Lecture Notes on Multidisciplinary Industrial Engineering Series Editor: J. Paulo Davim Uday Shanker Dixit Editors R. Ganesh Narayanan Strengthening and Joining by Plastic Deformation Select Papers from AIMTDR 2016 Lecture Notes on Multidisciplinary Industrial Engineering Series editor J. Paulo Davim, Department of Mechanical Engineering, University of Aveiro, Aveiro, Portugal “Lecture Notes on Multidisciplinary Industrial Engineering” publishes special volumes of conferences, workshops and symposia in interdisciplinary topics of interest.Disciplinessuchasmaterialsscience,nanosciences,sustainabilityscience, management sciences, computational sciences, mechanical engineering, industrial engineering, manufacturing, mechatronics, electrical engineering, environmental and civil engineering, chemical engineering, systems engineering and biomedical engineering are covered. Selected and peer-reviewed papers from events in these fields can be considered for publication in this series. More information about this series at http://www.springer.com/series/15734 Uday Shanker Dixit R. Ganesh Narayanan (cid:129) Editors Strengthening and Joining by Plastic Deformation Select Papers from AIMTDR 2016 123 Editors Uday ShankerDixit R. GaneshNarayanan Department ofMechanical Engineering Department ofMechanical Engineering Indian Institute of Technology Guwahati Indian Institute of Technology Guwahati Guwahati, Assam Guwahati, Assam India India ISSN 2522-5022 ISSN 2522-5030 (electronic) Lecture NotesonMultidisciplinary Industrial Engineering ISBN978-981-13-0377-7 ISBN978-981-13-0378-4 (eBook) https://doi.org/10.1007/978-981-13-0378-4 LibraryofCongressControlNumber:2018940420 ©SpringerNatureSingaporePteLtd.2019 Thisworkissubjecttocopyright.AllrightsarereservedbythePublisher,whetherthewholeorpart of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission orinformationstorageandretrieval,electronicadaptation,computersoftware,orbysimilarordissimilar methodologynowknownorhereafterdeveloped. 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Printedonacid-freepaper ThisSpringerimprintispublishedbytheregisteredcompanySpringerNatureSingaporePteLtd. partofSpringerNature Theregisteredcompanyaddressis:152BeachRoad,#21-01/04GatewayEast,Singapore189721, Singapore Preface Thisbookfocusesonstrengtheningandjoiningofmaterialsbyplasticdeformation. Most of the metals strain-harden after plastic deformation. This phenomenon has been used as an advantage during material processing for improving their mechanical properties. The strengthening by plastic deformation is prevalent in automotive, aerospace, construction, household appliance and ship-building industries. Joining by plastic deformation is also popularly used. In terms of environmental degradation, this process is superior to commonly employed fusion welding processes. Moreover, because of plastic deformation, the mechanical properties improve during joining, resulting in better products. In the era of increasing importance to sustainable manufacturing, strengthening and joining by plastic deformation will find more application in industries. These processes will helptoreducetheweightsoftheproducts,therebyhelpinginreducingthematerial and energy consumption. The book includes ten chapters. These are extended versions of peer-reviewed papers presented at the 6th International and the 27th All India Manufacturing Technology, Design and Research (AIMTDR) conference held at College of Engineering Pune (COEP) during December 16–18, 2016. In the area of strength- ening, the topics covered are autofrettage, cryo-rolling and equal channel angular processing.Intheareaofjoining,frictionstirwelding,ultrasonicspotweldingand electromagnetic joining are covered. The book will be useful for final year under-graduate,post-graduateanddoctoralstudentsofengineering.Itcanalsoserve as avaluable resource material for industry experts,scientists and policymakers. Chapter 1 discusses an important method of enhancing the fatigue strength of thick-walled cylinders by thermal autofrettage in combination with shrink fit. Theoretical analysis highlights the contribution of autofrettage and shrink fit in enhancing the fatigue life. Chapter 2 describes cryo-rolling and short-annealing treatment of an aluminum alloy. The deformation and fracture behavior are ana- lyzed.Thetensilestrengthofthecryo-rolledsheetwasimprovedconsiderably,and the sheet was also having good formability. v vi Preface Chapters3–10concentrateonjoiningofmaterialsinvolvingplasticdeformation. Electromagnetic pulse crimping of aluminum tube on dual phase steel rod is attempted in Chap. 3. Electromagnetic pulse joining is a sustainable solid-state joining method. Hardness and pull-out tests were conducted to ascertain the mechanical strength of the joint. Chapter 4 describes the post-weld heat treatment processes on the corrosion and mechanical properties offriction stir welded 7xxx aluminum alloy. Friction stir spot welding of polymer core sandwich sheets is discussed in Chap. 5. The temperature evolution, hardness distribution, joint for- mation and static strength of the joints were evaluated to reveal the validity of the process for joining sandwich sheets. Chapter 6 focuses on the friction stir welding of thermoplastic polymers. A case study on welding of high-density polyethylene polymeraimingatstudyingtheeffectofweldingspeedandrotationalspeedonthe joint mechanical properties was performed. Chapter 7 presents an enhancement of mechanical properties of friction stir welded portion of Al 6061 by incorporating additional reinforcing particulates of silicon carbide and aluminum oxide at the weldinterface.Ultrasonicspotweldingofaluminumandcoppersheetsisdiscussed in Chap. 8. Mechanical and metallurgical tests confirmed the application of the welding method for joining of dissimilar metal sheets. Finite element simulations werealsoconductedtostudythedeformationandstressdistributionduringjoining. Chapter 9 describes the finite element simulation of magnetic pulse welding for predicting the distribution of electromagnetic force and magnetic field. Chapter 10 discussesthepotentialofelectromagneticweldingforfabricatingtubularstructures innuclearpowerindustry.Joiningofgradesofaluminumalloysandstainlesssteel was experimented, and interesting results have been presented. Thesechaptershighlightthesignificanceofstrengtheningandjoiningbyplastic deformation for a variety of materials including metals and polymers. Future directions for research are also provided. It is expected that the book will be welcomed by engineers and scientists, particularly those involved in mechanical, metallurgical,materialscience,manufacturingandindustrialengineeringfields.We solicit the valuable feedback of the readers. Guwahati, India Uday Shanker Dixit R. Ganesh Narayanan Editorial Acknowledgements WearethankfultoProfessorB.B.Ahuja,DirectorofCollegeofEngineeringPune (COEP), who was chairman and organizing secretary of AIMTDR 2016, for allowing us to publish the book from extending versions of selected papers of the conference.ThankstoDr.B.Rajiv,HeadofDepartmentofProductionEngineering and Industrial Management, College of Engineering Pune (COEP), and the orga- nizing team for their motivation and encouragement provided during conference organization that led to the publication of this book. We thank all the authors for contributing their valued research work as extended chapters for this book. The authors submitted the chapters and responded to the revisions promptly which could make it possible to publish the book without delay. We sincerely acknowl- edge the organizers and the National Advisory Committee (NAC) members of AIMTDR 2016 for their guidance and support. We are grateful to Prof. Amitabha Ghosh,Prof.V.K.Jain,Prof.V.Radhakrishnan,Prof.M.S.ShunmugamandProf. P. Radhakrishnan for their encouragement and suggestions. WeexpressourheartfeltappreciationtoProf.J.PauloDavimfromUniversityof Aveiro,theSeriesEditorofthisbook,forhisencouragementandguidance.Lastbut not least, we express our sincere gratitude to the staff members of Springer, particularly to Ms. Swati Meherishi, Ms. Aparajita Singh, Dr. Mayra Castro and Ms. Christy, for their dedicated support during publication process of this book. vii About the AIMTDR Conference AIMTDRconferenceisahighlyprestigious,biennialeventorganizedinthefieldof mechanical and production engineering in India. The conference has a glorious history of organization since its inception. The first conference entitled ‘All India Machine Tool Design and Research Conference’ was held at Jadavpur University, Kolkata,in1967.Inearly90s,itwasthoughtappropriatetowidenthescopeofthe conference to encompass areas related to different manufacturing process tech- nologies and systems. Accordingly, it was renamed as ‘All India Manufacturing Technology, Design and Research’ conference and the 16th in the series was organized at Central Machine Tool Institute, Bangalore, in 1994. It became an international event with the first international conference being held at Indian Institute of Technology Roorkee in 2006. The international conference aimed to bring together academicians, researchers and industry professionals working worldwide in the field of manufacturing to exchange and disseminate ideas. ThesubsequentinternationalAIMTDRconferenceswereheldatIITMadrasand AndhraUniversity,Visakhapatnam,respectively.JadavpurUniversityhostedsilver jubilee of the conference and organized 4th International and 25th AIMTDR conference at Kolkata. The fifth international conference was organized at IIT GuwahatiinDecember2014,whilethe6thone(AIMTDR2016)wasorganizedby Department of Production Engineering and Industrial Management, College of Engineering Pune (COEP), during December 16–18, 2016. ix Mission, Vision, Challenges and Direction of AIMTDR Conference (Excerpt from the address of Prof. Amitabha Ghosh, the Chief Guest of 26th AIMTDR conference, held at IIT Guwahati during December 12–14, 2014) Personally,IhaveacloseassociationwithAIMTDRconferencefromtheveryfirst one for which I happened to be a humble and young member of the organizing team. That event was organized jointly by Late Prof. Amitabha Bhattacharyya and Prof. A. K. De at Jadavpur University in the year 1967. Keeping in view the growingindustrializationofIndia,theAIMTDRconferencewasplannedalongthe line of MTDR conference that used to be organized by Profs. Tobias and Koenigsberger at Cambridge and Birmingham alternately. India being an emerging economy, the importance of ‘manufacturing’ was well recognizedandoneoftheprimarygoalsofAIMTDRconferencehasbeentobring the academicians, researchers and the engineers from the industry to a common platform for exchanging ideas and developing a deeper mutual understanding among all concerned. The organizers of the AIMTDR conference in the past were eminently successful in this regard. With time, this event has gained maturity and has emerged as one of the most important international and national conferences held in India for all who are associated with the field of manufacturing. Since the economic development of any country is very critically linked to the manufacturing sector, it is only very natural that the current political leadership of India has taken up ‘Manufacturing in India’ as one of its key objectives. In fact, xi