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TRANS. INDIAN INST. MET., VOL. 57, NO. 4, AUGUST 2004 It was found that both single and double reduction dies follow almost similar paths for circumferential stress, since the nature of the deformation is similar. Also the axial stress paths are almost similar for the first reduction and emergence from the first land. Since the percentage reduction is lesser at the first stage of the double reduction die as compared to the single reduction die, there are some tensile axial stresses at the center in the case of the former. Industrial trials with the new double reduction die design eliminated the cracks in the typical trial of 10,000 parts. This validated the design predictions. 7. CONCLUSIONS Advances in numerical techniques along with accurate modeling of material behavior have made it possible to analyze and optimize deformation and solidification processes for significant improvement in process quality and productivity. Recently, these techniques have been augmented by AI tools such as fuzzy reasoning and ANNs that enable incorporation of domain knowledge. In addition, SPC and robust design techniques have been integrated to reduce variability and to improve product properties. The collaborative industrial-governmental-academic research being conducted at the Manufacturing Research Group, The Ohio State University has resulted in significant cost reduction, and quality and productivity improvements for the participating industry. The cases presented in this paper are only a few examples of the application of these advanced theoretical techniques to the steel mills and the aerospace and automotive manufacturers (die casting and forging). The goal of this paper was to demonstrate the few successes of this collaborative effort. ACKNOWLEDGMENTS The support provided by the member companies (Timken, Inland steel and Chaparral steel) of the Consortium for the Advancement of Rolling Technology, by the Volvo Car Company, by the Sikorsky Aircraft Corporation, the Metaldyne Corporation and by the Dynamic Systems Incorporated (DSI) is gratefully acknowledged. The author also wishes to acknowledge the support from the Department of Energy and the UES, Inc; from SFTC, Columbus OH, for providing FEA software DE- FORM_2D TM ; and from TechSolve, Cincinnati OH for providing help with experiments for the machining research. The author finally expresses his appreciation to Praveen Pauskar, Jiang Hua, Shivakumar Kannan, Venkat Sankararaman, Ashish Pabalkar, Peeyush Mittal and Satish Kini, and the former and current research associates at The Ohio State University, for their hard work and efforts. REFERENCES 1. Kim N, Lee S M, Shin W, and Shivpuri R, J. of Engr. for Industry, 114 (1992) pp 329-335. 2. Shin W, Lee S M, Shivpuri R, and Altan T, J. Matls. Proc. Tech., 33(1-2) (1992) pp 141-154. 3. Lee S M, Shin W, and Shivpuri R, Int. J. Machine Tools and Manufacture, 32(3) (1992) pp. 315-327. 4. Shivpuri R, Shin W, and Mehrotra R, J. of Matls. and Manufac, Trans. Society of Automotive Engineers, (1992). 5. Sawamiphakdi K, Ives J E, Damm E B, Shivpuri R, and Pauskar P, Steel Rolling ’98, Seventh Int. Conf. on Steel Rolling, Tokyo, Japan, (1998). 6. Yoshimura K, Kini S, and Shivpuri R, Trans. NAMRI/ SME, Society of Manufacturing Engineers, XXV (1997) pp 55-60. 7. Kini S, and Shivpuri R, Proc. 40 th MWSP Conf., Iron and Steel Society, Pittsburgh, PA, (1998). 8. Shivpuri R, and Kini S, Proc. 39th MWSP Conference, Iron & Steel Society, Indianapolis, IN, (1997). 9. Kini S, and Shivpuri R, Iron and Steel Engineer, Iron and Steel Society, (2001). 10. Shivpuri R, Kini S, and Ji M, Proc. 8 th Int. Conf. on Steel Rolling & 44 th MWSP, Iron and Steel Society, Orlando, FL, (2002). 11. Ji M, Kini S, and Shivpuri R., Trans. NAMRI/SME, XXXI (2003) p. 475. 12. Pauskar P, Shivpuri R, Cho H, and Kim N, Trans. NAMRI/SME, Society of Manufacturing Engineers, XXV (1997) pp. 67-74. 13. Pauskar P, Phadke S, and Shivpuri R, Proc. 39th MWSP Conference, Iron & Steel Society, Indianapolis, IN, (1997). 14. Pauskar P, and Shivpuri R, Proc. 40 th MWSP Conf., 364
RAJIV SHIVPURI : NUMERICAL MODELING OF MANUFACTURING PROCESSES Iron and Steel Society, Pittsburgh, PA, (1998). 15. Pauskar P, and Shivpuri R, Trans.of NAMRI/SME, XXVII (1999) pp.61-67. 16. Pauskar P, and Shivpuri R, Annals of the CIRP, 48(1), (1999) p. 191- 194. 17. Pauskar P, and Shivpuri R, Advanced Technology of Plasticity, Proc. 6 th Int. Conf. Tech. Plasticity, Nuremburg, pp. 1967, 1999. 18. Kini S, and Shivpuri R, Proc. 42 nd MWSP Conf., Iron and Steel Society, Ontario, Canada, (2000). 19. Shivpuri R, Pauskar P, and Kini S, Proc. of joint JSME/ ASME Int. Conf. on Materials and Processing, Honolulu, Hawaii, (2002). 20. Pauskar P, Phadke S, and Shivpuri R, Trans. NAMRI/ SME, Society of Manufacturing Engineers, XXVI (1998) pp. 85-90. 21. Kini S, Pauskar P, and Shivpuri R, Proc. 22 nd Forging Industry Technical Conference, Lake Geneva, WI, (1999). 22. Phadke S, Pauskar P, and Shivpuri R, in print, J. Matls. Process. Tech, (2004). 23. Sellars C M, and Whiteman J A, Metal Science, March- (1979) pp. 187-194. 24. Karhausen K, and Kopp R, Proceedings of the International Symposium on Mathematical Modeling of Hot Rolling of Steel, (1990) 99-118. 25. Yanagimoto J, Karhausen K, Brand A J, and Kopp R, Proceedings of the 1995 Japanese Spring Conference for the Technology of Plasticity, (1995) 329-331. 26. Pauskar P, Damm B, Shivpuri R, Phadke S, Sawamiphakdi, K, and Ives, J, Proceedings of the 39th MWSPConf., ISS, 35 (1997). 27. Shivpuri R, Hua J, Mittal P, and Srivastava A, Annals of CIRP, 50(1) (2002). 28. Hua J, Mittal P, and Shivpuri R, Proc. 7 th ICTP, Int. Conf. on Technology of Plasticity, Yokohama, Japan, (2002). 29. Hua J, and Shivpuri R, In print J. of Materials Processing Tech., (2004). 30. Hua J, and Shivpuri R, Accepted J. of Engr. Matls. and Tech., (2004). 31. Umbrello D, Hua J, and Shivpuri R, ESAFORM 2004, Proc. 7th Esaform Conf. on Material Forming, Trondheim, Norway, (2004) pp 741-744. 32. Hua J, and Shivpuri R, Proceedings of the NSF Workshop on Research Needs in Thermal Aspects of Metal Removal Processes, Ed. Ranga Komanduri, Stillwater, OK, (2003). 33. Hua J, Mittal P, Shivpuri R, and Srivastava A, Proc. 6 th CIRP International Workshop on Modeling of Machining Operations, McMaster University, Ontario, Canada, (2003). 34. Schey J A, Introduction to Manufacturing Processes, 3rd Edition, McGraw-Hill, (2000). 35. Maekawa K, Nakano Y, and Kitagawa T, JSME International J. Series C, 39(4) (1996) pp. 864-870. 36. Lee W S, and Lin C F, J. Mater. Proc. Tech., 75 (1998) pp. 127-136. 37. Gartside M B, The Minerals, Metals & Materials Society, (1997) 101-108 38. Usui E, Obikawa T, and Shirakashi T, Proc. 5th Int. Conf. Production Eng., Tokyo, (1984) pp. 233-239 39. Lee D, J. Eng. Ind., 107(1) (1985) pp. 55-63. 40. Semiatin S L, Lahoti G D, and Oh S I, Plenum Press, New York, (1983) pp. 119-159. 41. Shivpuri R, Hua J, Mittal, P, Srivastava, A K, Annals of CIRP, 51(1) (2002) 71-74. 42. Hua J, Shivpuri R, Proceedings of the 9th ISPE International Conference on Concurrent Engineering, Cranfield, United Kingdom, (2002) pp. 357-365. 43. Sandstrom D R, and Hodowany J N, Machining Science and Technology, 2(2) (1998) pp. 343-353. 44. Kannan, S., Sankararaman, V. and Shivpuri, R., Trans. NAMRI/SME, Society of Manufacturing Engineers, XXVIII (2000) pp. 87-92. 45. Shivpuri R, Sankararaman V, and Kulkarni K, Trans. of NADCA, 2001 Die Casting Congress and Expo, Cincinnati, (2001) pp. 143- 150. 46. Shivpuri R, Pabalkar A, and Kini S, J. of Engineering Manufacture, Proc. Inst. Mech. Engr., Part B, B-08600, (2001) pp. 1377- 1384. 47. Pabalkar A, Kini S, and Shivpuri R, Trans. NAMRI/ SME, Society of Manufacturing Engineers, XXVIII (2000) pp. 63-68. 48. Pabalkar A, Shivpuri R, Proc. 23 rd Forging Industry Technical Conference, Reno, NV. (2001). 49. Hydrostatic Extrusion, Metals Handbook, American 365
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