an iterative linear interpolation scheme. The uncertainties in all the random variables including the four parameters of Richard model are considered. Two unique features of the proposed algorithm are that (1) actual earthquake time histories can be used to excite structures in the presence of major sources of non-linearity and uncertainty and (2) it is possible to estimate the risk corresponding to both the serviceability and strength limit states. The algorithm is verified using the Monte Carlo simulation technique. The verified algorithm is first used to study the reliability of a frame structure in the presence of PR connections with different degrees of flexibility. Then the algorithm is used to estimate the reliability of a frame structure excited by 13 actual recorded earthquake time histories, 12 of them recorded during the Northridge earthquake of 1994. As expected, the reliabilities of the frame are found to be quite different, when excited by several time histories of the Northridge earthquake.     

Simulation of the newtonian flow through an abruptly contracted tube using a mixed finite element method

The solutions of the Navier-Stokes equation for a Newtonian flow through a 4/1 contraction tube were obtained numerically using the Galerkin finite element method with the nine-node Lagrangian element which was believed to be one of the most accurate tools for mixed-type interpolating formulations. It was proved from this study that the vortex occurrence in the entrance corner region were confirmed but its size was gradually decreased with the increase of Reynolds numbers, and that the velocity profiles and pressure distributions along the applied mesh layers were in agreement with the experimental and the previously reported numerical results.     

Experiments on formation of the adiabatic shear band in sheet metal

Formation of the adiabatic shear band in sheet metal is investigated with experiments for high strength steel sheets, 60 C and 60 TRIP. Since the adiabatic shear band is formed as a result of adiabatic shear failure with a narrow band of concentrated shear strain, the adiabatic shear band plays an important role in the analysis of high speed deformation phenomena. For shear band experiments with a tension split Hopkinson bar, specimens are designed to induced large shear strain. The experimental results show that the shear deformation modes of two sheet metals, 60 TRIP and 60 C, are quite different from each other in that the adiabatic shear band is observed only in 60 C. The shear deformation in 60 TRIP is restrained by the abrupt increase of strength due to the plastic strain, which interferes with propagation of the shear crack. Instead, a tensile crack developed at the corner where the shear crack should have been initiated. As a result, the load-displacement curves show that the tensile load of 60 TRIP specimens becomes higher than that of 60 C at the same displacement.     

Nanoscale Investigation of Grain Growth in RF-Sputtered Indium Tin Oxide Thin Films by Scanning Probe Microscopy

This work studied the electronic characteristics of the grains and grain boundaries of indium tin oxide (ITO) thin films using electrostatic and Kelvin probe force microscopy. Two types of ITO films were compared, deposited using radiofrequency magnetron sputtering in pure argon or 99% argon + 1% oxygen, respectively. The average grain size and surface roughness increased with substrate temperature for the films deposited in pure argon. With the addition of 1% oxygen, the increase in the grain size was inhibited above 150°C, which was suggested to be due to passivation of the grains by the excess oxygen. Electrostatic force microscopy and Kelvin probe force microscopy (KPFM) images confirmed that the grain growth was defect mediated and occurred at defective interfaces at high temperatures. Films deposited at room temperature with 1% oxygen showed crystalline nature, while films deposited with pure argon at room temperature were amorphous as observed from KPFM images. The potential drop across the grain and grain boundary was determined by taking surface potential line profiles to evaluate the electronic properties.     

Synthesis fluorescent magnetic nanoparticles in a microchannel using the La Mer process and the characterization of their properties

This study presents a stable and controllable synthesis of fluorescent magnetic nanoparticles in a flow-through microchannel for the bimodal use of magnetic activated cells sorting and fluorescence-activated cell sorters. The La Mer process is carried out to synthesize magnetic nanoparticles using co-precipitation. Then, the magnetic nanoparticles are coated with conjugation of chitosan and fluorescent isothiocyanate with two different concentrations. The chemical composition of the magnetic nanoparticles is determined by comparing the standard X-ray diffraction peaks of Fe₃O₄, and their sizes are also examined by using field emission scanning electron microscopy and dynamic light scattering measurement. The magnetic property of saturation magnetization and coercive field is characterized in a vibrating sample magnetometer. Also, the possibility of external manipulation in the synthesis of the magnetic particles is demonstrated by separating the synthesized fluorescent magnetic nanoparticles into a non-reacting lamination flow. Finally, their fluorescence property is determined by measuring the fluorescence adsorption spectra and the photoluminescence emission spectra in UV–Vis spectroscopy.