Search results for: NiCr wire

Authors: Michal Duchek, Jan Palán, Tomas Kubina

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Bars made of titanium grade 2 and grade 4 were subjected to rotary forging with up to 2.2 true strain reduction in the cross-section from 10 to 3.81 mm. During progressive deformation, grain refinement in the transverse direction took place. In the longitudinal direction, ultrafine microstructure has not developed. It has been demonstrated that titanium grade 2 strengthens more than grade 4. The ultimate tensile strength increased from 650 MPa to 1040 MPa in titanium grade 4. Hardness profiles on the cross section in both materials show an increase in the centre of the wire.

Keywords: commercial-purity titanium, wire, rotary swaging, tensile test, hardness, modulus of elasticity, microstructure

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Authors: Ashkan Vatani, Petere Woodfiel, Nam-Trung Nguyen, Dzung Dao

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Thermomagnetic convection of a ferrofluid flow induced by the non-uniform magnetic field around a current-carrying wire was theoretically analyzed, numerically studied and experimentally validated. The dependency of the thermomagnetic convection on the current and fluid temperature has been studied. The Nusselt number for a heated 50um diameter wire in the ferrofluid exponentially scales with applied current to the micro-wire. This result is in good agreement with the correlated Nusselt number by curve-fitting the experimental data at different fluid temperatures. It was shown that at low currents, no significance is observed for thermomagnetic convection rather than the buoyancy-driven convection, while the thermomagnetic convection becomes dominant at high currents. Also, numerical simulations showed a promising cooling ability for large scale applications.

Keywords: ferrofluid, non-uniform magnetic field, Nusselt number, thermomagnetic convection

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Authors: Mandeep Kumar, Hari Singh

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The effective optimization of machining process parameters affects dramatically the cost and production time of machined components as well as the quality of the final products. This paper presents the optimization aspects of a Wire Electrical Discharge Machining operation using Inconel X-750 as work material. The objective considered in this study is minimization of the dimensional deviation. Six input process parameters of WEDM namely spark gap voltage, pulse-on time, pulse-off time, wire feed rate, peak current and wire tension, were chosen as variables to study the process performance. Taguchi's design of experiments methodology has been used for planning and designing the experiments. The analysis of variance was carried out for raw data as well as for signal to noise ratio. Four input parameters and one two-factor interaction have been found to be statistically significant for their effects on the response of interest. The confirmation experiments were also performed for validating the predicted results.

Keywords: ANOVA, DOE, inconel, machining, optimization

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Authors: Amitesh Goswami, Vishal Gulati, Annu Yadav

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In this paper, WEDM has been used to investigate the machining characteristics of Inconel-625 alloy. The machining characteristics namely material removal rate (MRR) and surface roughness (SR) have been investigated along with surface microstructure analysis using SEM and EDS of the machined surface. Taguchi’s L27 Orthogonal array design has been used by considering six varying input parameters viz. Pulse-on time (Ton), Pulse-off time (Toff), Spark Gap Set Voltage (SV), Peak Current (IP), Wire Feed (WF) and Wire Tension (WT) for the responses of interest. It has been found out that Pulse-on time (Ton) and Spark Gap Set Voltage (SV) are the most significant parameters affecting material removal rate (MRR) and surface roughness (SR) are. Microstructure analysis of workpiece was also done using Scanning Electron Microscope (SEM). It was observed that, variations in pulse-on time and pulse-off time causes varying discharge energy and as a result of which deep craters / micro cracks and large/ small number of debris were formed. These results were helpful in studying the effects of pulse-on time and pulse-off time on MRR and SR. Energy Dispersive Spectrometry (EDS) was also done to check the compositional analysis of the material and it was observed that Copper and Zinc which were initially not present in the Inconel 625, later migrated on the material surface from the brass wire electrode during machining

Keywords: MRR, SEM, SR, taguchi, Wire Electric Discharge Machining

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Authors: Babak Dizangian, Mohammad Reza Ghasemi, Akram Ghalandari

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Moment frames have considerable ductility against cyclic lateral loads and displacements; however, if this feature causes the relative displacement to exceed the permissible limit, it can impose unfavorable hysteretic behavior on the frame. Therefore, adding a bracing system with the capability of preserving the capacity of high energy absorption and controlling displacements without a considerable increase in the stiffness is quite important. This paper investigates the retrofitting of a single storey steel moment frame through a delayed wire-rope bracing system using a middle steel plate. In this model, the steel plate lies where the wire ropes meet, and the model geometry is such that the cables are continuously under tension so that they can take the most advantage of the inherent potential they have in tolerating tensile stress. Using the steel plate also reduces the system stiffness considerably compared to cross bracing systems and preserves the ductile frame’s energy absorption capacity. In this research, the software models of delayed wire-rope bracing system have been studied, validated, and compared with other researchers’ laboratory test results.

Keywords: cyclic loading, delayed wire rope bracing, ductile moment frame, energy absorption, hysteresis curve

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Authors: Sylwia Wiewiorowska, Zbigniew Muskalski

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The strain intensity and redundant strains, dependent in multistage TRIP wire drawing processes from values used single partial reductions, should influence on the intensity of transformation the retained austenite into martensite and thereby on mechanical properties of drawn wires. The numerical analysis of drawing processes with use of Drawing 2D programme, for steel wires made from TRIP steel with 0,29 % has been shown in the work. The change of strain intensity Ԑc and the values of redundant strain Ԑxy, has been determined for particular draws in dependence of used single partial reductions.

Keywords: steel wire, TRIP steel, drawing processes, fem modelling

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Authors: Mearg Berhe Gebregziabher

Abstract:

Wire-cut electric discharge machining (WEDM) is one of the advanced machining processes. Due to the development of the current manufacturing sector, there has been no research work done before about the optimization of the process parameters based on the availability of the workpiece of the Steel St-37 material in Ethiopia. Material Removal Rate (MRR) is considered as the experimental response of WCEDM. The main objective of this work is to investigate and optimize the process parameters on machining quality that gives high MRR during machining of Steel St-37. Throughout the investigation, Pulse on Time (TON), Pulse off Time (TOFF) and Velocities of Wire Feed (WR) are used as variable parameters at three different levels, and Wire tension, flow rate, type of dielectric fluid, type of the workpiece and wire material and dielectric flow rate are keeping as constants for each experiment. The Taguchi methodology, as per Taguchi‟ 's standard L9 (3^3) Orthogonal Array (OA), has been carried out to investigate their effects and to predict the optimal combination of process parameters over MRR. Signal to Noise ratio (S/N) and Analysis of Variance (ANOVA) were used to analyze the effect of the parameters and to identify the optimum cutting parameters on MRR. MRR was measured by using the Electronic Balance Model SI-32. The results indicated that the most significant factors for MRR are TOFF, TON and lastly WR. Taguchi analysis shows that, the optimal process parameters combination is A2B2C2, i.e., TON 6μs, TOFF 29μs and WR 2 m/min. At this level, the MRR of 0.414 gram/min has been achieved.

Keywords: ANOVA, MRR, parameter, Taguchi Methode

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Authors: Mahnaz Hosseinzadeh, Shaghayegh Rezaee Amiri

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This paper presents a methodology for serial production planning problem in wire and cable manufacturing process that addresses the problem of input-output imbalance in different consecutive stations, hoping to minimize the halt of machines in each stage. To this end, a linear Goal Programming (GP) model is developed, in which four main categories of constraints as per the number of runs per machine, machines’ sequences, acceptable inventories of machines at the end of each period, and the necessity of fulfillment of the customers’ orders are considered. The model is formulated based upon on the real data obtained from IKO TAK Company, an important supplier of wire and cable for oil and gas and automotive industries in Iran. By solving the model in GAMS software the optimal number of runs, end-of-period inventories, and the possible minimum idle time for each machine are calculated. The application of the numerical results in the target company has shown the efficiency of the proposed model and the solution in decreasing the lead time of the end product delivery to the customers by 20%. Accordingly, the developed model could be easily applied in wire and cable companies for the aim of optimal production planning to reduce the halt of machines in manufacturing stages.

Keywords: goal programming approach, GP, production planning, serial manufacturing process, wire and cable industry

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Authors: N. Q. Bau, N. V. Nghia

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The acoustomagnetoelectric (AME) field in a rectangular quantum wire with an infinite potential (RQWIP) is calculated in the presence of an external magnetic field (EMF) by using the quantum kinetic equation for the distribution function of electrons system interacting with external phonons and electrons scattering with internal acoustic phonon in a RQWIP. We obtained ananalytic expression for the AME field in the RQWIP in the presence of the EMF. The dependence of AME field on the frequency of external acoustic wave, the temperature T of system, the cyclotron frequency of the EMF and the intensity of the EMF is obtained. Theoretical results for the AME field are numerically evaluated, plotted and discussed for a specific RQWIP GaAs/GaAsAl. This result has shown that the dependence of the AME field on intensity of the EMF is nonlinearly and it is many distinct maxima in the quantized magnetic region. We also compared received fields with those for normal bulk semiconductors, quantum well and quantum wire to show the difference. The influence of an EMF on AME field in a RQWIP is newly developed.

Keywords: rectangular quantum wire, acoustomagnetoelectric field, electron-phonon interaction, kinetic equation method

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Authors: Khaja Moiduddin, Tamer Khalaf, Muthuramalingam Thangaraj

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Due to the variety of benefits over traditional cutting techniques, the usage of laser cutting technology has risen substantially in recent years. Hot wire machining can cut the leather in the required shape by controlling the wire by generating thermal energy. In the present study, an attempt has been made to investigate the effects of performance measures in the hot wire machining process on cutting leather specimens. Carbonization and material removal rates were considered as quality indicators. Burning leather during machining might cause carbon particles, reducing product quality. Minimizing the effect of carbon particles is crucial for assuring operator and environmental safety, health, and product quality. Hot wire machining can efficiently cut the specimens by controlling the current through it. Taguchi- DEAR-based optimization was also performed in the process, which resulted in a required Carbonization and material removal rate. Using the DEAR approach, the optimal parameters of the present study were found with 3.7% prediction error accuracy.

Keywords: cabronization, leather, MRR, current

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Authors: Muhammad Sohail Khan, Rehan Ali Shah

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The present paper applies the optimal homotopy perturbation method (OHPM) and the optimal homotopy asymptotic method (OHAM) introduced recently to obtain analytic approximations of the non-linear equations modeling the flow of polymer in case of wire coating of a corotational Maxwell fluid. Expression for the velocity field is obtained in non-dimensional form. Comparison of the results obtained by the two methods at different values of non-dimensional parameter l₁₀, reveal that the OHPM is more effective and easy to use. The OHPM solution can be improved even working in the same order of approximation depends on the choices of the auxiliary functions.

Keywords: corotational Maxwell model, optimal homotopy asymptotic method, optimal homotopy perturbation method, wire coating die

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Authors: Suwimon Saneewong Na Ayuttaya, Chainarong Chaktranond, Phadungsak Rattanadecho

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This study numerically investigates the effects of Electrohydrodynamic on flow patterns and heat transfer enhancement within a cavity which is on the lower wall of channel. In this simulation, effects of using ground wire and ground plate on the flow patterns are compared. Moreover, the positions of electrode wire respecting with ground are tested in the range of angles θ = 0 - 180°. High electrical voltage exposes to air is 20 kV. Bulk mean velocity and temperature of inlet air are controlled at 0.1 m/s and 60°C, respectively. The result shows when electric field is applied, swirling flow is appeared in the channel. In addition, swirling flow patterns in the main flow of using ground plate are widely spreader than that of using ground wire. Moreover, direction of swirling flow also affects the flow pattern and heat transfer in a cavity. These cause the using ground wire to give the maximum temperature and heat transfer higher than using ground plate. Furthermore, when the angle is at θ = 60°, high shear flow effect is obtained. This results show high strength of swirling flow and effective heat transfer enhancement.

Keywords: swirling flow, heat transfer, electrohydrodynamic, numerical analysis

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Authors: Walid Ibrahim, Abdul Kasem, Sudeendra Doddi, Ilaria Giono, Tareq Sabagh, Muhammad Ammar, Nermin Osman

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Background: wire-guided localization (WL) is the most widely used method for the localization of non-palpable breast lesions. SAVI SCOUT occult lesion localization (SSL) is a new technique in breast-conservative surgery. SSL has the potential benefit of improving radiology workflow as well as accurate localization. Purpose: The purpose of this study is to compare the breast tissue specimen volume and weight and margin excision between WL and SSL. Materials and methods: A single institution retrospective analysis of 377 female patients who underwent wide local breast excision with SAVI SCOUT and or wire-guided technique between 2018 and 2021 in a UK University teaching hospital. Breast department. Breast tissue specimen volume and weight, and margin excision have been evaluated in the three groups of different localization. Results: Three hundred and seventy-seven patients were studied. Of these, 261 had wire localization, 88 had SCOUT and 28 had dual localization techniques. Tumor size ranged from 1 to 75mm (Median 20mm). The pathology specimen weight ranged from 1 to 466gm (Median 46.8) and the volume ranged from 1.305 to 1560cm³ (Median 106.32 cm³). SCOUT localization was associated with a significantly low specimen weight than wire or the dual technique localization (Median 41gm vs 47.3gm and 47gm, p = 0.029). SCOUT was not associated with better specimen volume with a borderline significance in comparison to wire and combined techniques (Median 108cm³ vs 105cm³ and 105cm³, p = 0.047). There was a significant correlation between tumor size and pathology specimen weight in the three groups. SCOUT showed a better >2mm safety margin in comparison to the other 2 techniques (p = 0.031). Conclusion: Preoperative SCOUT localization is associated with better specimen weight and better specimen margin. SCOUT did not show any benefits in terms of specimen volume which may be due to difficulty in getting the accurate specimen volume due to the irregularity of the soft tissue specimen.

Keywords: scout, wire, localization, breast

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Authors: Dmitry V. Fomichev, Vladimir I. Solonin

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In this paper, experimental and numerical study of hydrodynamic characteristics of the air coolant flow in the test wire-wrapped assembly is presented. The test assembly has 37 rods, which are similar to the real fuel pins of the BREST-OD-300 fuel assemblies geometrically. Air open loop test facility installed at the “Nuclear Power Plants and Installations” department of BMSTU was used to obtain the experimental data. The obtaining altitudinal distribution of static pressure in the near-wall test assembly as well as velocity and temperature distribution of coolant flow in the test sections can give us some new knowledge about the mechanism of formation of the turbulence flow structure in the wire wrapped fuel assemblies. Numerical simulations of the turbulence flow has been accomplished using ANSYS Fluent 14.5. Different non-local turbulence models have been considered, such as standard and RNG k-e models and k-w SST model. Results of numerical simulations of the flow based on the considered turbulence models give the best agreement with the experimental data and help us to carry out strong analysis of flow characteristics.

Keywords: wire-spaces fuel assembly, turbulent flow structure, computation fluid dynamics

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Authors: Srishti Bhatt, Vaibhav Bhavsar, Adil Hussain, Aashay Mhaske, S. C. Bali, T. S. Srikanth

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Shape Memory Alloys (SMA) are widely known for their unique shape recovery properties. SMA based actuation systems have high-force to weight ratio, light weight and also bio-compatible material. Which is why they are being used in different fields of aerospace, robotics, automotive and biomedical industries. However, in the automotive industry plenty of patents are available but commercially viable products are very few in market. This could be due to SMA material limitations like small stroke, direct dependability of lifecycle on stroke, pull load of the wire and high cycle time. In automotive sector, SMA being considered as an actuator which is required to have high stroke and constraint arises to accommodate a long length of wire (to compensate maximum 4 % strain as per better fatigue life cycle) not only increases complexity but also adds on the cost. More than 200 different types of actuators are used in an automobile, few of them whose efficiency can highly increase by replacing them with SMA based actuators which include latch lock mechanism, glove box, Head lamp leveling, side mirror and rear mirror leveling, tailgate opener and fuel lid cap actuator. To overcome the limitation of available space for required stroke of an actuator which leads to study the effect of different loading positions on SMA wires, different orientations of SMA wire by using pulleys and lever based systems to achieve maximum stroke. This investigation summarizes the loading under the V shape orientation the required stroke and carrying load capacity in more compact in comparison with straight orientation of wire. Similarly, the U shape orientation its showing higher load carrying capacity but reduced stroke which is aligned with concept of bundled wire method. Life-cycle of these orientations were also evaluated.

Keywords: actuators, automotive, nitinol, shape memory alloy, SMA wire orientations

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Authors: Ali Kargar, Kamyar Mansour

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In this paper, experimental results of using hot wire anemometer and smoke visualization are presented. The results obtained on the hot wire anemometer for critical Reynolds number and transitional Reynolds number are compared by previous results. Excellent agreement is found for the transitional Reynolds number. The results for the transitional Reynolds number are also compared by previous linear stability results. The results of the smoke visualization clearly show the cross flow vortices which arise in the transition process from a laminar to a turbulent flow. A non-zero angle of attack is also considered. We compare our results by linear stability theory which was done by Garret et. Al (2007). We just emphasis, Also the visualization and hot wire anemometer results have been compared graphically. The goal in this paper is to check reliability of using hot wire anemometer and smoke visualization in transition problems and check reliability of linear stability theory for this case and compare our results with some trusty experimental works.

Keywords: transitional reynolds number, wind tunnel, rotating cone, smoke visualization

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Authors: Hamed Belloumi, Aymen Ammouri, Ferid Kourda

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A new trend in power converters is to design planar transformer that aim for low profile. However, at high frequency, the planar transformer ac losses become significant due to the proximity and skin effects. In this paper, the design and implementation of a novel planar litz conductor is presented in order to equalize the flux linkage and improving the current distribution. The developed PCB litz wire structure minimizes the losses in a similar way to the conventional multi stranded litz wires. In order to further illustrate the eddy current effect in different arrangements, a finite-element analysis (FEA) tool is used to analyze current distribution inside the conductors. Finally, the proposed planar transformer has been integrated in an electronic stage to test at high signal levels.

Keywords: planar transformer, finite-element analysis (FEA), winding losses, planar litz wire

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Authors: Javad Karimi

Abstract:

The grain morphology and size of the additively manufactured (AM) aluminium alloys play a vital role in the performance and mechanical properties. AM-fabricated aluminium parts exhibit a relatively coarse microstructure with a columnar morphology. Ceramic nanoparticles, such as Titanium carbide (TiC), have shown great potential to reduce grain size and consequently influence the mechanical properties. In this study, the microstructural and mechanical properties of aluminium parts with TiC nanoparticles will be investigated. AM aluminium components will be fabricated using wire arc additive manufacturing (WAAM). The effect of the addition of TiC nanoparticles with different wt% on the melt pool geometry will be examined, and the obtained results will be compared to those obtained from pure ER5183. The impact of TiC nanoparticles addition in the AM parts will be analyzed comprehensively, and the results will be discussed in detail.

Keywords: additive manufacturing, wire arc additive manufacturing, nanoparticles, grain refinement

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Authors: Nauman Idrees

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Modeling and simulation during the conceptual design phase are the most effective means of system testing resulting in time and cost savings as compared to the testing of hardware prototypes, which are mostly not available during the conceptual design phase. This paper uses the model-based design (MBD) method in designing the fly-by-wire flight controls system of a fighter aircraft using Simulink. The process begins with system definition and layout where modeling requirements and system components were identified, followed by hierarchical system layout to identify the sequence of operation and interfaces of system with external environment as well as the internal interface between the components. In the second step, each component within the system architecture was modeled along with its physical and functional behavior. Finally, all modeled components were combined to form the fly-by-wire flight controls system of a fighter aircraft as per system architecture developed. The system model developed using this method can be simulated using any simulation software to ensure that desired requirements are met even without the development of a physical prototype resulting in time and cost savings.

Keywords: fly-by-wire, flight controls system, model based design, Simulink

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Authors: Hamed Belloumi, Amira Zouaoui, Ferid kourda

Abstract:

A new trend in power converters is to design planar transformer that aim for low profile. However, at high frequency, the planar transformer ac losses become significant due to the proximity and skin effects. In this paper, the design and implementation of a novel planar Litz conductor is presented in order to equalize the flux linkage and improving the current distribution. The developed PCB litz wire structure minimizes the losses in a similar way to the conventional multi stranded Litz wires. In order to further illustrate the eddy current effect in different arrangements, a Finite-Element Analysis (FEA) tool is used to analyze current distribution inside the conductors. Finally, the proposed planar transformer has been integrated in an electronic stage to test at high signal levels.

Keywords: planar transformer, finite-element analysis, winding losses, planar Litz wire

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Authors: Qi Lu, Jian Deng, Daishun Huang, Chao Guo

Abstract:

The lead cooled fast reactor is considered as one of the most potential Generation IV nuclear systems due to the low working pressure, the appreciable neutron economy, and the considerable passive characteristics. Meanwhile, the lead bismuth eutectic (LBE) has the related advantages of lead with the weaker corrosiveness, which has been paid much attention by recent decades. Moreover, the sub-channel code is a necessary analysis tool for the reactor thermal-hydraulic design and safety analysis, which has been developed combined with the accumulation of LBE experimental data and the understanding of physical phenomena. In this study, a sub-channel code available for LBE was developed, and the corresponding geometric characterization method of typical sub-channels was described in detail, especially for for the fuel assembly with wire spacer. As for this sub-channel code, the transversal thermal conduction through gap was taken into account. In addition, the physical properties, the heat transfer model, the flow resistance model and the turbulent mixing model were analyzed. Finally, the thermal-hydraulic experiments of LBE conducted on THEADES (THErmal-hydraulics and Ads DESign) were selected as the evaluation data of this sub-channel code, including 19 rods with wire spacer, and the calculated results were in good agreement with the experimental results.

Keywords: lead bismuth eutectic, sub-channel code, wire spacer, transversal thermal conduction

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Authors: Ali Kadivar, Kaveh Niayesh

Abstract:

This work simulates the voltage drop and resistance of the explosion of copper wires of diameters 25, 40, and 100 µm surrounded by 1 bar nitrogen exposed to a 150 A current and before plasma formation. The absorption of electrical energy in an exploding wire is greatly diminished when the plasma is formed. This study shows the importance of considering radiation and heat conductivity in the accuracy of the circuit simulations. The radiation of the dense plasma formed on the wire surface is modeled with the Net Emission Coefficient (NEC) and is mixed with heat conductivity through PLASIMO® software. A time-transient code for analyzing wire explosions driven by a slow current rise rate is developed. It solves a circuit equation coupled with one-dimensional (1D) equations for the copper electrical conductivity as a function of its physical state and Net Emission Coefficient (NEC) radiation. At first, an initial voltage drop over the copper wire, current, and temperature distribution at the time of expansion is derived. The experiments have demonstrated that wires remain rather uniform lengthwise during the explosion and can be simulated utilizing 1D simulations. Data from the first stage are then used as the initial conditions of the second stage, in which a simplified 1D model for high-Mach-number flows is adopted to describe the expansion of the core. The current was carried by the vaporized wire material before it was dispersed in nitrogen by the shock wave. In the third stage, using a three-dimensional model of the test bench, the streamer threshold is estimated. Electrical breakdown voltage is calculated without solving a full-blown plasma model by integrating Townsend growth coefficients (TdGC) along electric field lines. BOLSIG⁺ and LAPLACE databases are used to calculate the TdGC at different mixture ratios of nitrogen/copper vapor. The simulations show both radiation and heat conductivity should be considered for an adequate description of wire resistance, and gaseous discharges start at lower voltages than expected due to ultraviolet radiation and the exploding shocks, which may have ionized the nitrogen.

Keywords: exploding wire, Townsend breakdown mechanism, streamer, metal vapor, shock waves

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Authors: You-Lin Wu, Zong-Xian Wu, Jing-Jenn Lin, Shih-Hung Lin

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In this work, a polysilicon wire (PSW) coated with a mixture of 3-aminopropyltriethoxysilane (r-APTES) and Al2O3 nanoparticles as the sensing membrane prepared with various Al2O3/r-APTES and dispersing agent/r-APTES ratios for pH sensing is studied. The r-APTES and dispersed Al2O3 nanoparticles mixture was directly transferred to PSW surface by solution phase deposition (SPD). It is found that using a mixture of Al2O3 nanoparticles and r-APTES as the sensing membrane help in improving the pH sensing of the PSW sensor and a 5 min SPD deposition time is the best. Dispersing agent is found to be necessary for better pH sensing when preparing the mixture of Al2O3 nanoparticles and r-APTES. The optimum condition for preparing the mixture is found to be Al2O3/r-APTES ratio of 2% and dispersing agent/r-APTES ratio of 0.3%.

Keywords: al2o3 nanoparticles, ph sensing, polysilicon wire sensor, r-aptes

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Authors: Krishna Nand, Mohammad Taufik

Abstract:

Fused Filament Fabrication (FFF) is one of the most popular additive manufacturing (AM) technology. In FFF technology, a wire form material (filament) is fed inside a heated chamber, where it gets converted into semi-solid form and extruded out of a nozzle to be deposited on the build platform to fabricate the part. FFF technology is expanding and covering the market at a very rapid rate, so the need of raw materials for 3D printing is also increasing. The cost of 3D printing is directly affected by filament cost. To make 3D printing more economic, a compact and portable filament/wire extrusion system is needed. Wire extrusion systems to extrude ordinary wire/filament made of a single material are available in the market. However, extrusion system to make a composite wire/filament are not available. Hence, in this study, initial efforts have been made to develop a table-top composite wire extruder. The developed system is consisted of mechanical parts, electronics parts, and a control system. A multiple channel hopper, extrusion screw, melting chamber and nozzle, cooling zone, and spool winder are some mechanical parts. While motors, heater, temperature sensor, cooling fans are some electronics parts, which are used to develop this system. A control board has been used to control the various process parameters like – temperature and speed of motors. For the production of composite wire/filament, two different materials could be fed through two channels of hopper, which will be mixed and carried to the heated zone by extrusion screw. The extrusion screw is rotated by a motor, and the speed of this motor will be controlled by the controller as per the requirement of material extrusion rate. In the heated zone, the material will melt with the help of a heating element and extruded out of the nozzle in the form of wire. The developed system occupies less floor space due to the vertical orientation of its heating chamber. It is capable to extrude ordinary filament as well as composite filament, which are compatible with 3D printers available in the market. Further, the developed system could be employed in the research and development of materials, processing, and characterization for 3D printer. The developed system presented in this study could be a better choice for hobbyists and researchers dealing with the fused filament fabrication process to reduce the 3D printing cost significantly by recycling the waste material into 3D printer feed material. Further, it could also be explored as a better alternative for filament production at the commercial level.

Keywords: additive manufacturing, 3D Printing, filament extrusion, pellet extrusion

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Authors: Bunty Tomar, Shiva S.

Abstract:

Fabrication of steel and copper-based functionally graded material (FGM) through cold metal transfer-based wire arc additive manufacturing is a novel exploration. Components combining Cu and steel show significant usage in many industrial applications as they combine high corrosion resistance, ductility, thermal conductivity, and wear resistance to excellent mechanical properties. Joining steel and copper is challenging due to the mismatch in their thermo-mechanical properties. In this experiment, a functionally graded material (FGM) structure of pure copper (Cu) and 316L stainless steel (SS) was successfully developed using cold metal transfer-based wire arc additive manufacturing (CMT-WAAM). The interface of the fabricated samples was characterized under optical microscopy, field emission scanning electron microscopy, and X-ray diffraction techniques. Detailed EBSD and TEM analysis was performed to analyze the grain orientation, strain distribution, grain boundary misorientations, and formation of metastable and intermetallic phases. Mechanical characteristics of deposits was also analyzed using tensile and wear testing. This works paves the way to use CMT-WAAM to fabricate steel/copper FGMs.

Keywords: wire arc additive manufacturing (waam), cold metal transfer (cmt), metals and alloys, mechanical properties, characterization

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Authors: Hikari Ryu, Yuki Fukuda, Kento Oishi, Chiharu Igarashi, Shogo Kiryu

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Recently, wireless power transfer has been developed in various fields. Magnetic coupling is popular for feeding power at a relatively short distance and at a lower frequency. Electro-magnetic wave coupling at a high frequency is used for long-distance power transfer. The wireless power transfer has attracted attention in e-textile fields. Rigid batteries are required for many body-worn electric systems at the present time. The technology enables such batteries to be removed from the systems. Flexible coils have been studied for such applications. Coils with a high Q factor are required in the magnetic-coupling power transfer. Antennas with low return loss are needed for the electro-magnetic coupling. Litz wire is so flexible to fabricate coils and antennas sewn on fabric and has low resistivity. In this study, the electric characteristics of some coils and antennas fabricated with the Litz wire by using two sewing techniques are investigated. As examples, a coil and an antenna are described. Both were fabricated with 330/0.04 mm Litz wire. The coil was a planar coil with a square shape. The outer side was 150 mm, the number of turns was 15, and the pitch interval between each turn was 5 mm. The Litz wire of the coil was overstitched with a sewing machine. The coil was fabricated as a receiver coil for a magnetic coupled wireless power transfer. The Q factor was 200 at a frequency of 800 kHz. A wireless power system was constructed by using the coil. A power oscillator was used in the system. The resonant frequency of the circuit was set to 123 kHz, where the switching loss of power FETs was small. The power efficiencies were 0.44 – 0.99, depending on the distance between the transmitter and receiver coils. As an example of an antenna with a sewing technique, a fractal pattern antenna was stitched on a 500 mm x 500 mm fabric by using a needle punch method. The pattern was the 2nd-oder Vicsec fractal. The return loss of the antenna was -28 dB at a frequency of 144 MHz.

Keywords: e-textile, flexible coils and antennas, Litz wire, wireless power transfer

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Authors: Aphinan Phukaoluan, Surachai Dechkunakorn, Niwat Anuwongnukroh, Anak Khantachawana, Pongpan Kaewtathip, Julathep Kajornchaiyakul, Wassana Wichai

Abstract:

Aims: This study aims to address the amount of force delivered by a NiTiCu orthodontic wire with a ternary composition ratio of 46.0 Ni: 49.0 Ti: 5.0 Cu and to compare the results with a commercial NiTiCu 35 °C orthodontic archwire. Materials and Methods: Nickel (purity 99.9%), Titanium (purity 99.9%), and Copper (purity 99.9%) were used in this study with the atomic weight ratio 46.0 Ni: 49.0 Ti: 5.0 Cu. The elements were melted to form an alloy using an electrolytic arc furnace in argon gas atmosphere and homogenized at 800 °C for 1 hr. The alloys were subsequently sliced into thin plates (1.5mm) by EDM wire cutting machine to obtain the specimens and were cold-rolled with 30% followed by heat treatment in a furnace at 400 °C for 1 hour. Then, the three newly fabricated NiTiCu specimens were cut in nearly identical wire sizes of 0.016 inch x0.022 inch. Commercial preformed Ormco NiTiCu35 °C archwire with size 0.016 inch x 0.022 inches were used for comparative purposes. Three-point bending test was performed using a Universal Testing Machine to investigate the force of the load-deflection curve at oral temperature (36 °C+ 1) with deflection points at 0.25, 0.5, 0.75, 1.0. 1.25, and 1.5 mm. Descriptive statistics was used to evaluate each variables and independent t-test was used to analyze the differences between the groups. Results: Both NiTiCu wires presented typical superelastic properties as observed from the load-deflection curve. The average force was 341.70 g for loading, and 264.18 g for unloading for 46.0 Ni: 49.0 Ti: 5.0 Cu wire. Similarly, the values were 299.88 g for loading, and 201.96 g for unloading of Ormco NiTiCu35°C. There were significant differences (p < 0.05) in mean loading and unloading forces between the two NiTiCu wires. The deflection forces in loading and unloading force for Ormco NiTiCu at each point were less than 46.0 Ni: 49.0 Ti: 5.0 Cu wire, except at the deflection point of 0.25mm. Regarding the force difference between each deflection point of loading and unloading force, Ormco NiTiCu35 °C exerted less force than 46.0 Ni: 49.0 Ti: 5.0 Cu wire, except at difference deflection at 1.5-1.25 mm of unloading force. However, there were still within the acceptable limits for orthodontic use. Conclusion: The fabricated ternary alloy of 46.0 Ni: 49.0 Ti: 5.0 Cu (atomic weight) with 30% reduction and heat treatment at 400°C for 1 hr. and Ormco 35 °C NiTiCu presented the characteristics of the shape memory in their wire form. The unloading forces of both NiTiCu wires were in the range of orthodontic use. This should be a good foundation for further studies towards development of new orthodontic NiTiCu archwires.

Keywords: loading force, ternary alloy, NiTiCu, shape memory, orthodontic wire

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Authors: Nixon Kuruvila, H. V. Ravindra

Abstract:

Wire-cut Electro Discharge Machining (WEDM) is a special form of conventional EDM process in which electrode is a continuously moving conductive wire. The present study aims at determining parametric influence and optimum process parameters of Wire-EDM using Taguchi’s Technique and Genetic algorithm. The variation of the performance parameters with machining parameters was mathematically modeled by Regression analysis method. The objective functions are Dimensional Accuracy (DA) and Material Removal Rate (MRR). Experiments were designed as per Taguchi’s L16 Orthogonal Array (OA) where in Pulse-on duration, Pulse-off duration, Current, Bed-speed and Flushing rate have been considered as the important input parameters. The matrix experiments were conducted for the material Oil Hardened Non Shrinking Steel (OHNS) having the thickness of 40 mm. The results of the study reveals that among the machining parameters it is preferable to go in for lower pulse-off duration for achieving over all good performance. Regarding MRR, OHNS is to be eroded with medium pulse-off duration and higher flush rate. Finally, the validation exercise performed with the optimum levels of the process parameters. The results confirm the efficiency of the approach employed for optimization of process parameters in this study.

Keywords: dimensional accuracy (DA), regression analysis (RA), Taguchi method (TM), volumetric material removal rate (VMRR)

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Authors: Mohammed A. M. Ibrahim

Abstract:

This paper investigate the utilization of wire and wireless networks to be platform for distributed educational monitoring system. Universities in developing countries suffer from a lot of shortages(staff, equipment, and finical budget) and optimal utilization of the wire and wireless network, so universities can mitigate some of the mentioned problems and avoid the problems that maybe humble the education processes in many universities by using our implementation of the examinations system as a test-bed to utilize the network as a solution to the shortages for academic staff in Taiz University. This paper selects a two areas first one quizzes activities is only a test bed application for wireless network learning environment system to be distributed among students. Second area is the features and the security of wireless, our tested application implemented in a promising area which is the use of WLAN in higher education for leering environment.

Keywords: networking wire and wireless technology, wireless network security, distributed computing, algorithm, encryption and decryption

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Authors: R. A. Ribeiro, P. D. Angelo Assunção, E. M. Braga

Abstract:

The microhardness in weld beads is a function of the microstructure obtained in the welding process, and this by its time is dependent of the input variables established at the outset of the process. In this study the influence of angle between the plate and the cold wire, the position in which the cold wire is introduced and the rate in which this introduction is made are assessed as input parameters in CW-GMAW process. This paper looks to show that ordinary changes in the frame of CW-GMAW can improve microhardness, which is expected to vary as the input parameters change. To properly correlate the changes in the input parameters to consequent changes in microhardness of the weld bead, a full factorial design was employed. In fact, changes in the operational parameters improved the overall microhardness of the weld bead, which in turns can be an indication of improvement in the resistance to abrasive wear, constituting a cheap way to augment the abrasion wear resistance of welds used for cladding.

Keywords: abrasion, CW-GMAW, full factorial design, microhardness

Procedia PDF Downloads 547