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UNIVERSITI PUTRA MALAYSIA
AHMAD BAHARUDDIN BIN ABDULLAH
FK 2013 11
GEOMETRICAL AND DIMENSIONAL DEFECT EVALUATION OF COLD FORGED AA6061 PROPELLER BLADE
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GEOMETRICAL AND DIMENSIONAL DEFECT EVALUATION OF COLD FORGED
AA6061 PROPELLER BLADE
By
AHMAD BAHARUDDIN BIN ABDULLAH
Thesis Submitted to the School of Graduate Studies, Universiti Putra Malaysia,
in Fulfillment of the Requirements for the Degree of Doctor of Philosophy
March 2013
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Abstract of thesis presented to the Senate of Universiti Putra Malaysia in fulfillment of the
requirement for the degree of Doctor of Philosophy
GEOMETRICAL AND DIMENSIONAL DEFECT EVALUATION OF COLD FORGED
AA6061 PROPELLER BLA DE
By
AHMAD BAHARUDDIN ABDULLAH
March 2013
Chair: Mohd Sapuan Salit, PhD, PEng
Faculty: Engineering
Accuracy is a key issue in cold forging process. Component defect is one of the major problems
in cold forging because the process depends on many factors including complexity of the
component. Defect not only affects the performance of the component but may also harm the
assembly. The problem of defect becomes more critical as the complexity of the component
increases, but the size and complexity of the part limit the effective assessment of the defect.
This project aims to investigate the geometrical and dimensional defects that occur in
Autonomous Underwater Vehicle propeller blades produced using the cold forging process.
Typically the manufacturing of the blade can be divided into five stages namely, blanking,
forming, trimming, heading and twisting. The defect was evaluated based on the three main
criteria of the blade. First, the overall geometrical and dimensional accuracy of the blade was
measured. In this study, the profile of the forged blade was considered as the final part, whereas
the profile obtained from the punch was considered as the targeted profile. The profile was
captured using a commercial focus variation based 3D surface measurement system, the Infinite
Alicona System. The constructed 3D profile was then compared to a nominal model. Next, the
filling ability of the pin head during the cold embossing or heading process was investigated,
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because an imperfect or defective pin head may affect the final assembly of the blade. In this
work, the effects of design and process parameters, including punch diameter and distance to
edge on the formation of defect, were studied using the commercial 2D finite element analysis
software DEFORM-2D. The defect can be estimated based on the incomplete filling of the
region and the amount of bulging based on the captured images of the simulation result. In
addition, the defect was predicted by investigating the design parameters and its effect on the
material flow pattern. Comparison between the simulation result and the fabricated pin head
show a geometrically similar pattern. Finally, the twist springback was measured. In this study,
defect was considered based on profile deviation, which was obtained from the 3D surface
measurement technique. An algorithm was developed to measure the deviation. The result
showed that the thickness error depended on the deformation ratio whereas the twist angle
accuracy relied on the amount of twist and thickness of the blade. In the other case, the
simulation results indicated that the most significant parameter for the filling ability and amount
of bulging was the distance to edge, whereas the punch taper was not relevant for cases of edge
embossing. In the case of twist springback, the results implied that the twist springback increased
as the twist angle increased. The highest springback was found to be at 16.11% for section E,
while the lowest is 2.58% for section A. Similarly, the twist springback increased with the
increase in deformation ratio. The coordinate measurement machine was used to validate the
result. This study will contribute to the development of effective evaluation method in the non-
contact measurement of geometrical and dimensional defect of component with complex profile
such as the propeller blade.
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Abstrak tesis yang dikemukakan kepada Senat Universiti Putra Malaysia sebagai memenuhi
keperluan untuk ijazah Doktor Falsafah
PENILAIAN KECACATAN GEOMETRIKAL DAN DIMENSI BILAH PENUJAH
AA6061 YANG DIHASILKAN SECARA TEMPAAN SEJUK
Oleh
AHMAD BAHARUDDIN ABDULLAH
Mac 2013
Pengerusi: Mohd Sapuan Salit PhD, PEng
Fakulti: Kejuruteraan
Kejituan merupakan kunci utama dalam proses tempaan sejuk. Kecacatan komponen adalah
merupakan salah satu masalah utama dalam tempaan sejuk disebabkana proses ini bergantung
kepada banyak faktor termasuklah kerumitan komponen. Kecacatan bukan sahaja memberi kesan
kepada prestasi komponen, tetapi ianya juga akan merosakkan pemasangan. Masalah kecacatan
akan menjadi lebih kritikal selaras dengan peningkatan kerumitan komponen tersebut, ini kerana,
saiz dan kerumitan komponen telah menghadkan keberkesanan penilaian kecacatan tersebut.
Projek ini bertujuan untuk menyiasat kecacatan geometrikal dan dimensi yang wujud dalam
bilah-bilah penujah Kenderaan Bawah-Air Autonomous yang telah dihasilkan menggunakan
proses tempaan sejuk. Secara dasarnya, pembuatan bilah boleh dibahagikan kepada lima
peringkat, yang dinamakan sebagai pengosongan, pembentukan, perapian, penghasilan kepala
dan piuhan. Kecacatan dinilai berdasarkan tiga kriteria dan sifat. Yang pertama ialah pengukuran
kejituan keseluruhan kecacatan geometrikal dan dimensi bilah. Dalam kajian ini, profil bilah
yang dihasilkan melalui tempaan mewakili komponen akhir yang terhasil, manakala profil yang
terhasil daripada penghentam dikira sebagai profil yang diharapkan pada bilah. Profil-profil ini
akan terhasil dengan menggunakan sistem pengukuran permukaan 3D komersial yang
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dibangunkan berdasarkan variasi fokus yang dinamakan, Infinite Alicona System. Profil 3D yang
dihasilkan kemudiannya akan dibandingkan dengan model nominal bilah. Seterusnya kriteria
yang kedua dan paling utama ialah kajian keboleh-isian kepala pin yang dihasilkan semasa
proses penimbulan sejuk. Ini kerana ketidak sempurnaan atau kepala pin yang cacat akan
memberi kesan kepada pemasangan akhir bilah. Dalam kajian ini, kesan parameter-parameter
rekabentuk dan proses termasuklah diameter penghentam dan jarak ke bucu kepada
pembentukan kecacatan telah dikaji dengan menggunakan perisian komersial analisis unsur
terhingga DEFORM-2D. Kecacatan telah dianggarkan berdasarkan ketidak-sempurnaan
pengisian kawasan dan bonjolan daripada imej yang diambil daripada keputusan simulasi. Selain
itu, kecacatan juga diramal dengan menyiasat parameter rekabentuk dan kesannya kepada bentuk
aliran bahan yang menjurus kepada kemunculan cacat. Akhir sekali, bidas-balik piuhan telah
diukur. Dalam kajian ini, kecacatan dipertimbangkan berdasarkan sisihan profil yang terhasil
daripada teknik pengukuran permukaan 3D. Algoritma dibina untuk mengukur sisihan.
Keputusan daripada kajian yang telah dijalankan menunjukkan ralat ketebalan bergantung
kepada nisbah perubahan-bentuk, manakala kejituan sudut piuhan bergantung kepada amaun
piuhan dan ketebalan bilah. Dalam kes lain, keputusan simulasi menunjukkan yang parameter
yang paling signifikan kepada keboleh-pengisian dan amaun bonjol adalah jarak ke bucu,
malahan penghentam dengan serongan pun tidak relevan kepada kes proses penimbulan bucu.
Perbandingan antara keputusan simulasi dan hasil tempaan sejuk menujukkan bentuk yang
secara geometrinya sama. Manakala dalam kajian bidasan-balik piuhan menunjukkan
peningkatan bidas-balik selaras dengan peningkatan sudut piuhan. Piuhan paling tinggi adalah
16.11% bagi seksyen E, manakala yang paling rendah adalah 2.58% untuk seksyen A. Begitu
juga, bidasan-balik piuhan bertambah dengan pengingkatan nisbah perubahan-bentuk. Dalam
kajian ini, mesin pengukuran koordinat digunakan untuk mengesahkan keputusan yang
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diperolehi. Kajian ini menyumbang kepada kaedah penilaian yang lebih efektif dalam mengukur
tanpa-sentuh kecacatan geometrikal dan dimensi komponen berprofil rumit seperti bilah penujah.
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ACKNOWLEDGEMENTS
In the name of Allah, Most gracious, Most merciful. Alhamdulillah, with His blessing, I have
completed this research and the preparation of this thesis.
I would like to express my gratitude to my supervisory committee chairman, Professor Ir. Dr.
Mohd. Sapuan Salit, who constantly motivated me with his knowledge and insight, throughout
the course of my study. I am also grateful to the members of the supervisory committee,
Associate Professor Dr. Zahurin Samad and Dr. Nuraini Abdul Aziz for sharing their expertise
and experience.
I am forever grateful to my parents, who have taught me a lot of things about lives. Sadly they
are not here to share the happiness. May Allah bless them and put them in Jannah. To my wife
and children for their patient and prayers. Appreciation also goes to my friends and colleagues,
all members and technicians at the School of Mechanical Engineering, Universiti Sains
Malaysia. I cannot imagine doing this job without supports from all of you.
Finally, my appreciation to Universiti Sains Malaysia and Ministry of Higher Education for the
scholarship during my study leave from 2007 to 2011 and financial support through Research
University Grant (RU) and Fundamental Research Grant Scheme (FRGS) to sponsor this project.
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APPROVAL
I certify that an Examination Committee met on 12 March 2013 to conduct the final examination
of Ahmad Baharuddin Abdullah on his Doctor of Philosophy thesis entitled “Geometrical and
Dimensional Defect Evaluation of Cold Forged AA6061 Propeller Blade” in accordance with
Universiti Pertanian Malaysia (Higher Degree) Act 1980 and Universiti Pertanian Malaysia
(Higher Degree) Regulations 1981. The Committee recommends that the candidate be awarded
the Doctor of Philosophy.
Members of the Examination Committee are as follows:
Chairman, PhD
Professor Dr. Shamsudin Bin Sulaiman
Universiti Putra Malaysia
(Chairman)
Examiner 1, PhD
Professor Ir. Dr. Barkawi Bin Sahari
Universiti Putra Malaysia
(Internal Examiner)
Examiner 2, PhD
Associate Professor Dr. Mohd Rizal Zahari
Universiti Putra Malaysia
(Internal Examiner)
Examiner 3, PhD
Professor Dr. Mohammad Hameedullah
Aligarh Muslim University, 202002 Aligarh, India
(External Examiner)
SEOW HENG FONG, Ph.D Professor and Deputy Dean
School of Graduate Studies
Universiti Putra Malaysia
Date:
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This thesis was submitted to the Senate of Universiti Putra Malaysia and has been accepted as
fulfillment of the requirements for the degree of Doctor of Philosophy. The members of the
Supervisory Committee were as follows:
Mohd. Sapuan Salit, PhD, PEng
Professor
Faculty of Engineering
Universiti Putra Malaysia
(Chairman)
Zahurin Samad, PhD
Associate Professor
School of Mechanical Engineering
Universiti Sains Malaysia Engineering Campus
(Member)
Nuraini Abdul Aziz, PhD
Senior Lecturer
Faculty of Engineering
Universiti Putra Malaysia
(Member)
_____________________________
BUJANG BIN KIM HUAT, PhD Professor and Dean
School of Graduate Studies
Universiti Putra Malaysia
Date:
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DECLARATION
I declare that the thesis is my original work except for quotations and citations which have been
duly acknowledged. I also declare that it has not been previously and is not concurrently,
submitted for any other degree at Universiti Putra Malaysia or other institution.
__________________________________
AHMAD BAHARUDDIN ABDULLAH
Date: 12 March 2013
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TABLE OF CONTENTS
Page
ABSTRACT ii
ABSTRAK iv
ACKNOWLEDGEMENT vii
APPROVAL viii
DECLARATION x
TABLE OF CONTENTS xi
LIST OF TABLES xiv
LIST OF FIGURES xix
LIST OF ABBREVIATIONS xx
CHAPTER
1 INTRODUCTION 1
1.1 Overview 1
1.2 Previous Work 4
1.3 Significance of the Study 5
1.4 Problem Statement 6
1.5 Objectives of the Study 7
1.6 Scope of the Study 7
1.7 Organization of the Thesis 8
2 LITERATURE REVIEW 9
2.1 Background 9
2.2 Definition 10
2.3 Types of Geometrical Defects 15
2.4 Investigation Tools 17
2.5 Measurement Methods 20
2.5.1 Contact 20
2.5.2 Non-contact 21
2.6 Representations of Profile Deviation 22
2.6.1 Average Radius 22
2.6.2 Absolute Area 24
2.6.3 Surface Deviation 25
2.6.4 Deformation Path 26
2.6.5 Flange Contour 27
2.6.6 Orthogonal Positions 28
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2.6.7 Contact Point 29
2.7 Defect Remediation Methods 31
2.8 Support System 32
2.9 Summary 34
3 METHODOLOGY 36
3.1 Finite Element Simulation using DEFORM 37
3.1.1 Cold embossing of the Pin Head – Overview 37
3.1.2 Cold embossing of the Pin Head – Modeling 40
3.2 3D Surface Measurements 46
3.2.1 Geometrical and Dimensional Defect 46
3.2.2 Twist Springback Measurement 50
3.3 Experimental Apparatus 56
3.3.1 Mechanical Press Machine 56
3.3.2 Infinite Alicona System 58
3.3.3 Coordinate Measurement Machine (CMM) 59
3.3.4 Universal Tensile Machine (UTM) 61
3.3.5 Physical Modeling 62
3.3.6 Tooling 63
3.4 Materials 66
3.5 Summary 66
4 RESULTS AND DISCUSSION 68
4.1 Geometrical and Dimensional Deviation 68
4.2 Pin Head Embossing 75
4.3 Material Flow Pattern 96
4.4 Physical Modeling 101
4.5 Twist Springback 105
4.6 Summary 111
5 CONCLUSIONS AND RECOMMENDATION FOR FUTURE
RESEARCH
112
5.1 General 112
5.2 Overall Geometrical and Dimensional Error 112
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5.3 Pin Head Embossing 113
5.4 Effect of Punch Geometries 114
5.5 Twist Springback 114
5.6 Recommendations for Future Work 115
REFERENCES 116
BIODATA OF STUDENT 128
LIST OF PUBLICATIONS 129