TITLE: Study Of Barreling Phenomenon of Sintered Aluminum Composite Under Hot Upset Forging Deformation.

NAME: KRISHANT CHAND(S11159411), KOKORIA. BATOROMAIO(S11125765)

INTRODUCTION METHODOLOGY RESULTS Calculated R vs Height strain parameter

Investigating barreling phenomena in aluminum 80
preform composites during hot upsetting forging. Method And Data Analysis: 70 4WC0.6
4TiC0.6
60 4Mo2C0.6
The project intends to improve our understanding of Methodology: The study encompasses several 4Fe3C0.6
50
the behavior of these materials during upsetting key steps, from material selection and powder
40

R
forging by in-depth analysis of the materials mixing to powder compaction, ejection, 30
AL4Fe3C, AL4Mo2C, AL4TiC, and AL4WC, with sintering, and final cooling and finishing. 20
different aspect ratios. The findings of this research 10
Mechanical Testing: Uniaxial compression tests
will be invaluable in streamlining the processes used 0
to produce these materials, which will enhance the are conducted on cylindrical powder metal 0.0 0.5 1.0 1.5
eh
quality and effectiveness of metal parts used in composites to analyze their mechanical behavior,
industrial applications. This research will work with covering aspects like densification, plastic flow, Calculated R vs Hoop stress ratio
1.8
the recent investigation of barreling to correlate and fracture. Figure 2: Depicts schematic diagram of barreling 1.6
significant theories to recent authors’ investigations Mass Constancy Principle: The study employs before deformation and after deformation 1.4
1.2
and follow a standard systematic framework to the Mass Constancy Principle (MCP) to establish 1.0
achieve a particular investigation analysis of Investigating Aluminum Composite Barreling:

sq / seff
stress-strain ratio parameters and derive the 0.8 4WC0.6
theoretical and experimental concepts from this Paper:
expression for the circular barreling arc. • Focus on stress-strain parameters and changing 0.6 4TiC0.6
4Mo2C0.6
0.4
Some features of hot forging of powder metallurgy barrel radius in aluminum composites, 4Fe3C0.6
0.2
sintered high strength 4%titanium carbide composite including AL4TiC, AL4WC, AL4Mo2C, AND 0.0
steel performs under different stress state conditions AL4Fe3C, with varying relative density and
0 10 20 30
R 40 50 60 70 80

Material Selection: aspect ratios. Calculated R vs Theatrical density

•Four aluminum composites
chosen: Al4TiC, Al4WC,
Secondary • Densification Rate and Circular Arc: Identifies 0.92

Al4Mo2C, Al4Fe3C. Deformation 0.90 4WC0.6

•Composites possess a relative Process: the densification rate among these composites 4TiC0.6
density of 0.82. 0.88 4Mo2C0.6
•Aspect ratios of 0.2 and 0.6
•Hot upsetting conducted
under dry friction
and establishes linear relationships between 4Fe3C0.6
were considered. conditions. 0.86
measured and calculated barrel radius,

Figure 1: PM process Theoretical
Calculation of
Barreling Arc:
•Using theoretical
OBJECTIVE
formulas derived from
prior research (e.g.,
Narayansamy et al.).
•Calculation of
•
theoretical barreling
Focus on the intersection of material science and arc of curvature.
manufacturing processes.
• to understand the impact of powder metallurgy on
waste reduction and energy efficiency in metal part
production
• Understanding barreling mechanics is essential to
Relationship
enhance manufacturing processes and product Analysis:
quality. •Correlating stress-strain
FTD
•Measurement of
dimensional changes 0.84
during deformation. displaying a circular arc profile.
Barrel Radius
• Detailed Data: Tables 3-8 in the appendix 0.82
0.80
Measurements: Densification Rate present stress and strain ratio parameter 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
•Experimental Evaluation from
measurements theoretical variations against calculated R for different R
conducted. formula and
•Vernier caliper literature review: aluminum composites and Aspect Ratios. CONCUSION
measurements.
•SolidWorks software
•Assessing how each
composite responds • Industrial Insights: The study’s data can be ✓ The dentification rate of the composites, all
measurements. to hot upsetting.
•Validation of •Understanding the leveraged to optimize manufacturing processes follow straight line relationship and have
experimental densification process
measurements. and behavior under
stress.
and control engineering properties in sintered greater rate of dentification for higher AR
powder metallurgy components. expect for Al4WC which has higher rates of
Calculated Rc vs Measured Rm dentification for lower AR.
35 ✓ Barreling follows circular arc profile.
30
Data Validation:
25
•Comparing results from:
•Vernier caliper measurement of bulging barreling 20 4WC0.2
4TiC0.2
curvature.
ACKNOWLEDGEMENTS
Rc

4Mo2C0.2
ratio parameters with •SolidWorks dimensioning measurements. 15 4Fe3C0.2
• establishing the relationship between various
barrel radius.
•Parameters: 𝜀𝑧/𝜀𝑒𝑓𝑓,
•Theoretical calculations of barreling arc.
•then plotted the calculated value and measured 10
Heartfelt appreciation to our supervisor, Dr.
𝜎𝑧/𝜎𝑒𝑓𝑓, 𝜀𝜃/𝜀𝑒𝑓𝑓, value corresponding to its barreling parameters.
5
Rajesh Kananan Anthnarayan, and the course
stress and strain parameters and barreling in 𝜎𝜃/𝜎𝑒𝑓𝑓. •Ensuring accuracy and reliability of research
findings.
0 coordinator, Dr. Sumesh Narayan, for their
aluminum preform composites.
0 5 10 15 20 25 30 35 constant guidance and support at every stage of
Rm
the project.