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Planetary riveting of electric bimetallic micro-contacts
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Planetary Planetary riveting riveting of of electric electric bimetallic bimetallic micro-contacts micro-contacts
Manufacturing Engineering Society International Conference 2017, MESIC 2017, 28-30 June * * Presz 2017, VigoW. (Pontevedra), Spain W. Presz Institute of Manufacturing Technologies, Warsaw University of Technology, ul. Narbutta 85, 02-524 Warsaw, Poland Institute of Manufacturing Technologies, Warsaw University of Technology, ul. Narbutta 85, 02-524 Warsaw, Poland
Costing models for capacity optimization in Industry 4.0: Trade-off Abstract between used capacity and operational efficiency Abstract In recent years, there has been a clear change towards the replacement of devices using different types of energy with electrical In recent years, there has been a clear changea towards the replacement of devices a,* b using different btypes of energy with electrical P. Afonso , A. Zanin , R.other Wernke devices. These devices, forA. theSantana most part,, have a simpler construction than devices, which predisposes them to devices. These devices, for the most part, have a simpler construction than other devices, which predisposes them to miniaturization. An important element ofa electrical devices is micro-contacts successfully riveted by means of planetary riveting. miniaturization. An important element of University electrical of devices micro-contacts successfully riveted by means of planetary riveting. Minho,is4800-058 Guimarães, Recently, the monolithic contacts are replaced by bimetallic contacts. In theirPortugal case, the use of planetary processes leads to b Recently, the monolithic contacts are replaced by bimetallic contacts. InSC, their case, the use of planetary processes leads to Unochapecó, 89809-000 Chapecó, Brazil delamination of materials at various stages of riveting or exploitation. The riveting process was modeled using the two proposed delamination of materials at various stages of riveting or exploitation. The riveting process was modeled using the two proposed FEM-2d models and the FEM-3d model. Convergence results were obtained in all three cases. Based on the results of FEM, it FEM-2d models and the FEM-3d model. Convergence results were obtained in all three cases. Based on the results of FEM, it has been shown that obtaining the desired material distribution in contact when using planetary riveting involves the risk of has been shown that obtaining the desired material distribution in contact when using planetary riveting involves the risk of delamination of materials. The risk in principle does not occur in the case of classic riveting. Based on the FEM simulation, it has Abstract delamination of materials. The risk in principle does not occur in the case of classic riveting. Based on the FEM simulation, it has been demonstrated that there may be a technological window leading to the desired material distribution by means of planetary been demonstrated that there may be a technological window leading to the desired material distribution by means of planetary riveting without the risk of delamination. The technology window, however, is relatively narrow. Modeling did not take into Under concept of of "Industry 4.0",The production will be is pushed to narrow. be increasingly riveting the without the risk delamination. technologyprocesses window, however, relatively Modeling interconnected, did not take into account dynamical and heat activated phenomena that can inhibit delamination. information basedand on heat a real time basis and, necessarily, much more efficient. In this context, capacity optimization account dynamical activated phenomena that can inhibit delamination.
goes beyond the traditional aim capacity maximization, contributing also for organization’s profitability and value. © 2018 The Authors. Published byof Elsevier B.V. 2019 The B.V. © 2018 Authors. Publishedand by Elsevier B.V. improvement approaches suggest capacity optimization instead of Indeed, lean management continuous This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) This is an open access articleof under the CCoptimization BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) maximization. The study and costing models is an important research topic that deserves undercapacity committee of ICAFT/SFU/AutoMetForm 2018. Selection and peer-review responsibility of the scientific Selection and peer-review under responsibility of the scientific committee of ICAFT/SFU/AutoMetForm 2018. a mathematical contributions from both the practical and theoretical perspectives. This paper presents and discusses Keywords: orbital/planetary riveting, contact rivets, FEM modelling model formicroforming, capacity management based on bimetalic different costing models (ABC and TDABC). A generic model has been Keywords: microforming, orbital/planetary riveting, bimetalic contact rivets, FEM modelling developed and it was used to analyze idle capacity and to design strategies towards the maximization of organization’s value. The trade-off capacity maximization vs operational efficiency is highlighted and it is shown that capacity 1. Introduction optimization might hide operational inefficiency. 1. Introduction
© 2017 The Authors. Published by Elsevier B.V. In recentunder years,responsibility there has been a definite towards thermal Engineering motors withSociety electric motors and, in general, Peer-review of the scientificshift committee of replacing the Manufacturing International Conference In recent years, there has been a definite shift towards replacing thermal motors with electric motors and, in general, 2017. replacing devices using various types of energy with electrical devices. Electrical devices, in the vast majority have a
replacing devices using various types of energy with electrical devices. Electrical devices, in the vast majority have a different type of construction that is simpler than other devices. This feature in particular predisposes them to different Cost typeModels; of construction that is simpler thanIdle other devices. This Efficiency feature in particular predisposes them to Keywords: ABC;inTDABC; Capacity Management; Capacity; Operational miniaturization, which the 21st century is ubiquitous. Micro-Electro-Mechanical Systems, Micro-Opto-Elektrominiaturization, which in the 21st century is ubiquitous. Micro-Electro-Mechanical Systems, Micro-Opto-Elektro1. Introduction * Corresponding author. Tel.: +48 696844998; fax: +48 22 849 9797 * The Corresponding author. Tel.: +48 fax: +48 22 849 9797 for companies and their management of extreme importance cost of idle capacity is 696844998; a fundamental information E-mail address: [email protected] E-mail address: [email protected]
in modern production systems. In general, it is defined as unused capacity or production potential and can be measured 2351-9789 2018 The Authors. Published by Elsevier B.V.hours of manufacturing, etc. The management of the idle capacity in several©ways: tons of production, available 2351-9789 © 2018 The Authors. Published by Elsevier B.V. This is anAfonso. open access under the761; CC BY-NC-ND (https://creativecommons.org/licenses/by-nc-nd/4.0/) * Paulo Tel.:article +351 253 510 +351 253license 604 741 This is an open access article under the CC fax: BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) Selection and peer-review under responsibility of the scientific committee of ICAFT/SFU/AutoMetForm 2018. E-mail address: [email protected] Selection and peer-review under responsibility of the scientific committee of ICAFT/SFU/AutoMetForm 2018.
2351-9789 © 2017 The Authors. Published by Elsevier B.V. Peer-review under of the scientificbycommittee the Manufacturing Engineering Society International Conference 2017. 2351-9789 © 2019responsibility The Authors. Published Elsevier of B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) Selection and peer-review under responsibility of the scientific committee of ICAFT/SFU/AutoMetForm 2018. 10.1016/j.promfg.2018.12.048
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Mechanical Systems, micro-sensors, micro-machines and micro-robots are no longer futuristic. These advanced systems require parts and, to a large extent, metal parts. Parts that must meet high requirements for dimensional accuracy and surface quality. These requirements can be met by parts made using metal forming technology [1,2] and precisely speaking, the microforming [3] technology. Microforming mainly due to the so-called “scale effects” [4-7] have been isolated from the area of metal forming and are now a separate field. Miniaturization in this field refer to all components of the technological process, and thus also to the tools [8, 9] and tooling [10-12]. In this technology, special emphasis is placed on the precise control of the material structure [13,14] and the structure of the surface layer [12-16], which have a large impact on the processes and the broadly understood quality of the products. Therefore, lubrication methods [17-18] and surface modification of micro-billets and micro-tools [19-21] are developed. The construction of micro-mechanisms requires appropriate joining technologies. Attention is paid to those technologies that do not affect the precisely controlled material structure of micro-parts – the technologies of mechanical joining [22-24]. In the area of these technologies, a similar tendency is observed as in the case of metal forming, i.e. the tendency to separation of mechanical micro-joining technologies [25]. In the construction optimization, solid constructions have long been replaced with constructions made of materials with different characteristics. This concept is being observed on a larger scale in the area of metal forming [26-28], and interest in methods of forming of objects composed of various materials is increasing. Such objects are a particular technological challenge in the area of microforming [29,30]. Another area of metal forming technology that is experiencing turbulent development is incremental forming [31]. It is an interesting alternative to plastically forming the material in the whole volume. It consists in plasticizing only a part of the element's volume and successively transferring the deformation zone, so as to ultimately plastically deform the entire object. The main positive features of such methods are the most common reduction in the maximum process force and local reduction of pressure and friction forces. The presented subject of the analysis of the technology of making a bimetallic electric micro-contact with the process of planetary riveting is in line with the latest trends in the development of technology and refers to relatively unknown issues. 2. Problem statement and method of solution The standard technological process for the production of electrical contacts of small dimensions envisages the use of semi-finished products offered on the market in a wide range of dimensions in the form of rivets made of silver, Fig. 1a. These rivets are combined with the frames most often by means of the planetary riveting process. This technology is well-controlled and widely used. There are also available riveting machines in a wide range of dimensions. Recently, in order to reduce material costs, a significant part of the silver is replaced with copper and bimetallic rivets consisting of a copper shaft and a silver contact part, Fig. 1b. In the analyzed case, Fig.1c, direct replacement of the solid rivet with a bimetallic rivet in the manufacturing process carried out by planetary riveting encountered serious difficulties. In some parts of the products the delamination of the silver part from the copper part was observed, Fig. 1d. This phenomenon occurred at various stages of production and operation.
Fig. 1. (a) basic dimensions of riveting process components ; (b) assembled contact; (c) delaminated contact.
The FEM modeling was chosen to determine the cause of delamination during planetary riveting of bimetallic electric contacts.
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3. Desired material distribution in bimetallic micro-contact The distribution of materials in bimetallic contact due to the functional requirements of the contact is not indifferent. As it was established [32], the most desirable form is when outside material is "recessed" in the core material, which forms a small shell at the edge of the rivet. In this case, during the contact work, the flow directions of the constituent materials are convergent, which protects against delamination, Fig. 1e. When the dividing surface is convex, Fig. 1f, the materials tend to delaminate. Material distribution can be controlled by "matching" the plastic properties of both materials. This feature was parameterized through the Coefficient of Mutual Interactions of Plastic deformations (MIP): ������� � �� ∙ ����� �
��
��
∙
�� � � � ����� �� �� ��� ��
(1)
where: CA,B , nA,B – coefficients in flow curves (2) of material A and B, εS,E the range of equivalent strain during riveting. ����� ��� � ���� ∙ � ����
(2)
On the basis of the simulation of the riveting process, acceptable ranges of the MIP coefficient values were determined and the nomogram shown in Fig. 4a was drawn up. 4. Modeling of the planetary riveting Two 2d-models and one 3d-model were proposed. The 2d models: Mod-A and Mod-B isolate the most important feature of the planetary riveting (see Appendix A) which is the periodic change in the direction of "load" and thus the direction of deformation velocity. MarcMentat 2017 package as static, isothermal in a plain strain condition is used. The periodic deformation under the influence of the punch in Mod-A is shown as the alternating interaction of two punches, Fig. 2a. When the first punch is deforming the material, the second is withdrawing, followed by
Fig. 2.(a) Mod-A; (b) velocities of punches in Mod-A; (c) Mod-B; (d) punch velocities in Mod-B; (e) Mod-D; (f) movements in Mod-D; A – 1, material B – 2, frame – 3, base – 4, punches – 5, 6.
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changing their roles.The runs of the synchronized velocities of both punches are shown in Fig. 2b. In Mod-B, shown in Fig. 2c, the punch moves downward with simultaneous swinging motion described by the sinusoidal course of the angular velocity, Fig. 2d. In these modelling, Fig. 2ac: material A – 1, material B – 2 and frame – 3 are deformable bodies, the base – 4 and punches – 5, 6 are rigid bodies. In case of 3d-modeling the commercial package Simufact is used. Forming 14.0 is used in isothermal static conditions. The 3d-model – Mod-D - shown in Fig. 2e consists of 2 deformable bodies: material A – 1 and material B – 2 and rigid bodies: frame – 3, base – 4 and punch – 5. Punch movement is a planetary motion according to the rosette, Fig. 2f, described by (7) and constant angular velocity; see Appendix A. Mod-D’is a version of Mod-D without planetary movement. � ��� � � � ��� � � � ��� � � �� � � � ��� �
(3)
where: r – is calculated based on and P1 position, P,Q – parameters. During the process, the base and frame move at a velocity directed along the axis. Detailed process data are collected in table 1 and table 2. Table 1. Parameters of FEM models Model Mod-A Mod-B Mod-D Mod-D’
V [mm/s] 0.24/0.1 0.7 0.22 0.22
[rd/s] (-0.08,0.08) 8.4 -
[deg] 4 4 4 0
P0 [mm] 0 0 -
P1 [mm] 0.7 -
P/Q 11/7 -
μ 0.2 0.2 0.2 0.2
Table 2. Mechanical properties of modeled materials Contact body Material A,B Frame
E [MPa] 110000 120000
ν 0.32 0.32
C (reference) [MPa] 250 720
n 0.25 0.48
5. Results Modelling of different variants of combinations of materials in an electrical bimetallic micro-contact was limited to situations in which the coefficients n of both constituent materials are equal (4) that leads to (5). �� � �� (4) ������� � �� �
��
��
(5)
This circumstances means testing along a vertical line starting at point 1, Fig. 4a. In this situation, according to (5) the distribution of materials depends only on Hc. The values of this coefficient provided for simulations are defined by (6) and (7). The expected range of coefficients Hc with the desired material distribution results from the segment "2" shown in Fig.4a. ����������� �
�� �� �� ��
� �� � � ��� ���� �� ����
Hc,A,B,D,D’ = {0.4, 0.6. 7, 1, 1.5,1.7, 2, 2.5}, i=1,2, … , 8
(6) (7)
Initial optimization of the numerical models has been applied to the types and sizes of elements, as well as the remeshing parameters. Selected test results are presented in a synthetic form in Fig. 3. This figure shows the qualitative distribution of stresses at the cross-sections of the rivet heads in the last phase of the riveting processes.
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Material distributions are also visible. There were cases in which local delamination of materials was observed in different process phases and in different places of rivet – all these are marked with red frames. The recommended material distribution area because of the functional requirements that was stated in paragraph 3 is marked with a green frame.
Fig. 3. Summary of selected results of FEM modeling of riveting processes of bimetallic contacts- description in text.
6. Analysis of results The occurrence of the delamination of materials during deformation is presented in the form of a graph in Fig. 4b. From the point of view of the occurrence or not of the delamination phenomenon, the results of all simulations of the planetary riveting process are similar. Two dimensional modeling processes put a bit more stringent conditions and narrow the area free from delamination. On the other hand delamination does not occur in
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simple upsetting processes: Mod-D. Closer conclusions can be drawn based on the analysis of Fig. 3. Delamination occurs for Hc values above the neutral point which is Hc = 1. Hc values around 1.5 appear to be limit values.
Fig. 4. (a) nomogram for planning material distribution in standard riveting of bimetallic contacts [xx], description in text; (b) visualisation of FEM results.
In the vicinity of this value, the nature of the material distribution changes from the "convex" dividing surface of materials, Fig. 1f to the "concave" distribution, Fig. 1e. Below Hc = 1 delamination occurs only for values below Hc=0.5-0.6. In the planetary riveting conditions, the "convex” material dividing surface appears to be more resistant to delamination during the riveting process. From the considerations in paragraph 3, however, one knows that such shape of surface separation is unfavorable. Therefore, to find theoretically accepted material conditions for planetary riveting of considered component it is necessary to find a common space for both safe zones, see Fig. 3. It seems to be rather hard technological requirement. On the other hand standard riveting shows a wide safety zone for material conditions. Seeking the answer to the question why the conducted simulations of planetary riveting led to delamination and the standard riveting is not showing such tendency, you have to look at Fig. 3 column 3 and 4. It presents the results of planetary and standard riveting, for different mutual plasticity of constituent materials determined by a factor Hc. The reference point is the case where Hc = 1, which means that the rivet is monolithic. In this situation, the distribution of deformations is almost identical for the planetary and standard process, Fig. 3e-3-4. When the value of coefficient Hc moves away from Hc = 1, the differences between the strain distributions in the planetary and standard deformed contact deepen. In extreme case, when Hc = 0.4 in the planetary forming, there is even a "global" asymmetry of deformation. The reason of the various strain distribution is the periodic change in the direction of deformation resulting in the accumulation of differences between different materials subjected to several times repeated common deformations. 7. Conclusions Two two-dimensional FEM models have been proposed that reflect the key features of the planetary but also orbital riveting processes, such as specific path of deformation and periodic changes in the direction of deformation. These models are dedicated in further development to the analysis of the microforming processes of the bimetallic micro-contacts. The results obtained on the basis of the analysis carried out using the proposed 2d-models are qualitatively consistent with the results obtained by means of 3d-modeling.
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Riveting bimetallic contacts from materials with identical plastic properties regardless of the riveting method leads to unfavorable, convex shape of contact surface between both materials. Favorable distribution of materials – a concave dividing surface – is obtained when the external material has a bigger yield stress in relation to the internal material. The use of planetary riveting for the production of bimetallic electrical contacts compared to the use of standard riveting increases the possibility of delamination of materials the more, the greater is the ratio of the yield stress of the external material to the yield stress of the internal material. These last two conclusions "interact" oppositely. It does not mean, however, that they must be mutually exclusive. The small acceptable area means however possible difficulties with finding a technological window. 8. Final remarks The results were obtained by mechanical and static FEM simulations. It should be noted that in the relatively fast process of planetary riveting, there is a generation of heat that can trigger many thermally activated processes that have not been included in these studies. Their role, favorable or unfavorable due to the possibility of delamination of the external material layer, should be the subject of further analysis. Appendix A. Orbital forging Orbital forging [33, 34] is an analogy to rolling, the punch moves around the circumference, affecting only a part of the surface of the deformed product. It is an incremental process, which involves reducing the maximum process force in relation to the classical upsetting force [35]. A comparison of the classical and orbital process is shown in Fig. A1a,b.
Fig. A1. (a) comparison of classical and orbital forging: F – process force, σz – axial stress, σp – yield strength, γ – tilt angle; (c) movements obtainable in accordance with (1).
The kinematics of presses that implement this type of process usually consists in the submission of two circular movements with independent drives. Such a machine has the theoretical possibility of implementing the entire path area described by equation (1) and shown in Fig. A1 c. ݔ ߙ ቁ ቀݕቁ ൌ ݎή ቀ ή ߙቁ ή ቀ ொ ߙ
(1)
where: r – the radius of the curve, P and Q – parameters whose ratio affects the type of the curve, α -angle. The motion is determined by the position of the fixed pivot point P0, point P1 that is moving along one of possible curves, Fig. A1c, the tilt angle , the angular velocity and the linear velocity V shown in Fig. A1 b.
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Acknowledgements The work reported in this paper is financially partly supported by the National Science Centre, Poland (UMO2011/01/B/ST8/07731) References [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] [16] [17] [18] [19] [20] [21] [22] [23] [24] [25] [26] [27] [28] [29] [30] [31] [32] [33] [34] [35]
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Planetary Planetary riveting riveting of of electric electric bimetallic bimetallic micro-contacts micro-contacts
Manufacturing Engineering Society International Conference 2017, MESIC 2017, 28-30 June * * Presz 2017, VigoW. (Pontevedra), Spain W. Presz Institute of Manufacturing Technologies, Warsaw University of Technology, ul. Narbutta 85, 02-524 Warsaw, Poland Institute of Manufacturing Technologies, Warsaw University of Technology, ul. Narbutta 85, 02-524 Warsaw, Poland
Costing models for capacity optimization in Industry 4.0: Trade-off Abstract between used capacity and operational efficiency Abstract In recent years, there has been a clear change towards the replacement of devices using different types of energy with electrical In recent years, there has been a clear changea towards the replacement of devices a,* b using different btypes of energy with electrical P. Afonso , A. Zanin , R.other Wernke devices. These devices, forA. theSantana most part,, have a simpler construction than devices, which predisposes them to devices. These devices, for the most part, have a simpler construction than other devices, which predisposes them to miniaturization. An important element ofa electrical devices is micro-contacts successfully riveted by means of planetary riveting. miniaturization. An important element of University electrical of devices micro-contacts successfully riveted by means of planetary riveting. Minho,is4800-058 Guimarães, Recently, the monolithic contacts are replaced by bimetallic contacts. In theirPortugal case, the use of planetary processes leads to b Recently, the monolithic contacts are replaced by bimetallic contacts. InSC, their case, the use of planetary processes leads to Unochapecó, 89809-000 Chapecó, Brazil delamination of materials at various stages of riveting or exploitation. The riveting process was modeled using the two proposed delamination of materials at various stages of riveting or exploitation. The riveting process was modeled using the two proposed FEM-2d models and the FEM-3d model. Convergence results were obtained in all three cases. Based on the results of FEM, it FEM-2d models and the FEM-3d model. Convergence results were obtained in all three cases. Based on the results of FEM, it has been shown that obtaining the desired material distribution in contact when using planetary riveting involves the risk of has been shown that obtaining the desired material distribution in contact when using planetary riveting involves the risk of delamination of materials. The risk in principle does not occur in the case of classic riveting. Based on the FEM simulation, it has Abstract delamination of materials. The risk in principle does not occur in the case of classic riveting. Based on the FEM simulation, it has been demonstrated that there may be a technological window leading to the desired material distribution by means of planetary been demonstrated that there may be a technological window leading to the desired material distribution by means of planetary riveting without the risk of delamination. The technology window, however, is relatively narrow. Modeling did not take into Under concept of of "Industry 4.0",The production will be is pushed to narrow. be increasingly riveting the without the risk delamination. technologyprocesses window, however, relatively Modeling interconnected, did not take into account dynamical and heat activated phenomena that can inhibit delamination. information basedand on heat a real time basis and, necessarily, much more efficient. In this context, capacity optimization account dynamical activated phenomena that can inhibit delamination.
goes beyond the traditional aim capacity maximization, contributing also for organization’s profitability and value. © 2018 The Authors. Published byof Elsevier B.V. 2019 The B.V. © 2018 Authors. Publishedand by Elsevier B.V. improvement approaches suggest capacity optimization instead of Indeed, lean management continuous This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) This is an open access articleof under the CCoptimization BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) maximization. The study and costing models is an important research topic that deserves undercapacity committee of ICAFT/SFU/AutoMetForm 2018. Selection and peer-review responsibility of the scientific Selection and peer-review under responsibility of the scientific committee of ICAFT/SFU/AutoMetForm 2018. a mathematical contributions from both the practical and theoretical perspectives. This paper presents and discusses Keywords: orbital/planetary riveting, contact rivets, FEM modelling model formicroforming, capacity management based on bimetalic different costing models (ABC and TDABC). A generic model has been Keywords: microforming, orbital/planetary riveting, bimetalic contact rivets, FEM modelling developed and it was used to analyze idle capacity and to design strategies towards the maximization of organization’s value. The trade-off capacity maximization vs operational efficiency is highlighted and it is shown that capacity 1. Introduction optimization might hide operational inefficiency. 1. Introduction
© 2017 The Authors. Published by Elsevier B.V. In recentunder years,responsibility there has been a definite towards thermal Engineering motors withSociety electric motors and, in general, Peer-review of the scientificshift committee of replacing the Manufacturing International Conference In recent years, there has been a definite shift towards replacing thermal motors with electric motors and, in general, 2017. replacing devices using various types of energy with electrical devices. Electrical devices, in the vast majority have a
replacing devices using various types of energy with electrical devices. Electrical devices, in the vast majority have a different type of construction that is simpler than other devices. This feature in particular predisposes them to different Cost typeModels; of construction that is simpler thanIdle other devices. This Efficiency feature in particular predisposes them to Keywords: ABC;inTDABC; Capacity Management; Capacity; Operational miniaturization, which the 21st century is ubiquitous. Micro-Electro-Mechanical Systems, Micro-Opto-Elektrominiaturization, which in the 21st century is ubiquitous. Micro-Electro-Mechanical Systems, Micro-Opto-Elektro1. Introduction * Corresponding author. Tel.: +48 696844998; fax: +48 22 849 9797 * The Corresponding author. Tel.: +48 fax: +48 22 849 9797 for companies and their management of extreme importance cost of idle capacity is 696844998; a fundamental information E-mail address: [email protected] E-mail address: [email protected]
in modern production systems. In general, it is defined as unused capacity or production potential and can be measured 2351-9789 2018 The Authors. Published by Elsevier B.V.hours of manufacturing, etc. The management of the idle capacity in several©ways: tons of production, available 2351-9789 © 2018 The Authors. Published by Elsevier B.V. This is anAfonso. open access under the761; CC BY-NC-ND (https://creativecommons.org/licenses/by-nc-nd/4.0/) * Paulo Tel.:article +351 253 510 +351 253license 604 741 This is an open access article under the CC fax: BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) Selection and peer-review under responsibility of the scientific committee of ICAFT/SFU/AutoMetForm 2018. E-mail address: [email protected] Selection and peer-review under responsibility of the scientific committee of ICAFT/SFU/AutoMetForm 2018.
2351-9789 © 2017 The Authors. Published by Elsevier B.V. Peer-review under of the scientificbycommittee the Manufacturing Engineering Society International Conference 2017. 2351-9789 © 2019responsibility The Authors. Published Elsevier of B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) Selection and peer-review under responsibility of the scientific committee of ICAFT/SFU/AutoMetForm 2018. 10.1016/j.promfg.2018.12.048
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Mechanical Systems, micro-sensors, micro-machines and micro-robots are no longer futuristic. These advanced systems require parts and, to a large extent, metal parts. Parts that must meet high requirements for dimensional accuracy and surface quality. These requirements can be met by parts made using metal forming technology [1,2] and precisely speaking, the microforming [3] technology. Microforming mainly due to the so-called “scale effects” [4-7] have been isolated from the area of metal forming and are now a separate field. Miniaturization in this field refer to all components of the technological process, and thus also to the tools [8, 9] and tooling [10-12]. In this technology, special emphasis is placed on the precise control of the material structure [13,14] and the structure of the surface layer [12-16], which have a large impact on the processes and the broadly understood quality of the products. Therefore, lubrication methods [17-18] and surface modification of micro-billets and micro-tools [19-21] are developed. The construction of micro-mechanisms requires appropriate joining technologies. Attention is paid to those technologies that do not affect the precisely controlled material structure of micro-parts – the technologies of mechanical joining [22-24]. In the area of these technologies, a similar tendency is observed as in the case of metal forming, i.e. the tendency to separation of mechanical micro-joining technologies [25]. In the construction optimization, solid constructions have long been replaced with constructions made of materials with different characteristics. This concept is being observed on a larger scale in the area of metal forming [26-28], and interest in methods of forming of objects composed of various materials is increasing. Such objects are a particular technological challenge in the area of microforming [29,30]. Another area of metal forming technology that is experiencing turbulent development is incremental forming [31]. It is an interesting alternative to plastically forming the material in the whole volume. It consists in plasticizing only a part of the element's volume and successively transferring the deformation zone, so as to ultimately plastically deform the entire object. The main positive features of such methods are the most common reduction in the maximum process force and local reduction of pressure and friction forces. The presented subject of the analysis of the technology of making a bimetallic electric micro-contact with the process of planetary riveting is in line with the latest trends in the development of technology and refers to relatively unknown issues. 2. Problem statement and method of solution The standard technological process for the production of electrical contacts of small dimensions envisages the use of semi-finished products offered on the market in a wide range of dimensions in the form of rivets made of silver, Fig. 1a. These rivets are combined with the frames most often by means of the planetary riveting process. This technology is well-controlled and widely used. There are also available riveting machines in a wide range of dimensions. Recently, in order to reduce material costs, a significant part of the silver is replaced with copper and bimetallic rivets consisting of a copper shaft and a silver contact part, Fig. 1b. In the analyzed case, Fig.1c, direct replacement of the solid rivet with a bimetallic rivet in the manufacturing process carried out by planetary riveting encountered serious difficulties. In some parts of the products the delamination of the silver part from the copper part was observed, Fig. 1d. This phenomenon occurred at various stages of production and operation.
Fig. 1. (a) basic dimensions of riveting process components ; (b) assembled contact; (c) delaminated contact.
The FEM modeling was chosen to determine the cause of delamination during planetary riveting of bimetallic electric contacts.
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3. Desired material distribution in bimetallic micro-contact The distribution of materials in bimetallic contact due to the functional requirements of the contact is not indifferent. As it was established [32], the most desirable form is when outside material is "recessed" in the core material, which forms a small shell at the edge of the rivet. In this case, during the contact work, the flow directions of the constituent materials are convergent, which protects against delamination, Fig. 1e. When the dividing surface is convex, Fig. 1f, the materials tend to delaminate. Material distribution can be controlled by "matching" the plastic properties of both materials. This feature was parameterized through the Coefficient of Mutual Interactions of Plastic deformations (MIP): ������� � �� ∙ ����� �
��
��
∙
�� � � � ����� �� �� ��� ��
(1)
where: CA,B , nA,B – coefficients in flow curves (2) of material A and B, εS,E the range of equivalent strain during riveting. ����� ��� � ���� ∙ � ����
(2)
On the basis of the simulation of the riveting process, acceptable ranges of the MIP coefficient values were determined and the nomogram shown in Fig. 4a was drawn up. 4. Modeling of the planetary riveting Two 2d-models and one 3d-model were proposed. The 2d models: Mod-A and Mod-B isolate the most important feature of the planetary riveting (see Appendix A) which is the periodic change in the direction of "load" and thus the direction of deformation velocity. MarcMentat 2017 package as static, isothermal in a plain strain condition is used. The periodic deformation under the influence of the punch in Mod-A is shown as the alternating interaction of two punches, Fig. 2a. When the first punch is deforming the material, the second is withdrawing, followed by
Fig. 2.(a) Mod-A; (b) velocities of punches in Mod-A; (c) Mod-B; (d) punch velocities in Mod-B; (e) Mod-D; (f) movements in Mod-D; A – 1, material B – 2, frame – 3, base – 4, punches – 5, 6.
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changing their roles.The runs of the synchronized velocities of both punches are shown in Fig. 2b. In Mod-B, shown in Fig. 2c, the punch moves downward with simultaneous swinging motion described by the sinusoidal course of the angular velocity, Fig. 2d. In these modelling, Fig. 2ac: material A – 1, material B – 2 and frame – 3 are deformable bodies, the base – 4 and punches – 5, 6 are rigid bodies. In case of 3d-modeling the commercial package Simufact is used. Forming 14.0 is used in isothermal static conditions. The 3d-model – Mod-D - shown in Fig. 2e consists of 2 deformable bodies: material A – 1 and material B – 2 and rigid bodies: frame – 3, base – 4 and punch – 5. Punch movement is a planetary motion according to the rosette, Fig. 2f, described by (7) and constant angular velocity; see Appendix A. Mod-D’is a version of Mod-D without planetary movement. � ��� � � � ��� � � � ��� � � �� � � � ��� �
(3)
where: r – is calculated based on and P1 position, P,Q – parameters. During the process, the base and frame move at a velocity directed along the axis. Detailed process data are collected in table 1 and table 2. Table 1. Parameters of FEM models Model Mod-A Mod-B Mod-D Mod-D’
V [mm/s] 0.24/0.1 0.7 0.22 0.22
[rd/s] (-0.08,0.08) 8.4 -
[deg] 4 4 4 0
P0 [mm] 0 0 -
P1 [mm] 0.7 -
P/Q 11/7 -
μ 0.2 0.2 0.2 0.2
Table 2. Mechanical properties of modeled materials Contact body Material A,B Frame
E [MPa] 110000 120000
ν 0.32 0.32
C (reference) [MPa] 250 720
n 0.25 0.48
5. Results Modelling of different variants of combinations of materials in an electrical bimetallic micro-contact was limited to situations in which the coefficients n of both constituent materials are equal (4) that leads to (5). �� � �� (4) ������� � �� �
��
��
(5)
This circumstances means testing along a vertical line starting at point 1, Fig. 4a. In this situation, according to (5) the distribution of materials depends only on Hc. The values of this coefficient provided for simulations are defined by (6) and (7). The expected range of coefficients Hc with the desired material distribution results from the segment "2" shown in Fig.4a. ����������� �
�� �� �� ��
� �� � � ��� ���� �� ����
Hc,A,B,D,D’ = {0.4, 0.6. 7, 1, 1.5,1.7, 2, 2.5}, i=1,2, … , 8
(6) (7)
Initial optimization of the numerical models has been applied to the types and sizes of elements, as well as the remeshing parameters. Selected test results are presented in a synthetic form in Fig. 3. This figure shows the qualitative distribution of stresses at the cross-sections of the rivet heads in the last phase of the riveting processes.
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Material distributions are also visible. There were cases in which local delamination of materials was observed in different process phases and in different places of rivet – all these are marked with red frames. The recommended material distribution area because of the functional requirements that was stated in paragraph 3 is marked with a green frame.
Fig. 3. Summary of selected results of FEM modeling of riveting processes of bimetallic contacts- description in text.
6. Analysis of results The occurrence of the delamination of materials during deformation is presented in the form of a graph in Fig. 4b. From the point of view of the occurrence or not of the delamination phenomenon, the results of all simulations of the planetary riveting process are similar. Two dimensional modeling processes put a bit more stringent conditions and narrow the area free from delamination. On the other hand delamination does not occur in
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simple upsetting processes: Mod-D. Closer conclusions can be drawn based on the analysis of Fig. 3. Delamination occurs for Hc values above the neutral point which is Hc = 1. Hc values around 1.5 appear to be limit values.
Fig. 4. (a) nomogram for planning material distribution in standard riveting of bimetallic contacts [xx], description in text; (b) visualisation of FEM results.
In the vicinity of this value, the nature of the material distribution changes from the "convex" dividing surface of materials, Fig. 1f to the "concave" distribution, Fig. 1e. Below Hc = 1 delamination occurs only for values below Hc=0.5-0.6. In the planetary riveting conditions, the "convex” material dividing surface appears to be more resistant to delamination during the riveting process. From the considerations in paragraph 3, however, one knows that such shape of surface separation is unfavorable. Therefore, to find theoretically accepted material conditions for planetary riveting of considered component it is necessary to find a common space for both safe zones, see Fig. 3. It seems to be rather hard technological requirement. On the other hand standard riveting shows a wide safety zone for material conditions. Seeking the answer to the question why the conducted simulations of planetary riveting led to delamination and the standard riveting is not showing such tendency, you have to look at Fig. 3 column 3 and 4. It presents the results of planetary and standard riveting, for different mutual plasticity of constituent materials determined by a factor Hc. The reference point is the case where Hc = 1, which means that the rivet is monolithic. In this situation, the distribution of deformations is almost identical for the planetary and standard process, Fig. 3e-3-4. When the value of coefficient Hc moves away from Hc = 1, the differences between the strain distributions in the planetary and standard deformed contact deepen. In extreme case, when Hc = 0.4 in the planetary forming, there is even a "global" asymmetry of deformation. The reason of the various strain distribution is the periodic change in the direction of deformation resulting in the accumulation of differences between different materials subjected to several times repeated common deformations. 7. Conclusions Two two-dimensional FEM models have been proposed that reflect the key features of the planetary but also orbital riveting processes, such as specific path of deformation and periodic changes in the direction of deformation. These models are dedicated in further development to the analysis of the microforming processes of the bimetallic micro-contacts. The results obtained on the basis of the analysis carried out using the proposed 2d-models are qualitatively consistent with the results obtained by means of 3d-modeling.
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Riveting bimetallic contacts from materials with identical plastic properties regardless of the riveting method leads to unfavorable, convex shape of contact surface between both materials. Favorable distribution of materials – a concave dividing surface – is obtained when the external material has a bigger yield stress in relation to the internal material. The use of planetary riveting for the production of bimetallic electrical contacts compared to the use of standard riveting increases the possibility of delamination of materials the more, the greater is the ratio of the yield stress of the external material to the yield stress of the internal material. These last two conclusions "interact" oppositely. It does not mean, however, that they must be mutually exclusive. The small acceptable area means however possible difficulties with finding a technological window. 8. Final remarks The results were obtained by mechanical and static FEM simulations. It should be noted that in the relatively fast process of planetary riveting, there is a generation of heat that can trigger many thermally activated processes that have not been included in these studies. Their role, favorable or unfavorable due to the possibility of delamination of the external material layer, should be the subject of further analysis. Appendix A. Orbital forging Orbital forging [33, 34] is an analogy to rolling, the punch moves around the circumference, affecting only a part of the surface of the deformed product. It is an incremental process, which involves reducing the maximum process force in relation to the classical upsetting force [35]. A comparison of the classical and orbital process is shown in Fig. A1a,b.
Fig. A1. (a) comparison of classical and orbital forging: F – process force, σz – axial stress, σp – yield strength, γ – tilt angle; (c) movements obtainable in accordance with (1).
The kinematics of presses that implement this type of process usually consists in the submission of two circular movements with independent drives. Such a machine has the theoretical possibility of implementing the entire path area described by equation (1) and shown in Fig. A1 c. ݔ ߙ ቁ ቀݕቁ ൌ ݎή ቀ ή ߙቁ ή ቀ ொ ߙ
(1)
where: r – the radius of the curve, P and Q – parameters whose ratio affects the type of the curve, α -angle. The motion is determined by the position of the fixed pivot point P0, point P1 that is moving along one of possible curves, Fig. A1c, the tilt angle , the angular velocity and the linear velocity V shown in Fig. A1 b.
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Acknowledgements The work reported in this paper is financially partly supported by the National Science Centre, Poland (UMO2011/01/B/ST8/07731) References [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] [16] [17] [18] [19] [20] [21] [22] [23] [24] [25] [26] [27] [28] [29] [30] [31] [32] [33] [34] [35]
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