Niche Electronics’ Post

Today's KNOWLEDGE Share Let's imagine we do a fatigue test on a 40% GF filled polymer. Visually, such material will always show what appears to be a brittle failure. Even a less severe quasi-static tensile test will typically show failure at 1 or 1.5 % strain, which we mentally associate with "BRITTLE FAILURE". However, you'd be surprised to see to what an extent such failures are largely due to plasticity/ductile mechanisms. If we do our fatigue test (with a classic stress ratio R=0.1 ) at 1 Hz and then we repeat it on a fresh sample at 2 Hz, very often we will observe that life-time is the same, despite doubling the number of cycles ! This indicates that failure is essentially controlled by the underlying creep and accumulated plastic strain. A totally ductile mechanism ! If we were to observe failure two times faster, i.e. at the same number of cycles, this would point towards a dominant crack growth/brittle mechanism. In real life, we may also find something in between, demonstrating that failure mechanisms are often the result of concurrent damage mechanisms involving plasticity and cavitation. This is what modern "progressive damage" models (e-Xstream engineering, part of Hexagon’s Manufacturing Intelligence division for instance) will implement. source:Vito leo https://lnkd.in/gZF_6Pn2

Novel sensor technologies and data-driven approaches play a key-role in today's manufacturing business for process understanding, process improvement and eventually for increased productivity and sustainability. Cold forging is one of the most resource-efficient processes for the manufacture of metallic precision components in large series for many industry sectors worldwide 🌐. 🏭 The challenge: To maintain tight tolerances during transient process phases (e.g. during ramp-up), certain adjustment of the tooling is necessary. For this purpose, highly skilled machine operators perform manual inspection of the parts in a separate measuring device and adjust the machine based on these results. In cup backward extrusion of novel e-mobility parts, such as rotor shafts, concentricity errors must be minimal, but are present due to bending effects of the punch as a consequence of imperfect tool adjustment or varying billet properties. 📈 Our mission and task: "How can we support the machine operator in this complicated adjustment process to achieve higher efficiency ⏱ and less scrap parts?" 💡 Our solution: In the latest article "Thin-film sensors for data-driven concentricity prediction in cup backward extrusion", published in the prestigious Annals of the CIRP (Collège International pour la Recherche en Productique), we introduce a novel piezo-electric thin-film sensor disc, which allows to measure pressure distribution in the main load path of the tooling system. Bending of the punch can be detected by measuring the eccentric pressure distribution in the contact zone above the tool. Results show, that the resulting concentricity error of the formed part can be well predicted right after the forming stroke using sensor data and #MachineLearning! As a result, there is no need for manual part inspection, which saves time and money. This technology can be transfered to many more applications in the future. Whenever you are interested in measuring uneven load distribution in the contact zone with a very thin sensor (thickness about 10 µm!) and high normal pressure, this system might be interesting for you. 🏢 The sensor technology was developed by our colleagues from Fraunhofer IST in Braunschweig. Many thanks to Prof. Christoph Herrmann, Anna Schott and Martin Rekowski for the great collaboration in this project! Experimental cold forging trials for validation of the sensor concept were performed at our IFU - Institut für Umformtechnik, Universität Stuttgart. Many thanks to Prof. Mathias Liewald for his constant support in all regards. Thanks to our student assistant Andreas Hansen Gonçalves for his great help during the test trials in our laboratory. Please find the article below: https://lnkd.in/e2AJKuZ6 #ColdForging #ThinFilmSensor #MachineLearning #MetalForming #Sustainability #ScrapReduction #Productivity

We are celebrating the success with one of our collaborators - Pacific Northwest National Laboratory (PNNL) - over the recent launching of their new extrusion machine, and the advancements PNNL is making with their patented technology, Shear Assisted Processing and Extrusion (ShAPE™). Bond designed and supplied PNNL with their new Friction Extrusion (FE) machine that brings their patented technique closer to industrial applications. ShAPE™ is a step beyond traditional extrusion, capable of creating materials and components with extraordinary properties that cannot be achieved through conventional manufacturing. Now, with Bond's help, the next-generation ShAPE machine has arrived at PNNL. “ShAPE 2,” which is up and running, is designed to allow researchers to produce larger, more complex extrusions—a major step toward many real-world industrial applications for the ShAPE technique. "We are honored to work with PNNL on this project," said Dave Hofferbert, President of Bond Technologies. "These technologically impressive machines use frictional heat to plasticize material that is extruded into shapes such as rods, tubes and beams. The material properties of these parts is unlike conventional extruded products, providing superior strength, ductility and other desirable properties." Congrats to PNNL! We are excited for the future of Friction Extrusion! Read more about PNNL's patented ShAPE™ technology and the work their team is doing here: https://loom.ly/menFb1U #IndustrialApplications #Engineering #FrictionExtrusion #PNNL #BondTechnologies #MachineDesign

🔍 Behind the Scenes of Crystal Oscillators! Ever wondered how crystal blanks are crafted for precision? 🛠️✨ Discover the cutting-edge process that defines stability and accuracy in oscillators. From AT-cut to SC-cut, this article breaks it down step by step! 📖 Dive in now and explore the science behind the frequency! 👉 https://lnkd.in/gMQNuiaN #CrystalOscillators #Manufacturing #Innovation #FrequencyStability 🌐

Laser cutting is transforming manufacturing with incredible precision and speed! From detailed designs to industrial-scale projects, this technology cuts through metal and other materials with remarkable accuracy. Check out this quick demonstration to see how laser cutting is shaping the future of fabrication. #BreseightAustralia #LaserCutting #PrecisionEngineering #ManufacturingInnovation

💡Have you wondered how far you can push the boundaries of material properties in manufacturing? Check out this article to learn more about how Electroforming can help expand material property capabilities. https://hubs.li/Q02Lx69r0 #Electroforming #MaterialProperties #Innovation #Electroplating

🔍 Behind the Scenes of Crystal Oscillators! Ever wondered how crystal blanks are crafted for precision? 🛠️✨ Discover the cutting-edge process that defines stability and accuracy in oscillators. From AT-cut to SC-cut, this article breaks it down step by step! 📖 Dive in now and explore the science behind the frequency! 👉 https://lnkd.in/gMEfckuZ #CrystalOscillators #Manufacturing #Innovation #FrequencyStability 🌐

Today we are capable of creating superior materials with today’s superior technology and advanced simulation techniques. And researchers are working to ProPeL us forward. 🫸 Composite materials, which typically consist of a plastic resin matrix reinforced with fibers like carbon or glass, offer significant advantages due to their high strength-to-weight ratios, essential for sustainable technologies. Effective integration of material characterization, manufacturing processes, and performance evaluation is crucial to optimally utilizing composite materials, particularly in sectors such as aerospace, automotive and energy. The ProPeL (Process and Performance Simulations of Lightweight Structures) project strives to address these complexities by creating a comprehensive approach to integrate material characterization, simulation and performance evaluation. #Simulation #Manufacturing

Can be axially laminated anisotropic synchronous reluctance machine used for high-speed machines 😵 ? Yes it CAN! 🤑 Our latest research has been published in the prestigious Transactions on Energy Conversion! 🏅 The paper, titled "Additive Manufacturing of Axially Laminated Anisotropic Synchronous Reluctance Machines for High-Speed Applications," explores a promising alternative to traditional permanent magnet machines, which rely on expensive and environmentally challenging rare earth materials. In this work, we propose a novel rotor geometry using multi-material additive manufacturing to create an axially laminated anisotropic synchronous reluctance machine optimized for high-speed performance. This breakthrough development offers: 🔹 A sustainable alternative to rare earth magnets 🔹 Improved rotor geometry, optimized using genetic algorithms 🔹 Successful use of 17-4PH magnetic and 316L non-magnetic steels 🔹 Feasibility of the design verified through tests at 60,000 rpm We believe this advancement has the potential to unlock new possibilities for high-speed industrial applications while also demonstrating the viability of multi-material additive manufacturing for electrical machines. Check out the full paper https://lnkd.in/e-MTEKri to learn more! #Research #AdditiveManufacturing #EnergyConversion #SustainableEngineering #HighSpeedMachines #ElectricMachines

Establish a ZY gear drive production line（12-５）Technology transfer. Prototype verification. Fatigue life Fatigue life test is one of the three difficulties in gear drive testing. Many gear manufacturers have their own experiences, and some countries and regions have some standards. Due to the multi-tooth meshing of the ZY gear pair, when the fatigue life is calculated according to Miner's theory (load ratio)^m, the result is quite conservative. Because even if only 6 pairs of teeth are meshed, 6^m is much larger than 6. For example, in a fatigue life test conducted by Beijing Institute of Technology, the ZY gear drive achieved 2*10^9 converted stress cycles under twice the load of the current drive of the same weight, and no cumulative fatigue damage was observed. On the other hand, the rolling meshing's compaction and bridging effect is conducive to eliminating the propagation of microcracks and avoiding the tooth surface adhesion caused by sliding friction. I have completed the fatigue life calculation method for ZY gear pairs of medium carbon steel and ductile iron in HB245-310. If there are research conditions, we would like to further study the use of gray cast iron to manufacture ZY gears, as well as the use of light metal materials and engineering nylon to manufacture aircraft gears. At present, factories that accept technology transfer can use theoretical calculations and comparative testing with known fatigue life gearboxes to obtain conservative fatigue life values for ZY gear drivers.