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Related Concept Videos

Plastic Deformation in Circular Shafts01:20

Plastic Deformation in Circular Shafts

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When materials are subjected to forces that surpass their yield strength, they undergo a process known as plastic deformation. This results in a permanent alteration or strain in their structure. This concept can be specifically applied to circular shafts, where the deformation leads to a change in its shape. The precise evaluation of this plastic deformation requires understanding the stress distribution within the circular shaft, which is achieved by calculating the maximum shearing stress in...
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When a rod is made of different materials or has various cross-sections, it must be divided into parts that meet the necessary conditions for determining the deformation. These parts are each characterized by their internal force, cross-sectional area, length, and modulus of elasticity. These parameters are then used to compute the deformation of the entire rod.
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In designing structural elements and machine parts using ductile materials, it is crucial to ensure that these components withstand applied stresses without yielding. Yielding is initially determined through a tensile test, which evaluates the material's response to uniaxial stress. However, tensile stress is insufficient when components face biaxial or plane stress conditions This condition requires advanced criteria to predict failure.
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Metallic Solids

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Metallic solids such as crystals of copper, aluminum, and iron are formed by metal atoms. The structure of metallic crystals is often described as a uniform distribution of atomic nuclei within a “sea” of delocalized electrons. The atoms within such a metallic solid are held together by a unique force known as metallic bonding that gives rise to many useful and varied bulk properties.
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It is essential to understand how structural members behave under plastic deformation when the bending stress exceeds the material's yield strength. This state of deformation permanently alters the shape of the member, in contrast to the linear elastic behavior observed before yielding. The strain at any point in the member is expressed in terms of maximum strain. Notably, the neutral axis, which coincides with the centroid during elastic bending, shifts away from the centroid under plastic...
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Related Experiment Video

Updated: May 30, 2025

Knowledge Based Cloud FE Simulation of Sheet Metal Forming Processes
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Prediction Model for Flake Line Defects in Metallic Injection Molding: Considering Skin-Core Velocity and Alignment.

Seungkwon Choi1, Donghwi Park1, Seungcheol Lee1

  • 1Department of Mechanical Engineering, Sogang University, Seoul 04107, Republic of Korea.

Polymers
|January 25, 2025
PubMed
Summary

This study introduces new models to predict metallic injection molding defects by analyzing aluminum flake behavior in both surface and core layers. The models achieved 50% accuracy, improving quality prediction for metallic components.

Keywords:
aluminum flakesappearance defectflake line defectsmetallic injection moldingmisalignment indexskin-core interactionvelocity model

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Area of Science:

  • Materials Science
  • Manufacturing Engineering
  • Polymer Science

Background:

  • Metallic injection molding (MIM) offers efficient production of components with metallic luster.
  • Flake line defects at rib/flow path intersections pose a significant challenge in MIM.
  • Existing prediction methods often overlook core layer flow dynamics.

Purpose of the Study:

  • To develop predictive models for appearance defects in MIM.
  • To understand the influence of aluminum flake orientation and flow characteristics on defect formation.
  • To improve the prediction accuracy beyond surface-layer analysis.

Main Methods:

  • Proposed a velocity model incorporating surface and core layer flow characteristics.
  • Developed an alignment model considering aluminum flake orientation.
  • Visualized defect mechanisms related to velocity differences, flake uniformity, and reflection angles.

Main Results:

  • Achieved 50% prediction accuracy for appearance defects.
  • Successfully identified two out of four observed defects.
  • Demonstrated the importance of core layer flow in defect prediction.

Conclusions:

  • The novel models provide a systematic approach to understanding MIM appearance defects.
  • Accounting for core layer flow significantly advances defect prediction capabilities.
  • This research is expected to reduce defects and enhance quality in metallic component manufacturing.