Past projects have included process modeling and experimental work related to understanding the thread rolling process and its effects on rolled fastener properties. Project accomplishments have included development of a two-dimensional finite element model for thread rolling which correlated very well with results and properties obtained from actual production fasteners. Additional efforts have included a student project which resulted in the successful design and fabrication of a small scale physical thread rolling simulator. Further details and a description of these activities are available in the following publications:
Dotson, Jarvis L. Henrey, Charles R. Domblesky, Joseph P. Experimental investigation of external thread rolling [Journal Article] Wire Journal International. v 35 n 11 November 2002. p 64-68.
Domblesky, J.P., Feng, F. Two-dimensional and three-dimensional finite element models of external thread rolling [Journal Article] Proceedings of the Institution of Mechanical Engineers Part B-Journal of Engineering Manufacture. v 216 n 4 2002. p 507-517.
Domblesky, Joseph P., Feng, Feng. A parametric study of process parameters in external thread rolling [Journal Article] Journal of Materials Processing Technology. v 121 n 2-3 Feb 28 2002. p 341-349.
Domblesky, J.P., Feng, F. Finite element modeling of external thread rolling [Journal Article] Wire Journal International. v 34 n 10 October 2001. p 110-115.
Past projects include three projects, funded by the Wisconsin Space Grant Consortium, intended to research the performance of laser and arc welding processes and arc characteristics related to sub-atmospheric conditions representative of outer space. This work included development and fabrication of a vacuum chamber which enabled observation of the arc under a variety of experimental conditions.
Provide a simple, accurate method for predicting the resulting density distribution after axial compression of metal powders. The prediction should be capable of providing guidelines for tooling design, fill levels, and motion set-up.
Finite element simulation is investigated as a means for prediction of final powder compact density distribution. An appropriate powder material model has been selected known as the “cap” constitutive model, which has been used extensively in the area of soil mechanics. In this model, powder yield in both the elastic and plastic regimes for a large deformation process may be handled. In this manner the entire compaction sequence from die filling through ejection can be accommodated.
The commercial software “ABAQUS” has been chosen as the FEM engine due to its ability to handle various user defined material models such as the “cap” model. Prediction is being validated with powder compacts, which have been produced with both single, and multiple level forms.