The Metal Processing Laboratory currently operates under the direction of Professor Jack Jeswiet.

The research work carried out is in cold rolling, metal forming, powder metallurgy, and environmentally conscious design and manufacturing. Sensor development and diagnostics in the foregoing areas are also of interest; for example designing, constructing and interpreting the results of sensors for measuring friction at metal forming/die interfaces. Metal forming processes are important in part manufacture and therefore have an impact upon the environment. Hence an area of interest is the environmental conscious manufacture, ECM, of parts. Using ECM methods not only reduces environmental impact but is also profitable as has been shown.

Facilities

Laboratory equipment includes a rolling mill, ahydraulic metalforming press and a CNC incremental foming mill. The rolling mill is two-high, with 220 mm diameter work rolls and a roll surface speed capability up to 150 mm/s.A double acting hydraulic press is used for metal forming experimental research work and has an 80 ton capacity. It is computer controlled with necessary sensors associated with control feedback. The hydraulic press is used for work in Powder metallurgy, Coining andOpen Die Forging. The CNC Single Point Incremental Forming Sheet Metal Mill has spindle speed capabilities up to 12,000 RPM. The work of this laboratory has resulted in the publication of more than 90 technical journal papers in the last 10 years More than 15 graduate and 20 undergraduate students have undertaken research in the laboratory in the last ten years.

Projects

Among the projects the metal processing lab is currently involved with or has recently completed are:

  • The measurement of friction and temperatures at the rolling interface. This includes the development of sensors for measuring temperatures and friction inmetal forming.
  • The development of Single Point Incremental Forming of Sheet Metal, including the measurement of tool/die friction.
  • Studies in Powder Metallurgy (PM), specifically the ejection phase and friction in the PMprocess.
  • Astudy of Coining.
  • The development of models in all of the above processes.
  • A major project on the emission of CO2 in manufacturing processes. This work deals withenvironmentally friendly methods of manufacture. It includes evaluation of LCA methods of calculation, developing databases that designers and manufacturers can use in environmentally friendly design and manufacture, the assessment and use of metal forming simulation software in environmentally conscious manufacturing.

Further information can be obtained by contacting J. Jeswiet jeswiet@me.queensu.ca