A Holistic Approach to Cooling System Selection and Injection Molding Process Optimization Based on Non-Dominated Sorting

This study applied a holistic approach to the problem of controlling the temperature of critical areas of tools using conformal cooling. The entire injection molding process is evaluated at the tool design stage using four criteria, one from each stage of the process cycle, to produce a tool with effective cooling that enables short cycle times and ensures good product quality. Tool manufacturing time and cost, as well as tool life, are considered in the optimization by introducing a novel tool-efficiency index. The multi-objective optimization is based on numerical simulations. The simulation results show that conformal cooling effectively cools the critical area of the tool and provides the shortest cycle times and the lowest warpage, but this comes with a trade-off in the tool-efficiency index. By using the tool-efficiency index with non-dominated sorting, the number of relevant simulation cases could be reduced to six, which greatly simplifies the decision regarding the choice of cooling system and process parameters. Based on the study, a tool with conformal cooling channels was made, and a coolant inlet temperature of 20 °C and a flow rate of 5 L/min for conformal and 7.5-9.5 L/min for conventional cooling channels were selected for production. The simulation results were validated by experimental measurements.

On the psychological origins of tool use

The ubiquity of tool use in human life has generated multiple lines of scientific and philosophical investigation to understand the development and expression of humans' engagement with tools and its relation to other dimensions of human experience. However, existing literature on tool use faces several epistemological challenges in which the same set of questions generate many different answers. At least four critical questions can be identified, which are intimately intertwined-(1) What constitutes tool use? (2) What psychological processes underlie tool use in humans and nonhuman animals? (3) Which of these psychological processes are exclusive to tool use? (4) Which psychological processes involved in tool use are exclusive to Homo sapiens? To help advance a multidisciplinary scientific understanding of tool use, six author groups representing different academic disciplines (e.g., anthropology, psychology, neuroscience) and different theoretical perspectives respond to each of these questions, and then point to the direction of future work on tool use. We find that while there are marked differences among the responses of the respective author groups to each question, there is a surprising degree of agreement about many essential concepts and questions. We believe that this interdisciplinary and intertheoretical discussion will foster a more comprehensive understanding of tool use than any one of these perspectives (or any one of these author groups) would (or could) on their own.

Pilot Demonstration of Hot Sheet Metal Forming Using 3D Printed Dies

Since the popularization of press hardening in the early noughties, die and tooling systems have experienced considerable advances, with tool refrigeration as an important focus. However, it is still complicated to obtain homogeneous cooling and avoid hot spot issues in complex geometries. Additive Manufacturing allows designing cavities inside the material volume with little limitation in terms of channel intersection or bore entering and exit points. In this sense, this technology is a natural fit for obtaining surface-conforming cooling channels: an attractive prospect for refrigerated tools. This work describes a pilot experience in 3D-printed press hardening tools, comparing the performance of additive manufactured Maraging steel 1.2709 to conventional wrought hot work tool steel H13 on two different metrics: durability and thermal performance. For the first, wear studies were performed in a controlled pilot plant environment after 800 hot stamping strokes in an omega tool configuration. On the second, a demonstrator tool based on a commercial tool with hot spot issues, was produced by 3D printing including surface-conformal cooling channels. This tool was then used in a pilot press hardening line, in which tool temperature was analyzed and compared to an equivalent tool produced by conventional means. Results show that the Additive Manufacturing technologies can be successfully applied to the production of press hardening dies, particularly in intricate geometries where new cooling channel design strategies offer a solution for hot spots and inhomogeneous thermal loads.

Investigating the Linear Thermal Expansion of Additively Manufactured Multi-Material Joining between Invar and Steel

This work investigated the linear thermal expansion properties of a multi-material specimen fabricated with Invar M93 and A36 steel. A sequence of tests was performed to investigate the viability of additively manufactured Invar M93 for lowering the coefficient of thermal expansion (CTE) in multi-material part tooling. Invar beads were additively manufactured on a steel base plate using a fiber laser system, and samples were taken from the steel, Invar, and the interface between the two materials. The CTE of the samples was measured between 40 °C and 150 °C using a thermomechanical analyzer, and the elemental composition was studied with energy dispersive X-ray spectroscopy. The CTE of samples taken from the steel and the interface remained comparable to that of A36 steel; however, deviations between the thermal expansion values were prevalent due to element diffusion in and around the heat-affected zone. The CTEs measured from the Invar bead were lower than those from the other sections with the largest and smallest thermal expansion values being 10.40 μm/m-K and 2.09 μm/m-K. In each of the sections, the largest CTE was measured from samples taken from the end of the weld beads. An additional test was performed to measure the aggregate expansion of multi-material tools. Invar beads were welded on an A36 steel plate. The invar was machined, and the sample was heated in an oven from 40 °C and 160 °C. Strain gauges were placed on the surface of the part and were used to analyze how the combined thermal expansions of the invar and steel would affect the thermal expansion on the surface of a tool. There were small deviations between the expansion values measured by gauges placed in different orientations, and the elongation of the sample was greatest along the dimension containing a larger percentage of steel. On average, the expansion of the machined Invar surface was 42% less than the expansion of the steel surface. The results of this work demonstrate that additively manufactured Invar can be utilized to decrease the CTE for multi-material part tooling.

Dexterity and technique in termite fishing by chimpanzees (Pan troglodytes troglodytes) in the Goualougo Triangle, Republic of Congo

Although the phenomenon of termite fishing by chimpanzees (Pan troglodytes) has historical and theoretical importance for primatology, we still have a limited understanding of how chimpanzees accomplish this activity, and in particular, about details of skilled actions and the nature of individual variation in fishing techniques. We examined movements, hand positions, grips, and other details from remote video footage of seven adult and subadult female chimpanzees using plant probes to extract Macrotermes muelleri termites from epigeal nests. Six chimpanzees used exclusively one hand (left or right) to grip the probe during termite fishing. All chimpanzees used the same repertoire of actions to insert, adjust, and withdraw the probe but differed in the frequency of use of particular actions. Chimpanzees have been described as eating termites in two ways—directly from the probe or by sweeping them from the probe with one hand. We describe a third technique: sliding the probe between the digits of one stationary hand as the probe is extracted from the nest. The sliding technique requires complementary bimanual coordination (extracting with one hand and grasping lightly with the other, at the same time). We highlight the importance of actions with two hands—one gripping, one assisting—in termite fishing and discuss how probing techniques are correlated with performance. Additional research on digital function and on environmental, organismic, and task constraints will further reveal manual dexterity in termite fishing.

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Using remote video footage from camera traps in Goualougo Triangle, Republic of Congo, we describe chimpanzees' manual actions, postures, and positions, and movements of the probe while they fished for termites in epigeal termite nests.

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Chimpanzees used diverse grips, with and without the thumb, and two hands—one gripping, one assisting—to handle the probe delicately and to move it precisely.

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We describe a new technique for recovering termites: sliding the probe between the digits of one stationary hand as the probe is extracted from the nest with the other hand, and a new action: oscillatory movements of the probe while it was inserted in the nest.

Bearded capuchin monkeys use joint synergies to stabilize the hammer trajectory while cracking nuts in bipedal stance

The transition from occasional to obligate bipedalism is a milestone in human evolution. However, because the fossil record is fragmentary and reconstructing behaviour from fossils is difficult, changes in the motor control strategies that accompanied this transition remain unknown. Quadrupedal primates that adopt a bipedal stance while using percussive tools provide a unique reference point to clarify one aspect of this transition, which is maintaining bipedal stance while handling massive objects. We found that while cracking nuts using massive stone hammers, wild bearded capuchin monkeys (Sapajus libidinosus) produce hammer trajectories with highly repeatable spatial profiles. Using an uncontrolled manifold analysis, we show that the monkeys used strong joint synergies to stabilize the hammer trajectory while lifting and lowering heavy hammers. The monkeys stringently controlled the motion of the foot. They controlled the motion of the lower arm and hand rather loosely, showing a greater variability across strikes. Overall, our findings indicate that while standing bipedally to lift and lower massive hammers, an arboreal quadrupedal primate must control motion in the joints of the lower body more stringently than motion in the joints of the upper body. Similar changes in the structure of motor variability required to accomplish this goal could have accompanied the evolutionary transition from occasional to obligate bipedalism in ancestral hominins.