Journal of Japan Institute of Light Metals
Online ISSN : 1880-8018
Print ISSN : 0451-5994
ISSN-L : 0451-5994
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Volume 61, Issue 3
Displaying 1-6 of 6 articles from this issue
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RESEARCH REPORT
  • Effect of probe shape on dispersibility of alumina particle into 6061 aluminum alloy by friction stir processing
    Dai Nakama, Kazuyoshi Katoh, Hiroshi Tokisue
    Article type: Research Report
    2011 Volume 61 Issue 3 Pages 95-99
    Published: March 30, 2011
    Released on J-STAGE: April 30, 2011
    DOIhttps://doi.org/10.2464/jilm.61.95
    JOURNAL FREE ACCESS
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    Alumina particles were dispersed in a 6061-T6 aluminum alloy plate with 6 mm in thickness by friction stir processing in order to enhance the strength. The macro- and microstructures and mechanical properties of processed specimens were investigated. The plates were machined for insert the alumina particles of groove with 3 mm or 5 mm in width and 3 mm in depth. Three types; pillar, taper and left screw were used of the type of probe shapes. The insert depth of the probes from the surface was 5 mm or 6 mm. The area of dispersed alumina particles became large in order of pillar, taper and left screw. In case of the probe inserted 5 mm into the plate, alumina particles were dispersed near the surface of the plate. Using the left screw probe, alumina particles were dispersed in onion ring of the stir zone. Hardness of the processed plate was enhanced by dispersion of alumina particles that showed a higher value than that of the base metal, and the highest hardness value was obtained approximately 161HV0.1. Maximum tensile strength of the processed specimen was obtained using the taper probe, groove width of 3 mm and inserted 6 mm into plate, which was showed approximately 189 MPa.
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  • Comparison of cutting forces and cut surfaces between new shearing method with horizontal tool movement and conventional shearing
    Datao Lu, Makoto Murata, Takashi Kuboki, Yingjun Jin
    Article type: Research Report
    2011 Volume 61 Issue 3 Pages 100-106
    Published: March 30, 2011
    Released on J-STAGE: April 30, 2011
    DOIhttps://doi.org/10.2464/jilm.61.100
    JOURNAL FREE ACCESS
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    Sheet metal cutting is a general metal forming. A new shearing method has been invented for sheet metal cutting by authors. It has been named MM shearing. Sheet metal is cut by vertical movement of the tool for conventional shearing. In contrast, sheet metal is cut by horizontal movement of the tool for MM shearing. There are several advantages in MM shearing, for example small and inexpensive tools are applicable. There are some important parameters in the MM shearing, such as tool angle, clearance between the tool and die, sheet thickness, cutting speed and so on. In this paper, a series of experiments were carried out to compare MM shearing, conventional shearing and repetitive vertical shearing. The cutting force and cut surface were discussed in the various shearing methods. For MM shearing, the effect of clearance, sheet holding method, scrap width and cutting velocity on cutting force were also discussed. As a result, characteristics of MM shearing method were clarified.
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  • Deep drawing of 5052 aluminum alloy sheets using diamond tools without lubricant
    Nobuhiro Koga, Changlong Xu
    Article type: Research Report
    2011 Volume 61 Issue 3 Pages 107-111
    Published: March 30, 2011
    Released on J-STAGE: April 30, 2011
    DOIhttps://doi.org/10.2464/jilm.61.107
    JOURNAL FREE ACCESS
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    Marked improvement in tool life and stable production of high-precision products can be expected if a sintered polycrystalline diamond (PCD) or a boron-doped conductive diamond formed by chemical vapor deposition (CVD), which can be three-dimensionally shaped by electrical discharge machining, is used as a material for tools such as punches and dies for plastic working. In this study, friction and wear tests and shaving tests of these diamonds were first carried out to determine the wear resistance, adhesion resistance, and shock resistance of the diamonds. Therefore, the applicability of the diamond as a material for plastic working tools was examined. On the basis of the obtained findings, a diamond tool for deep drawing was fabricated and was used in deep drawing without lubricant. The results indicate that the limiting drawing ratio (LDR) of the developed diamond tool is higher than that of the conventional carbide tool. In the continuous deep drawing experiments using a progressive-type die without lubricant, defects such as scratches in the side wall of the products were observed after 20–30 repetitions of drawing using the conventional steel tool. In contrast, high-precision products, with the same precision as that of the first product, can be stably machined up to 5,000 repetitions of drawing using the diamond deep-drawing tool and demonstrate the efficacy of the developed diamond tool.
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