Search results for: material parameters

Authors: Nandhini Ravi, Muthukumaran Shanmugam

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Metals are being replaced by thermoplastic polymer composites in automotive industries because of their low density, easiness to fabricate, low cost and good wear resistance. Complex polymer components consist of assemblies of smaller parts which can be joined by friction stir welding. This study deals with the additive friction stir welding of 15 wt.% glass fiber reinforced polyamide 66 composite which is a modified technique of the conventional friction stir welding by the addition of a filler plate for the heating of the composite work piece through the tool during the welding process. Welding at different combinations of tool rotational speed, travel speed and tool plunge depth was done after which the tensile strength of the respective experiments was determined. The maximum tensile strength obtained was 77 MPa which was 80% of the strength of the base material. The process parameters were optimized using the L9 orthogonal array and also the effect of individual welding parameter on the tensile strength was studied. The optimum parameter combination was determined with the help of ANOVA studies. The hardness of the welded joints was studied with the help of Shore Durometer which yielded the maximum of D 75.

Keywords: additive friction stir welding, polyamide 66, process parameters, thermoplastic polymer composite

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Authors: Misganaw Abebe Baye, Ji-Woo Park, Beom-Soo Kang

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The product quality of multi-point dieless forming (MDF) is identified to be dependent on the process parameters. Moreover, a certain variation of friction and material properties may have a substantially worse influence on the final product quality. This study proposed on how to compensate the MDF product defects by minimizing the sensitivity of noise parameter variations. This can be attained by reliability-based robust optimization (RRO) technique to obtain the optimal process setting of the controllable parameters. Initially two MDF Finite Element (FE) simulations of AA3003-H14 saddle shape showed a substantial amount of dimpling, wrinkling, and shape error. FE analyses are consequently applied on ABAQUS commercial software to obtain the correlation between the control process setting and noise variation with regard to the product defects. The best prediction models are chosen from the family of metamodels to swap the computational expensive FE simulation. Genetic algorithm (GA) is applied to determine the optimal process settings of the control parameters. Monte Carlo Analysis (MCA) is executed to determine how the noise parameter variation affects the final product quality. Finally, the RRO FE simulation and the experimental result show that the amendment of the control parameters in the final forming process leads to a considerably better-quality product.

Keywords: dimpling, multi-point dieless forming, reliability-based robust optimization, shape error, variation, wrinkling

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Authors: Eyob Messele Sefene, Atinkut Atinafu Yilma

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The highest strength-to-weight ratio criterion has fascinated increasing curiosity in virtually all areas where weight reduction is indispensable. One of the recent advances in manufacturing to achieve this intention endears friction stir welding (FSW). The process is widely used for joining similar and dissimilar non-ferrous materials. In FSW, the mechanical properties of the weld joints are impelled by property-selected process parameters. This paper presents verdicts of optimum process parameters in attempting to attain enhanced mechanical properties of the weld joint. The experiment was conducted on a 5 mm 6061 aluminum alloy sheet. A butt joint configuration was employed. Process parameters, rotational speed, traverse speed or feed rate, axial force, dwell time, tool material and tool profiles were utilized. Process parameters were also optimized, making use of a mixed L18 orthogonal array and the Grey relation analysis method with larger is better quality characteristics. The mechanical properties of the weld joint are examined through the tensile test, hardness test and liquid penetrant test at ambient temperature. ANOVA was conducted in order to investigate the significant process parameters. This research shows that dwell time, rotational speed, tool shape, and traverse speed have become significant, with a joint efficiency of about 82.58%. Nine confirmatory tests are conducted, and the results indicate that the average values of the grey relational grade fall within the 99% confidence interval. Hence the experiment is proven reliable.

Keywords: friction stir welding, optimization, 6061 AA, Taguchi

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Authors: Md. Z. Alam, Devi R. Asih, Md. N. Salleh

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Immobilization of lipase enzyme produced from palm oil mill effluent (POME) by the activated carbon (AC) among the low cost support materials was optimized. The results indicated that immobilization of 94% was achieved by AC as the most suitable support material. A sequential optimization strategy based on a statistical experimental design, including one-factor-at-a-time (OFAT) method was used to determine the equilibrium time. Three components influencing lipase immobilization were optimized by the response surface methodology (RSM) based on the face-centered central composite design (FCCCD). On the statistical analysis of the results, the optimum enzyme concentration loading, agitation rate and carbon active dosage were found to be 30 U/ml, 300 rpm and 8 g/L respectively, with a maximum immobilization activity of 3732.9 U/g-AC after 2 hrs of immobilization. Analysis of variance (ANOVA) showed a high regression coefficient (R2) of 0.999, which indicated a satisfactory fit of the model with the experimental data. The parameters were statistically significant at p<0.05.

Keywords: activated carbon, POME based lipase, immobilization, adsorption

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Authors: A. Fettahoglu

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Theory of viscoelasticity is used by many researchers to represent the behavior of many materials such as pavements on roads or bridges. Several researches used analytical methods and rheology to predict the material behaviors of simple models. Today, more complex engineering structures are analyzed using Finite Element Method, in which material behavior is embedded by means of three dimensional viscoelastic material laws. As a result, structures of unordinary geometry and domain can be analyzed by means of Finite Element Method and three dimensional viscoelastic equations. In the scope of this study, rheological models embedded in ANSYS, namely, generalized Maxwell model and Prony series, which are two methods used by ANSYS to represent viscoelastic material behavior, are presented explicitly. Afterwards, a guide is illustrated to ease using of viscoelasticity tool in ANSYS.

Keywords: ANSYS, generalized Maxwell model, finite element method, Prony series, viscoelasticity, viscoelastic material curve fitting

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Authors: Veronika Přivřelová

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Well-designed composite steel and concrete structures highlight the good material properties and lower the deficiencies of steel and concrete, in particular they make use of high tensile strength of steel and high stiffness of concrete. The most common composite steel and concrete structure is a simply supported beam, which concrete slab transferring the slab load to a beam is connected to the steel cross-section. The aim of this paper is to find the most adequate numerical model of a simply supported composite beam with the cross-sectional and material parameters based on the results of a processed parametric study and numerical analysis. The paper also evaluates the suitability of using compact concrete with the lightweight aggregates for composite steel and concrete beams. The most adequate numerical model will be used in the resent future to compare the results of laboratory tests.

Keywords: composite beams, high-performance concrete, high-strength steel, lightweight concrete slab, modeling

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Authors: Kuen Ming Shu, Ren Kai Ho

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Ultrasonic horn has the functions of amplifying amplitude and reducing resonant impedance in ultrasonic system. Its primary function is to amplify deformation or velocity during vibration and focus ultrasonic energy on the small area. It is a crucial component in design of ultrasonic vibration system. There are five common design methods for ultrasonic horns: analytical method, equivalent circuit method, equal mechanical impedance, transfer matrix method, finite element method. In addition, the general optimization design process is to change the geometric parameters to improve a single performance. Therefore, in the general optimization design process, we couldn't find the relation of parameter and objective. However, a good optimization design must be able to establish the relationship between input parameters and output parameters so that the designer can choose between parameters according to different performance objectives and obtain the results of the optimization design. In this study, an ultrasonic horn provided by Maxwide Ultrasonic co., Ltd. was used as the contrast of optimized ultrasonic horn. The ANSYS finite element analysis (FEA) software was used to simulate the distribution of the horn amplitudes and the natural frequency value. The results showed that the frequency for the simulation values and actual measurement values were similar, verifying the accuracy of the simulation values. The ANSYS DesignXplorer was used to perform Response Surface optimization, which could shows the relation of parameter and objective. Therefore, this method can be used to substitute the traditional experience method or the trial-and-error method for design to reduce material costs and design cycles.

Keywords: horn, natural frequency, response surface optimization, ultrasonic vibration

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Authors: D. S. Vardar, A. S. Kipcak, F. T. Senberber, E. M. Derun, S. Piskin, N. Tugrul

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Zinc borate is an important inorganic hydrate borate material, which can be use as a flame retardant agent and corrosion resistance material. This compound can loss its structural water content at higher than 290°C. Due to thermal stability; Zinc Borate can be used as flame reterdant at high temperature process of plastic and gum. In this study, the ultrasonic reaction of zinc borates were studied using hydrozincite (Zn5(CO3)2•(OH)6) and boric acid (H3BO3) raw materials. Before the synthesis raw materials were characterized by X-Ray Diffraction (XRD) and Fourier Transform Infrared Spectroscopy (FT-IR). Ultrasonic method is a new application on the zinc borate synthesis. The synthesis parameters were set to 90°C reaction temperature and 55 minutes of reaction time, with 1:1, 1:2, 1:3, 1:4 and 1:5 molar ratio of starting materials (Zn5(CO3)2•(OH)6 : H3BO3). After the zinc borate synthesis, the products analyzed by XRD and FT-IR. As a result, optimum molar ratio of 1:5 (Zn5(CO3)2•(OH)6:H3BO3) is determined for the synthesis of zinc borates with ultrasonic method.

Keywords: borate, ultrasonic method, zinc borate, zinc borate synthesis

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Authors: Iuliia Riabenko, Konstantin Beloshenko, Sergey Shulga, Valeriy Shulga

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An optical system has been developed consisting of a TIR lens and an aspherical surface designed to collect Stokes radiation from biomolecules. The freeform material is SYLGARD-184, which provides a low level of noise associated with the luminescence of the substrate. The refractive index of SYLGARD-184 is 1.4028 for a wavelength of 632 nm, the Abbe number is 72, these material parameters make it possible to design the desired shape for the wavelength range of 640-700 nm. The system consists of a TIR lens, inside which is placed a high-quality resonant system consisting of a biomolecule and a metal colloid. This system can be described using the coupled oscillator model. The laser excitation radiation was fed through the base of the TIR lens. The sample was mounted inside the TIR lens at a distance of 8 mm from the base. As a result of Raman scattering of laser radiation, a Stokes bend appeared from the biolayer. The task of this work was that it was necessary to collect this radiation emitted at a 4π steradian angle. For this, an internal aspherical surface was used, which made it possible to defocus the beam emanating from the biolayer and direct its radiation to the borders of the TIR lens at the Brewster angle. The collated beam of Stokes radiation contains 97% of the energy scattered by the biolayer. Thus, a simple scheme was proposed for collecting and collimating the Stokes radiation of biomolecules.

Keywords: TIR lens, freeform material, raman scattering, biolayer, brewster angle

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Authors: X. Li, Y. Liu, H. Wong, B. Pardoen, A. Fabbri, F. McGregor, E. Liu

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The target of this paper is to investigate how saturated poroelastic soils subject to freezing temperatures behave and how different boundary conditions can intervene and affect the thermo-hydro-mechanical (THM) responses, based on a particular but classical configuration of a finite homogeneous soil layer studied by Terzaghi. The essential relations on the constitutive behavior of a freezing soil are firstly recalled: ice crystal - liquid water thermodynamic equilibrium, hydromechanical constitutive equations, momentum balance, water mass balance, and the thermal diffusion equation, in general, non-linear case where material parameters are state-dependent. The system of equations is firstly linearized, assuming all material parameters to be constants, particularly the permeability of liquid water, which should depend on the ice content. Two analytical solutions solved by the classic Laplace transform are then developed, accounting for two different sets of boundary conditions. Afterward, the general non-linear equations with state-dependent parameters are solved using a commercial code COMSOL based on finite elements method to obtain numerical results. The validity of this numerical modeling is partially verified using the analytical solution in the limiting case of state-independent parameters. Comparison between the results given by the linearized analytical solutions and the non-linear numerical model reveals that the above-mentioned linear computation will always underestimate the liquid pore pressure and displacement, whatever the hydraulic boundary conditions are. In the nonlinear model, the faster growth of ice crystals, accompanying the subsequent reduction of permeability of freezing soil layer, makes a longer duration for the depressurization of water liquid and slower settlement in the case where the ground surface is swiftly covered by a thin layer of ice, as well as a bigger global liquid pressure and swelling in the case of the impermeable ground surface. Nonetheless, the analytical solutions based on linearized equations give a correct order-of-magnitude estimate, especially at moderate temperature variations, and remain a useful tool for preliminary design checks.

Keywords: chemical potential, cryosuction, Laplace transform, multiphysics coupling, phase transformation, thermodynamic equilibrium

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Authors: Maciej Szeląg, Stanisław Fic

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The impact of elevated temperatures on the construction materials manifests in change of their physical and mechanical characteristics. Stresses and thermal deformations that occur inside the volume of the material cause its progressive degradation as temperature increase. Finally, the reactions and transformations of multiphase structure of cementitious composite cause its complete destruction. A particularly dangerous phenomenon is the impact of thermal shock – a sudden high temperature load. The thermal shock leads to a high value of the temperature gradient between the outer surface and the interior of the element in a relatively short time. The result of mentioned above process is the formation of the cracks and scratches on the material’s surface and inside the material. The article describes the use of computer image analysis techniques to identify and assess the structure of the cluster cracks on the surfaces of modified cement pastes, caused by thermal shock. Four series of specimens were tested. Two Portland cements were used (CEM I 42.5R and CEM I 52,5R). In addition, two of the series contained metakaolinite as a replacement for 10% of the cement content. Samples in each series were made in combination of three w/b (water/binder) indicators of respectively 0.4; 0.5; 0.6. Surface cracks of the samples were created by a sudden temperature load at 200°C for 4 hours. Images of the cracked surfaces were obtained via scanning at 1200 DPI; digital processing and measurements were performed using ImageJ v. 1.46r software. In order to examine the cracked surface of the cement paste as a system of closed clusters – the dispersal systems theory was used to describe the structure of cement paste. Water is used as the dispersing phase, and the binder is used as the dispersed phase – which is the initial stage of cement paste structure creation. A cluster itself is considered to be the area on the specimen surface that is limited by cracks (created by sudden temperature loading) or by the edge of the sample. To describe the structure of cracks two stereological parameters were proposed: A ̅ – the cluster average area, L ̅ – the cluster average perimeter. The goal of this study was to compare the investigated stereological parameters with the mechanical properties of the tested specimens. Compressive and tensile strength testes were carried out according to EN standards. The method used in the study allowed the quantitative determination of defects occurring in the examined modified cement pastes surfaces. Based on the results, it was found that the nature of the cracks depends mainly on the physical parameters of the cement and the intermolecular interactions on the dispersal environment. Additionally, it was noted that the A ̅/L ̅ relation of created clusters can be described as one function for all tested samples. This fact testifies about the constant geometry of the thermal cracks regardless of the presence of metakaolinite, the type of cement and the w/b ratio.

Keywords: cement paste, cluster cracks, elevated temperature, image analysis, metakaolinite, stereological parameters

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Authors: Girts Bumanis, Diana Bajare

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With demand for primary energy continuously growing, search for renewable and efficient energy sources has been high on agenda of our society. One of the most promising energy sources is biogas technology. Residues coming from dairy industry and milk processing could be used in biogas production; however, low efficiency and high cost impede wide application of such technology. One of the main problems is management and conversion of organic residues through the anaerobic digestion process which is characterized by acidic environment due to the low whey pH (<6) whereas additional pH control system is required. Low buffering capacity of whey is responsible for the rapid acidification in biological treatments; therefore alkali activated material is a promising solution of this problem. Alkali activated material is formed using SiO2 and Al2O3 rich materials under highly alkaline solution. After material structure forming process is completed, free alkalis remain in the structure of materials which are available for leaching and could provide buffer capacity potential. In this research porous alkali activated material was investigated. Highly porous material structure ensures gradual leaching of alkalis during time which is important in biogas digestion process. Research of mixture composition and SiO2/Na2O and SiO2/Al2O ratio was studied to test the buffer capacity potential of alkali activated material. This research has proved that by changing molar ratio of components it is possible to obtain a material with different buffer capacity, and this novel material was seen to have considerable potential for using it in processes where buffer capacity and pH control is vitally important.

Keywords: alkaline material, buffer capacity, biogas production, bioreactors

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Authors: Michal Urzynicok, Krzysztof Kwiecinski

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The development of materials used in the power generation industry for the production of boilers and their parts is characterized by high steam parameters, which present new challenges. Implementation of new combinations of alloying elements that lead to the best possible mechanical properties, including creep resistance, greatly affects new steels' weldability. All new grades have to undergo many different examinations, in regards to bending and welding, in order to enable the development of fabrication technologies, ensuring failure-free production and assembly of boiler components. 12% Cr martensitic steels like THOR™ 115 or VM-12 SHC are characterized by high oxidation resistance in high-temperature environments. At the moment, VM-12 SHC can be found in many boilers where both headers and superheater coils were produced. As this material is very difficult to obtain, a search for a proper replacement has begun. A new creep strength-enhanced ferritic steel for service in supercritical and ultra-supercritical boiler applications was developed by Tenaris in Italy and it is designated as Thor™115 (Tenaris High Oxidation Resistance). As high demand in power plants occurred to replace some parts of existing installations fabricated from VM12-SHC with other alternatives, a new development of welding procedures has begun to prepare fabricators for the challenges of joining old components with new THOR™ 115 material. This paper covers the first research of welding of dissimilar joints made out of VM12-SHC and THOR™ 115.

Keywords: thor, vm12, dissimilar welding, weldability

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Authors: D. B. Gohil

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Closed die forging is a very complex process, and measurement of actual forces for real material is difficult and time consuming. Hence, the modelling technique has taken the advantage of carrying out the experimentation with the proper model material which needs lesser forces and relatively low temperature. The results of experiments on the model material then may be correlated with the actual material by using the theory of similarity. There are several methods available to resolve the complexity involved in the closed die forging process. Finite Element Method (FEM) and Finite Difference Method (FDM) are relatively difficult as compared to the slab method. The slab method is very popular and very widely used by the people working on shop floor because it is relatively easy to apply and reasonably accurate for most of the common forging load requirement computations.

Keywords: experimentation, forging, process modeling, strain distribution

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Authors: W. Swiderski

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Composite materials are one answer to the growing demand for materials with better parameters of construction and exploitation. Composite materials also permit conscious shaping of desirable properties to increase the extent of reach in the case of metals, ceramics or polymers. In recent years, composite materials have been used widely in aerospace, energy, transportation, medicine, etc. Fiber-reinforced composites including carbon fiber, glass fiber and aramid fiber have become a major structural material. The typical defect during manufacture and operation is delamination damage of layered composites. When delamination damage of the composites spreads, it may lead to a composite fracture. One of the many methods used in non-destructive testing of composites is active infrared thermography. In active thermography, it is necessary to deliver energy to the examined sample in order to obtain significant temperature differences indicating the presence of subsurface anomalies. To detect possible defects in composite materials, different methods of thermal stimulation can be applied to the tested material, these include heating lamps, lasers, eddy currents, microwaves or ultrasounds. The use of a suitable source of thermal stimulation on the test material can have a decisive influence on the detection or failure to detect defects. Samples of multilayer structure carbon composites were prepared with deliberately introduced defects for comparative purposes. Very thin defects of different sizes and shapes made of Teflon or copper having a thickness of 0.1 mm were screened. Non-destructive testing was carried out using the following sources of thermal stimulation, heating lamp, flash lamp, ultrasound and eddy currents. The results are reported in the paper.

Keywords: Non-destructive testing, IR thermography, composite material, thermal stimulation

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Authors: Assem Sallam, Aly Elzahaby, Ahmed Makled, Mohamed Khalil

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Change in design parameters of launch vehicle affects its overall flight path trajectory. In this paper, several design parameters are introduced to study their effect. Selected parameters are the launch vehicle mass, which is presented in the form of payload mass, the maximum allowable angle of attack the launch vehicle can withstand, the flight path angle that is predefined for the launch vehicle second stage, the required inclination and its effect on the launch azimuth and finally by changing the launch pad coordinate. Selected design parameters are studied for their effect on the variation of altitude, ground range, absolute velocity and the flight path angle. The study gives a general mean of adjusting the design parameters to reach the required launch vehicle performance.

Keywords: launch vehicle azimuth, launch vehicle trajectory, launch vehicle payload, launch pad location

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Authors: Yousef S. Kh. S. Hashem

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Accurate estimation of initial gas in place (IGIP) plays an important factor in the decision to develop a gas field. One of the methods that are available in the industry to estimate the IGIP is material balance. This method required that the well has to be shut-in while pressure is measured as it builds to average reservoir pressure. Since gas demand is high and shut-in well surveys are very expensive, flowing gas material balance (FGMB) is sometimes used instead of material balance. This work investigated the effect of reservoir properties (pressure, permeability, and reservoir size) on the estimation of IGIP when using FGMB. A gas reservoir simulator that accounts for friction loss, wellbore storage, and the non-Darcy effect was used to simulate 165 different possible causes (3 pressures, 5 reservoir sizes, and 11 permeabilities). Both tubing pressure and bottom-hole pressure were analyzed using FGMB. The results showed that the FGMB method is very sensitive for tied reservoirs (k < 10). Also, it showed which method is best to be used for different reservoir properties. This study can be used as a guideline for the application of the FGMB method.

Keywords: flowing material balance, gas reservoir, reserves, gas simulator

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Authors: Yusuf Nugroho Doyo Yekti, Budi Praptono, Fransiskus Tatas Dwi Atmaji

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There is no ergonomic prototype testing method for manual material handling yet. This study has been carried out to demonstrate the comprehensive ergonomic assessment. The ergonomic assessment is important to improve safety of products and to ensure usefulness of the product. The prototype testing is conducted by involving few intended users and ordinary people. In this study, there are four operators who participated in several tests. Also, there are 30 ordinary people who joined the usability test. All the ordinary people never do material handling activity nor use material handling device. The methods used in the tests are Rapid Entire Body Assessment (REBA), Recommended Weight Limit (RWL), and Cardiovascular Load (%CVL) other than usability test and questionnaire. The proposed testing methods cover comprehensive ergonomic aspects, i.e. physical aspect, mental aspect, emotional aspects of human.

Keywords: ergonomic, manual material handling, prototype testing, assessment

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Authors: Kittipong Tripetch

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This paper proposes for the first time symbolic formula of the power spectrum of cross couple oscillator and its modified circuit. Many principle existed to derived power spectrum in microwave textbook such as impedance, admittance parameters, ABCD, H parameters, etc. It can be compared by graph of power spectrum which methodology is the best from the point of view of practical measurement setup such as condition of impedance parameter which used superposition of current to derived (its current injection of the other port of the circuit is zero, which is impossible in reality). Four Graphs of impedance parameters of cross couple oscillator is proposed. After that four graphs of Scattering parameters of cross couple oscillator will be shown.

Keywords: optimization, power spectrum, impedance parameters, scattering parameter

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Authors: Mustafa Kemal Bilici, Memduh Kurtulmuş, İlyas Kartal, Ahmet İrfan Yükler

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Friction stir welding is a solid-state joining process that has gained acceptable progress in recent years. This method which was first used for welding of aluminum and its alloys is now employed for welding of other materials such as polymers and composites. The aim of the present work is to investigate the mechanical properties of butt joints produced by friction stir welding (FSW) in high density polyethylene sheets of 4 mm thickness. The effects of critical welding parameters and tool design have affected on mechanical properties, weld surface and macrostructure of friction stir welded polyethylene. Experiments were performed at tool rotational speeds of 600, 900, 1200 and 1500 r/min and traverse speeds of 30, 45 and 60 mm/min, tool diameters (d) of 4, 5, 6 mm and tool shoulder diameters (D) 20, 25, 30 mm. A strength value of 80 % of the base material was achieved at the isolated optimum welding condition. According to the tool design, the welding parameters and the mechanical properties changed to a great extent. The highest tensile strength was achieved at low feed rates, high tool rotation speeds and shoulder diameters/pin diameters ratio.

Keywords: friction stir welding, mechanical properties, polyethylene, high density polyethylene, tool design

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Authors: Zhou BingHai, Fradet Victor

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Lean philosophy follows the simple principle of “creating more value with fewer resources”. In accordance with this policy, material handling can be managed by the mean of Kanban which by triggering every feeding tour only when needed regulates the flow of material in one of the most efficient way. This paper focuses on Kanban Supermarket’s parameters and their optimization on a purely cost-based point of view. Number and size of forklifts, as well as size of the containers they carry, will be variables of the cost function which includes handling costs, inventory costs but also shortage costs. With an innovative computational approach encoded into industrial engineering software Tecnomatix and reproducing real-life conditions, a fictive assembly line is established and produces a random list of orders. Multi-scenarios are then run to study the impact of each change of parameter and the variation of costs it implies. Lastly, best-case scenarios financially speaking are selected.

Keywords: Kanban, supermarket, parts-feeding policies, multi-scenario simulation, assembly line

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Authors: Pankaj Chandna, Dinesh Kumar

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The present work analyses different parameters of end milling to minimize the surface roughness for AISI D2 steel. D2 Steel is generally used for stamping or forming dies, punches, forming rolls, knives, slitters, shear blades, tools, scrap choppers, tyre shredders etc. Surface roughness is one of the main indices that determines the quality of machined products and is influenced by various cutting parameters. In machining operations, achieving desired surface quality by optimization of machining parameters, is a challenging job. In case of mating components the surface roughness become more essential and is influenced by the cutting parameters, because, these quality structures are highly correlated and are expected to be influenced directly or indirectly by the direct effect of process parameters or their interactive effects (i.e. on process environment). In this work, the effects of selected process parameters on surface roughness and subsequent setting of parameters with the levels have been accomplished by Taguchi’s parameter design approach. The experiments have been performed as per the combination of levels of different process parameters suggested by L9 orthogonal array. Experimental investigation of the end milling of AISI D2 steel with carbide tool by varying feed, speed and depth of cut and the surface roughness has been measured using surface roughness tester. Analyses of variance have been performed for mean and signal-to-noise ratio to estimate the contribution of the different process parameters on the process.

Keywords: D2 steel, orthogonal array, optimization, surface roughness, Taguchi methodology

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Authors: Sanja Manchevska, Vaska Antevska, Lidija Todorovska, Beti Dejanova, Sunchica Petrovska, Ivanka Karagjozova, Elizabeta Sivevska, Jasmina Pluncevic Gligoroska

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Introduction: A number of positive effects on the player’s physical status, including the body mass components are attributed to training process. As young soccer players grow up qualitative and quantitative changes appear and contribute to better performance. Player’s anthropometric and physiologic characteristics are recognized as important determinants of performance. Material: A sample of 52 soccer players with an age span from 9 to 14 years were divided in two groups differentiated by age. The younger group consisted of 25 boys under 11 years (mean age 10.2) and second group consisted of 27 boys with mean age 12.64. Method: The set of basic anthropometric parameters was analyzed: height, weight, BMI (Body Mass Index) and body mass components. Maximal oxygen uptake was tested using the treadmill protocol by Brus. Results: The group aged under 11 years showed the following anthropometric and physiological features: average height= 143.39cm, average weight= 44.27 kg; BMI= 18.77; Err = 5.04; Hb= 13.78 g/l; VO2=37.72 mlO2/kg. Average values of analyzed parameters were as follows: height was 163.7 cm; weight= 56.3 kg; BMI = 19.6; VO2= 39.52 ml/kg; Err=5.01; Hb=14.3g/l for the participants aged 12 to14 years. Conclusion: Physiological parameters (maximal oxygen uptake, erythrocytes and Hb) were insignificantly higher in the older group compared to the younger group. There were no statistically significant differences between analyzed anthropometric parameters among the two groups except for the basic measurements (height and weight).

Keywords: body composition, young soccer players, BMI, physical status

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Authors: Bijit Kalita, R. Jayaganthan

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Additive manufacturing (AM) is a novel manufacturing method which provides more freedom in design, manufacturing near-net-shaped parts as per demand, lower cost of production, and expedition in delivery time to market. Among various metals, AM techniques, Laser Powder Bed Fusion (L-PBF) is the most prominent one that provides higher accuracy and powder proficiency in comparison to other methods. Particularly, 17-4 PH alloy is martensitic precipitation hardened (PH) stainless steel characterized by resistance to corrosion up to 300°C and tailorable strengthening by copper precipitates. Additively manufactured 17-4 PH stainless steel exhibited a dendritic/cellular solidification microstructure in the as-built condition. It is widely used as a structural material in marine environments, power plants, aerospace, and chemical industries. The excellent weldability of 17-4 PH stainless steel and its ability to be heat treated to improve mechanical properties make it a good material choice for L-PBF. In this study, the microstructures of martensitic stainless steels in the as-built state, as well as the effects of process parameters, building atmosphere, and heat treatments on the microstructures, are reviewed. Mechanical properties of fabricated parts are studied through micro-hardness and tensile tests. Tensile tests are carried out under different strain rates at room temperature. In addition, the effect of process parameters and heat treatment conditions on mechanical properties is critically reviewed. These studies revealed the performance of L-PBF fabricated 17–4 PH stainless-steel parts under cyclic loading, and the results indicated that fatigue properties were more sensitive to the defects generated by L-PBF (e.g., porosity, microcracks), leading to the low fracture strains and stresses under cyclic loading. Rapid melting, solidification, and re-melting of powders during the process and different combinations of processing parameters result in a complex thermal history and heterogeneous microstructure and are necessary to better control the microstructures and properties of L-PBF PH stainless steels through high-efficiency and low-cost heat treatments.

Keywords: 17–4 PH stainless steel, laser powder bed fusion, selective laser melting, microstructure, additive manufacturing

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Authors: Roman J. Jedrzejczyk, Damian K. Chlebda, Anna Dziedzicka, Rafal Wazny, Agnieszka Domka, Maciej Sitarz, Przemyslaw J. Jodlowski

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The aim of this study was to obtain antimicrobial material based on thin zirconium dioxide coatings on structured reactors doped with metal nanoparticles using the sonochemical sol-gel method. As a result, dense, uniform zirconium dioxide films were obtained on the kanthal sheets which can be used as support materials in antimicrobial converters with sophisticated shapes. The material was characterised by physicochemical methods, such as AFM, SEM, EDX, XRF, XRD, XPS and in situ Raman and DRIFT spectroscopy. In terms of antimicrobial activity, the material was tested by ATP/AMP method using model microbes isolated from the real systems. The results show that the material can be potentially used in the market as a good candidate for active package and as active bulkheads of climatic systems. The mechanical tests showed that the developed method is an efficient way to obtain durable converters with high antimicrobial activity against fungi and bacteria.

Keywords: antimicrobial properties, kanthal steel, nanocomposite, zirconium oxide

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Authors: Tania Bose, Minto Rattan, Neeraj Chamoli

Abstract:

In this paper, an attempt has been made to study the effect of thermal gradation on the steady-state creep behavior of rotating isotropic disc made of functionally graded material using threshold stress based Sherby’s creep law. The composite discs made of aluminum matrix reinforced with silicon carbide particulate have been taken for analysis. The stress and strain rate distributions have been calculated for the discs rotating at elevated temperatures having thermal gradation. The material parameters of creep vary radially and have been estimated by regression fit of the available experimental data. Investigations for discs made up of linearly increasing particle content operating under linearly decreasing temperature from inner to outer radii have been done using von Mises’ yield criterion. The results are displayed and compared graphically in designer friendly format for the above said disc profile with the disc made of particle reinforced composite operating under uniform temperature profile. It is observed that radial and tangential stresses show minor variation and the strain rates vary significantly in the presence of thermal gradation as compared to disc having uniform temperature.

Keywords: creep, isotropic, steady-state, thermal gradation

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Authors: L. Vivet, L. Benabou, O. Simon

Abstract:

With highly demanding applications in the field of power electronics, there is an increasing need to have interconnection materials with properties that can ensure both good mechanical assembly and high thermal/electrical conductivities. So far, lead-free solders have been considered an attractive solution, but recently, sintered joints based on nano-silver paste have been used for die attach and have proved to be a promising solution offering increased performances in high-temperature applications. In this work, the main parameters of the bonding process using silver oxalates are studied, i.e., the heating rate and the bonding pressure mainly. Their effects on both the mechanical and thermal properties of the sintered layer are evaluated following an experimental design. Pairs of copper substrates with gold metallization are assembled through the sintering process to realize the samples that are tested using a micro-traction machine. In addition, the obtained joints are examined through microscopy to identify the important microstructural features in relation to the measured properties. The formation of an intermetallic compound at the junction between the sintered silver layer and the gold metallization deposited on copper is also analyzed. Microscopy analysis exhibits a nanoporous structure of the sintered material. It is found that higher temperature and bonding pressure result in higher densification of the sintered material, with higher thermal conductivity of the joint but less mechanical flexibility to accommodate the thermo-mechanical stresses arising during service. The experimental design allows hence the determination of the optimal process parameters to reach sufficient thermal/mechanical properties for a given application. It is also found that the interphase formed between silver and gold metallization is the location where the fracture occurred after the mechanical testing, suggesting that the inter-diffusion mechanism between the different elements of the assembly leads to the formation of a relatively brittle compound.

Keywords: nanoporous structure, silver oxalate, sintering, mechanical strength, thermal conductivity, microelectronic packaging

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Authors: D. K. Lee, S. M. Shin, J. H. Lee

Abstract:

Topology optimization technique utilizes constant element densities as design parameters. Finally, optimal distribution contours of the material densities between voids (0) and solids (1) in design domain represent the determination of topology. It means that regions with element density values become occupied by solids in design domain, while there are only void phases in regions where no density values exist. Therefore the void regions of topology optimization results provide design information to decide appropriate depositions of web-opening in structure. Contrary to the basic objective of the topology optimization technique which is to obtain optimal topology of structures, this present study proposes a new idea that topology optimization results can be also utilized for decision of proper web-opening’s position. Numerical examples of linear elastostatic structures demonstrate efficiency of methodological design processes using topology optimization in order to determinate the proper deposition of web-openings.

Keywords: topology optimization, web-opening, structure, element density, material

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Authors: Ananta R. Adhikari

Abstract:

In today's era, polymer composite utilization has witnessed a significant increase across various fronts of material science advancement. Despite the development of many highly sophisticated technologies aimed at modifying polymer composites, there persists a quest for a technology that is straightforward, energy-efficient, easily controllable, cost-effective, time-saving, and environmentally friendly. Microwave technology has emerged as a major technique in material synthesis and modification due to its unique characteristics such as rapid, selective, uniform heating, and, particularly, direct heating based on molecular interaction. This study will be about the utilization of microwave energy as an alternative technique for material processing. Specifically, we will explore ongoing research conducted in our laboratory, focusing on its applications in the medical field.

Keywords: polymer composites, material processing, microstructure, microwave radiation

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Authors: Xu Jinsheng, Tong Xin, Zheng Jian, Zhou Changsheng

Abstract:

The NEPE (nitrate ester plasticized polyether) propellant is a kind of particle filling material with relatively high filling fraction. The experimental results show that the microcracks, microvoids and dewetting can cause the stress softening of the material. In this paper, a series of mechanical testing in inclusion with CCD technique were conducted to analyze the evolution of internal defects of propellant. The volume expansion function of the particle filling material was established by measuring of longitudinal and transverse strain with optical deformation measurement system. By analyzing the defects and internal damages of the material, a visco-hyperelastic constitutive model based on free energy theory was proposed incorporating damage function. The proposed constitutive model could accurately predict the mechanical properties of uniaxial tensile tests and tensile-relaxation tests.

Keywords: dewetting, constitutive model， uniaxial tensile tests, visco-hyperelastic, nonlinear

Procedia PDF Downloads 280