Investigations of ductile damage during the process chains of toothed functional components manufactured by sheet-bulk metal forming

Sheet-bulk metal forming processes combine conventional sheet forming processes with bulk forming of sheet semi-finished parts. In these processes the sheets undergo complex forming histories. Due to in- and out-of-plane material flow and large accumulated plastic strains, the conventional failure prediction methods for sheet metal forming such as forming limit curve fall short. As a remedy, damage models can be applied to model damage evolution during those processes. In this study, damage evolution during the production of two different toothed components from DC04 steel is investigated. In both setups, a deep drawn cup is upset to form a circumferential gearing. However, the two final products have different dimensions and forming histories. Due to combined deep drawing and upsetting processes, the material flow on the cup walls is three-dimensional and non-proportional. In this study, the numerical and experimental investigations for those parts are presented and compared. Damage evolution in the process chains is simulated with a Lemaitre damage criterion. Microstructural analysis by scanning electron microscopy is performed in the regions with high mechanical loading. It is observed that the evolution of voids in terms of void volume fraction is strongly dependent on the deformation path. The comparison of simulation results with microstructural data shows that the void volume fraction decreases in the upsetting stage after an initial increase in the drawing stage. Moreover, the concurrent numerical and microstructural analysis provides evidence that the void volume fraction decreases during compression in sheet-bulk metal forming.     

Science,technology and values: promoting ethics and social responsibility

The paper discusses the limitations of engineering ethics as implemented in practice, with a focus on the fact that engineering and other activities are carried out without any consideration of whether the activities are themselves ethical, and on the gap between legality and ethics. This leads to the following three central ideas of the paper. The first is the need for engineers to both be aware of and critique their own values and be able to widen their perspective to that of the ‘other’, i.e., marginalised and minority groups and the environment. This understanding of the ‘other’ and values is also applied to the discussion of ethical issues relating to minority world (‘developed’) country engineers working in majority world (‘developing’) countries. The second central idea is the fact that structural and contextual factors in the form of barriers and enablers affect ethical values and practices. Individuals are not necessarily unethical in themselves, but the context and organisational ethos may present barriers to ethical behaviour and encourage the development of unethical values. These barriers and enablers are investigated through a pilot survey. The third central idea is the relationship between individual and collective responsibility and the need for support to enable engineers to think and behave ethically.     

Young adults and the decline of the urban English pub: issues for planning

The numbers of English public houses or “pubs” have reduced significantly in the last two decades. Politicians have called on the planning system to resist their closure but, at the same time, demand further controls over high-street bars. This paper explores the reasons for the decline and the rationale for supporting the continuation of the “traditional” English pub. Using evidence drawn from a wider study of the relationships between places and youth drinking cultures, the paper discusses young adults' use of pubs. While recognising the adverse effects of heavy drinking, arguments are put forward in support of the traditional pub as a site for restrained and responsible social interaction for young adults. The paper discusses the issues this raises for the UK planning system in the context of responsibilities for social sustainability and public health.     

Manufacturing of advanced smart tooling for metal forming

Forming is widely used due to its high efficiency in material utilization and its high production rate in general. Most forming processes control the geometry of final products through a set of tooling. The increasing demands on lightweight products have challenged the performances and functionalities of tooling. This paper provides a systematic review of recent advancements related to tooling performance and functionalities, including tool materials, tooling fabrication processes (e.g., machining, heat treatment, coating, surface texturing, and additive manufacturing), sensing, and data analytics. Finally, recommendations on future research directions for metal forming tooling are provided.     

Germanium-antimony-selenium-tellurium thin films: Clusters formation by laser ablation and comparison with clusters from mixtures of elements

Quaternary germanium-antimony-selenium-tellurium (Ge-Sb-Se-Te) thin films deposited from Ge_19.4Sb_16.7Se_63.9−xTe_x (x = 5, 10, 15, and 20) glass-ceramics targets by radio frequency magnetron sputtering were studied using laser ablation quadrupole ion trap time of flight mass spectrometry. Binary, ternary, and quaternary Ge_aSb_bSe_cTe_d clusters were formed and their stoichiometry was determined. By comparison of the clusters obtained from quaternary Ge-Sb-Se-Te thin films and those from ternary Ge-Sb-Te materials, we found that Ge-Te species are not detected from the quaternary system. Furthermore, Ge-Se and Se-Te species are missing in mass spectra generated from Ge-Sb-Se-Te thin films. From the Ge-Sb-Se-Te thin films, 16 clusters were detected while ternary Ge-Sb-Se glasses yielded 26 species. This might be considered as a signal of higher stability of Ge-Sb-Se-Te thin films which is increasing with a higher content of Te. The missing (Se₂⁺, Ge_aSb⁺ (a = 1–4), and GeSe_c⁺ (c = 1, 2)) and new (Ge⁺ and Sb_bTe⁺ (b = 1–3)) clusters may indicate that some of the structural features of the films (Ge₂Se_6/2 and Se₂Sb-SbSe₂) were replaced by (GeSe_4−xTe_x and SbSe_3−xTe_x) ones. In addition, when comparing the stoichiometry of clusters formed from Ge-Sb-Se-Te thin films with those from the mixtures of the elements, only Sb₃⁺ and SbSe⁺ were observed in both cases. The knowledge gained concerning clusters stoichiometry contributes to the elucidation of the processes proceeding during plasma formation used for the chalcogenide thin films deposition.     

Mass‐transfer enhancement by a reversible chemical reaction across the interface of a bubble rising under Stokes flow

Mass transfer around a bubble rising in a liquid under Stokes regime is investigated when a reversible chemical reaction, , is taken into account. Four dimensionless parameters control the interfacial transfer rate: the Péclet and Damköhler numbers, the ratio of the diffusion coefficient of both species, and the reaction equilibrium constant. The mass‐transfer equations are solved numerically with a finite element technique. A boundary layer approach is also proposed and solved with a coupled technique of finite difference and Chebyshev‐spectral method. The equilibrium constant and the ratio of diffusion coefficients have a strong influence on the coupling between the chemical reaction and mass transfer leading to an increase of the Sherwood number. The interaction between the chemical reaction and advection is clearly established by the simulations. Conditions corresponding to Péclet number larger than the Damköhler number reduces the effect of the chemical reaction. © 2014 American Institute of Chemical Engineers AIChE J, 60: 3376–3388, 2014