N.A. Aziz

Geometrical Error Analysis of Cold Forged AUV Propeller Blade Using Optical Measurement Method

Accuracy is the key issue in the precision forging. Geometric and dimension errors are the two significant defects found in most of near net or net shape manufacturing process. It becomes more critical for complex part such as an AUV propeller blade. In this study, geometric error was quantified by comparing the blade profile obtained from nominal geometry of the blade and the profile constructed by commercial optical method namely Alicona system.

A Simplified Life Cycle Analysis of an Automotive Parking Brake Lever Using Polymer Composites

This paper presents a simplified life cycle analysis case study of a new developed automotive parking brake lever using polymer composites. Two composite materials were analysed for the component construction, namely glass fiber/polypropylene composites and hybrid kenaf/glass fiber/polypropylene composites. The rule of mixture and hybrid rule of mixture composite’s micromechanical models were utilized to determine the functional unit in the life cycle analysis. Later, the life cycle inventory data were defined for the production, use and end-of-life stages for the component. The Eco-indicator 99 method was selected for the overall LCA process. The final life cycle analysis results show that parking brake lever using the hybrid kenaf/glass fiber/polypropylene composites scores better environmental impact when compared to the similar component using glass fiber composites. This proved that the introduction of kenaf natural fiber, as the alternative reinforcement material in the polymer composites construction, is able to reduce the environmental impact throughout the product life cycle towards achieving better sustainable performance of the product.

Investigation of geometrical defect in cold embossing of a pin head

Under-filled in one of the major geometrical defect can be found in cold forging part. For net-shape manufacturing, defect will influence the assembly accuracy and tend to affect the performance of the system. Therefore, it must be predicted and minimized as early soon as possible before the manufacturing begins. The paper intents to investigate the geometrical defect of the cold embossing pin head. The pin head accuracy is very important in the propeller blade assembly. In this work, the effect of punch and pin head geometries to the formation of defect was studied using commercially software namely DEFORM-2D. The result is validated through experimental works.

Quality Evaluation of Cold Embossed Hole Based on Profile Measurement Technique

The main objective of this study is to assess the quality of the cold forging hole by focusing the roundness of the hole. In this study, a cold forging process of blind hole of Aluminum Alloy AA6061 experimental rig was developed. In the experiment, two major design parameters i.e. the depth of embossing and diameter of the punch were studied and their influence to the roundness was measured based on the profile obtained from the surface measurement technique. The results will be validated using commercial roundtest machine.

Twist Springback Measurement of AUV Propeller Blade Based on Profile Deviation

Geometrical error due to twist springback is one of major defects found in the near net or net shape part. It becomes more critical for complex part such as an Autonomous Underwater Vehicle (AUV) propeller blade. In this study, twist springback was quantified by comparing the blade and the die profiles obtained from commercial optical technique namely Alicona system. The results show a different pattern, where the twist springback becomes larger as the twist angle increases moving to the tip. The results show a strong agreement with the experiment.

Effect of Die Modification to Geometrical Defect of Cold Forged AUV Propeller Blade

Accuracy and characteristics of the die and punch plays a significant role in the forming process. The perfectness of the die and punch will not guarantee that the part form as desired. Therefore, the die or punch needs to be modified. In practice, the modifications will be carried by trial and error based on the experience of the fabricator and the amount or removed section is unknown. In this study, the contribution of die modification to the geometric defect will be quantified by comparing the blade profile obtained from the nominal geometry of the blade and the profile constructed by commercial optical method namely Alicona system. For validation, Coordinate Measurement Machine was used

Investigation of Geometrical Defect of AA6061-T4 Cold Embossing Using FEM

Accuracy of the net-shape manufacturing such as forging becomes critical as the process depends on many factors. Defect will harm the assembly tend to affect the performance of the part. Therefore, it must be detected and minimized it as soon as the manufacturing begins. Small size and complexity of the part limits the defective part to be assessed. The paper presents an investigation on the defect of the cold embossing pin. In this work, the effect of design and process parameters to the formation of defect was studied using 2-D FE analysis. The defect can be measured based on the incomplete filling of the region from the FE result. The results show that, the FE observations are in good agreement with the experimental result.