Purpose: Custom-designed metal bellows require alternate ways to produce the die to shorten lead time. The purpose of this study is to explore the possibility of using Additive Manufactured (AM) polymer die as direct rapid tool (RT) for metal bellow hydroforming. Design/methodology/approach: Finite element analysis (FEA) was used to simulate bellow forming and to evaluate the compatibility of AM die. Fused deposition modelling (FDM) technique is used to fabricate die with Acrylonitrile Butadiene Styrene (ABS) material. To validate, the width of the metal bellow convolutions obtained from the FEA simulation is compared with convolution formed during the experiment. Findings: FDM-made die can be used for a short production run of bellow hydroforming. FEA simulation shows that stress developed in some regions of die is less and these regions have potential for material reduction. Use of RT for this particular application is limited by the die material, forming pressure, width, convolution span and material of bellow. This supports the importance of FEA validation of RT before fabrication to evaluate and redesign die for the successful outcome of the tool. Research limitations/implications: The given methodology may be followed to design a RT with minimum material consumption for bellow forming application. Whenever there is a change in bellow design or the die material, simulation has to be done to evaluate the capability of the die. As this study was focused on a short production run for manufacturing one or few bellows, the die life is not a significant factor. Originality/value: This paper demonstrates about rapid tooling for metal bellow manufacturing using FDM technique for low volume production. Further, FEA is used to identify low stress regions and redesign the die for material reduction before die manufacturing. AM die can be used for developing customized metal bellow for applications such as defense, aerospace, automobiles, etc.

The natural fiber reinforced composites are highly utilized in the applications of building and construction industry, storage containers, transportation industry and in other industrial applications. The natural fibers are preferred for its distinct properties than synthetic fibers. Natural fibers are economically cheaper, recyclable and ecologically biodegradable. Many studies were proposed by the researchers to improve the machinability and mechanical behaviour of natural fiber reinforced composites. The addition of filler material is a kind of approach to improve the property of natural fiber reinforced composites. In this study the composite laminates are created by reinforcing bi-directional bast type jute and unidirectional leaf made sisal fibers into an epoxy LY556 resin matrix material. The silicon carbide (SiC) is used as filler material. Two types of composite laminates are manufactured. The first sample is considered in the ratio of 70% epoxy resin to 30% Jute + Sisal fiber composition without any filler material. The second composition includes the ratio of 70% epoxy resin to 30% Jute + Sisal fiber along with 10% SiC as filler material. The hardner HY951 of 10% is used in both compositions. The machining operation was performed by using HSS twist drill for three different machining parameters (Drill bit type, Spindle speed and Feed rate). The circularity and surface roughness are considered as output parameters. The machining is performed in the range of 20 different combinations as directed by the RSM software. The conformation tests are carried out to validate the RSM results. The optimization results shows that the sample with SiC filler exhibits better machinability behaviour than sample without filler material.

Progress in the manufacturing sector resulted in the need for products with enhanced mechanical properties, corrosion, and heat resistance. Thus, superalloy was produced with desired mechanical properties. Monel Alloy is one of those nickel-based superalloys, commonly used in industry for its high strength and resistance to corrosion. Monel is also acid- and saltwater resistant. Some properties such as gummy behavior and job hardening make machining superalloys by traditional methods difficult. For this purpose, in this analysis, near-dry wire electric discharge machining (WEDM) is chosen for Monel machining. The present research explores the feasibility of nearly dry Monel alloy WEDM using air and deionized water in nebulous or mist form to achieve the optimal surface finish and resolve environmental issues associated with wet WEDM. This work reflects the study of the influence of various input parameters on the output calculated in terms of the rate of material removal (MRR) and surface roughness (Ra). On an inference, near-dry WEDM formed a smooth surface on Monel alloy over traditional WEDM; however, ranges of MRR still elevate their support to wet WEDM.