International Scientific Journals
of Scientific Technical Union of Mechanical Engineering "Industry 4.0"

The aim of this work is to evaluate the residual stresses in advanced composite ceramic coatings (60wt% Al₂O₃ – 40wt% SiO₂) was produced by thermal spraying coating (flame spraying) on the mild steel substrate (AISI 1050) steel. The bond coat used in this work was AlNi alloy between metallic substrate and advanced composite ceramic coatings which was implemented by flame spraying technique. The thickness of bond coating was (150ϻm) and for composite ceramic coating was (450 ϻm). the residual stresses evaluated by X-Ray diffraction technique were compressive residual stresses ( -62.6099), while by finite element method were compressive residual stresses (-68.491). The percentage of agreement between the residual stresses evaluated by X-Ray diffraction technique and finite element technique was (91.509%).

Incremental sheet metal forming has been well-known as one of the flexible methods of forming metallic sheets, suitable for the production of prototypes or small batch sizes. Apprehending the deformation method in forming processes and selection of route parameters to avoid part failure are of vital importance, because marketing needs standard sound parts in a shortest possible time. This paper presents the study on the use of finite element modeling of incremental sheet metal forming of Al 1100 aluminum alloy to investigate the effect of tool diameter and step over on the forming induced stresses, part thickness distribution and forming forces. The results of finite element analysis are compared with experimental data while producing truncated pyramid parts. It has been shown that the developed finite element model is capable of providing reliable results in the prediction of the final thickness of the part, which matches the experimental results with a maximum discrepancy of 8%.