Manufacturing Processes
Hasan Ghafourian Nosrati; Mahdi Gerdooei
Abstract
In recent years, most industries such as the aerospace, automotive, and others have been pushed to methods for reducing costs. One of these methods is the rubber pad forming (RPF) process, which has been given more attention as a low-cost method than conventional methods. In RPF, unlike conventional ...
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In recent years, most industries such as the aerospace, automotive, and others have been pushed to methods for reducing costs. One of these methods is the rubber pad forming (RPF) process, which has been given more attention as a low-cost method than conventional methods. In RPF, unlike conventional methods which mainly use metals as tools, one of the tools will be made of elastic pads. The RPF process has attracted the attention of many researchers around the world. Researchers from Iran started their work in this field around 2001 and subsequently published several remarkable articles. The first published Iranian study of the RPF process dates back to 2003, indicating that the use of flexible tools has a history of two decades in Iran. However, in the last decade, the number of published Iranian articles in the RPF process field and the introduction of new methods based on RPF and its simulation has increased. This review article aims to outline Iran's involvement in the RPF process, and it emphasizes that Iranian researchers predominantly contribute to the RPF process through simulation, experimental endeavors, and the introduction of innovative methods utilizing flexible tools.
Manufacturing Processes
Ali Rugbani
Abstract
This research proposes a general formula for implementing in the control system of a dry-jet wet spinning machine to achieve a specific diameter size for Polysulfone hollow fibers. By employing Taguchi method, the effect of the operation parameters on the fiber geometry is investigated. The findings ...
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This research proposes a general formula for implementing in the control system of a dry-jet wet spinning machine to achieve a specific diameter size for Polysulfone hollow fibers. By employing Taguchi method, the effect of the operation parameters on the fiber geometry is investigated. The findings emphasize the significance of various fabrication parameters in determining the inner diameter (ID) and outer diameter (OD) of the hollow fibers. To mathematically predict the ID and OD, a first-order equation is developed using the least squares method. The accuracy of the proposed equation is validated through a series of experiments, where the ID and OD of the produced hollow fibers are determined using cross-sectional images by a scanning electron microscope. The results demonstrate a strong agreement between the proposed equation and the experimental data, with a maximum error of less than 7%. This research offers a valuable tool for optimizing hollow-fiber spinning plants and holds promise for improving their overall performance.
Manufacturing Processes
M. Dastagiri; P. Srinivasa Rao; P. Madar Valli
Abstract
Electro Discharge Machining (EDM) is an incredibly recognizable machining for ticklishness profiles in ’difficult to machine ‘materials. In EDM, the material ejection of the cathode is cultivated through exact controlled electric pulse (the flash), which changes the metals of two terminals ...
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Electro Discharge Machining (EDM) is an incredibly recognizable machining for ticklishness profiles in ’difficult to machine ‘materials. In EDM, the material ejection of the cathode is cultivated through exact controlled electric pulse (the flash), which changes the metals of two terminals into dissolve and vaporize, as a result of the breakdown of the dielectric medium. The most commonly used dielectric media are kerosene, paraffin, glycerin, transformer oil, and EDM oil; all are derived from petroleum. These dielectric media undergo pyrolysis and carbon soot formation is deposited on work electrode, and sometimes carbon precipitates into work. To overcome these effects vegetable oils are tried as alternate dielectric media. Pongamia Pinnetta is abundantly available in most countries; and it is cheaper and non-edible. Pongamia Pinnata (PP) oil is extracted from plant seeds, and is blended with EDM oil and several experimentations are done to find its suitability. Operational variables with respect to input and output parameters are identified. Some of these are best EWR, MRR, TWR, and SR with applied current (I), pulse on time (Ton), and pulse off time (Toff) are the ones picked as the input process factors; because for the industrial application many machinists choose these three as the input parameters; and other is constant and picked under specific requirements only. After the successful completion of this experimentations, Pongamia Pinnata oil blends are fit for the industrial application using technique of order preferancing with similar to ideal solution [TOPSIS]. It is observed that no carbon soot formation takes place in the work component with PP oil as the dielectric fluid.
Manufacturing Processes
Faiz F. Mustafa; Sadoon R. Daham
Abstract
Surface layer in many engineering applications is strengthened by ceramic grains where the main parts have higher structure toughness than the original material. This paper presents the effect of four process parameters that have been taken into consideration using Taguchi technique based on L9 orthogonal ...
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Surface layer in many engineering applications is strengthened by ceramic grains where the main parts have higher structure toughness than the original material. This paper presents the effect of four process parameters that have been taken into consideration using Taguchi technique based on L9 orthogonal array. These parameters are;1) transverse speed, 2) type of nano- powders, 3) rotational speed, and 4) groove’s depth friction stir welding T-joints aluminum alloy 6061-T6. This work combines welding T-joint sections and creating MMNCs in welding region simultaneously. The predicted optimum parameters and their percentage of contribution are estimated, utilizing the analysis of variance and signal to noise ratio techniques, depending on tensile test in skin and stringers direction, and hardness test of the joint. Optical microscope and scanning electron microscope (SEM) analysis are used to verify the microstructure and dispersion of nano-powders in welding joint. The best ultimate tensile stress (UTSskin) equal to (177MPa) for the skin welded part was obtained at the optimal conditions of 1550rpm rotational speed, 15mm/min transverse speed, Al2O3 type of powder and 1mm groove’s depth. SEM micrographic for metal matrix nanocomposite of all nine experiments revealed that the nano-particles are irregularly dispersed in nugget zone due to one pass. The rotational speeds of 960rpm, the transverse speed of 15mm/min, type of powder TiO2, and groove’s depth of 1.5mm, give the greatest hardness value of 80HV in nugget zone. The analysis of variance shows that the groove’s depth is the most significant parameter in this investigation.
Manufacturing Processes
Sachin Ghalme; Yogesh Bhalerao; Kamlesh Phapale
Abstract
Composite materials have proven their applicability for various structural components. Excellent properties of glass fiber reinforced plastic (GFRP) composite materials have presented GFRP composites for potential applications in aerospace and automobile-related industries. Drilling is an important operation ...
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Composite materials have proven their applicability for various structural components. Excellent properties of glass fiber reinforced plastic (GFRP) composite materials have presented GFRP composites for potential applications in aerospace and automobile-related industries. Drilling is an important operation for composite structures during final assembly. This paper investigates the factors affecting delamination in GFRP composite during the drilling process. Drill speed and feed rate are selected two parameters affecting delamination during the drilling process. The response surface methodology approach has been used for experimental design and analysis of variance. Delamination was evaluated at the entry, middle, and exit positions of the hole. An attempt has been made to optimize the speed and feed rate for minimization of delamination at the three positions using grey relational analysis. The results of this work will help in selecting an optimum level of speed and feed rate to minimize delamination at the entry, middle, and exit positions of the hole to improve quality of the drilled hole.
Manufacturing Processes
A. Ravendran; S. Rianmora
Abstract
Edge is an indispensable characteristic of an image, defined as the contour between two regions with significant variance in terms of surface reflectance, illumination, intensity, color, and texture. Detection of edges is a basic requirement for diverse contexts for design automation. This study presents ...
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Edge is an indispensable characteristic of an image, defined as the contour between two regions with significant variance in terms of surface reflectance, illumination, intensity, color, and texture. Detection of edges is a basic requirement for diverse contexts for design automation. This study presents a guideline to assign appropriate threshold and sigma values for the Canny edge detector to increase the efficiency of additive manufacturing. The algorithm uses different combinations of threshold and sigma on a color palette, and the results are statistically formulated using multiple regression analysis with an accuracy of 95.93%. An image-based acquisition technique system is designed and developed for test applications to create three-dimensional objects. In addition, a graphical user interface is developed to convert a selected design of a complex image to a three-dimensional object with the generation of Cartesian coordinates of the detected edges and extrusion. The developed system reduces the cost and time of developing an existing design of an object for additive manufacturing by 20% and 70%, respectively.
Manufacturing Processes
M. Nasrollahzade; S. J. Hashemi; H. Moslemi Naeini; Amir H. Roohi; Sh. Imani Shahabad
Abstract
Aluminum alloys are considered a lot in the automotive and aerospace industry because of their high strength to weight ratio. In this manuscript, the gas forming process of aluminum AA6063 tubes at high temperatures up to 500°C is investigated, through experimental and numerical tests. Therefore, ...
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Aluminum alloys are considered a lot in the automotive and aerospace industry because of their high strength to weight ratio. In this manuscript, the gas forming process of aluminum AA6063 tubes at high temperatures up to 500°C is investigated, through experimental and numerical tests. Therefore, an experimental setup is prepared and so, tube specimens are formed in a die with square cross section. Finite element simulation of the hot gas forming process is carried out to investigate the effects of process parameters including time period of forming process, temperature, and loading path. Uniaxial tensile tests under various temperatures and strain rates is performed, in order to obtain flow stress curves of the material. Corner radius and thickness distribution of tubular formed parts is investigated. The results show smaller corner radii could be formed at higher temperatures, whereas lower forming pressure is necessary. Increasing the time period of the process enhances the corners of the specimens to be formed. In addition, the maximum of formability is obtained when the gas pressure increases rapidly at the beginning of the process. However, the increasing rate of gas pressure must be reduced to form a smaller corner radius.
Manufacturing Processes
Elhachemi Bahloul
Abstract
In contour milling, to render the machining process more automated with significant productivity without remaining material after machining, a new recovery coefficient was developed. The coefficient was inserted in the computation of contour parallel tool paths to fix the radial depth of cut in the way ...
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In contour milling, to render the machining process more automated with significant productivity without remaining material after machining, a new recovery coefficient was developed. The coefficient was inserted in the computation of contour parallel tool paths to fix the radial depth of cut in the way to ensure an optimized overlap area between the passes in the corners, without residuals. Thus, this parameter, which has been earlier inserted by the user, is now being independent and is implemented automatically from the input data of the contour shape of the pocket. In order to prove the effectiveness of the present approach, a detailed comparison with the classical methods found in the literature we also performed. The results clearly show that the new method removes the residuals efficiently in an automatic way and minimizes the toolpath length respect to the other methods. Furthermore, this proposed approach can easily be worked on the actual machine tool.
Manufacturing Processes
Tran Minh Duc; Tran The Long; Tran Bao Ngoc
Abstract
SKD 11 tool steel is among the most popular metals in mold industries for making different kinds of cold work molds and dies with high accuracy and long service life. The demand for higher quality, lower manufacturing costs, particularly the environmentally friendly characteristics, have provided the ...
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SKD 11 tool steel is among the most popular metals in mold industries for making different kinds of cold work molds and dies with high accuracy and long service life. The demand for higher quality, lower manufacturing costs, particularly the environmentally friendly characteristics, have provided the stimuli for manufacturers and researchers to find alternative solutions. An excellent media is formed in the cutting zone by using MQL nanofluids in order to enhance the thermal conductivity and tribological characteristics; therefore, improving the machining performance. The formation of the lubricating film as well as the rolling action of nanoparticles in contact zones has gained much attention in the machining field. In this research work, the application of MQL Al2O3 nanofluids with vegetable oils and emulsion 5% is developed for slotting end milling of SKD 11 steel using normal HSS tool. The cutting forces, tool wear, tool life, and surface roughness are investigated to evaluate the effectiveness of MQL nanofluid on cutting performance. The experimental results reveal that the cutting forces and cutting temperature decrease and the surface quality and tool life enhance. Furthermore, the improvement of the thermal conductivity of nanofluids is proven when compared to pure fluids. Due to the rise of viscosity and thermal conductivity, the soybean oil-based nanofluid, which is almost inherently nontoxic, gives superior lubricating and cooling properties suitable for MQL application compared to emulsion-based nanofluids. The novel environmental friendly technology definitely brings out many technological and economic benefits in machining practice.
Manufacturing Processes
Mahdi Moghimi; Naeem Jalali
Abstract
Micromixer is a significant component of microfluidics particularly in lab-on-chip applications so that there has been a growing need for design and fabrication of micromixers with a shorter length and higher efficiency. Despite most of the passive micromixers that suffer from long mixing path and complicated ...
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Micromixer is a significant component of microfluidics particularly in lab-on-chip applications so that there has been a growing need for design and fabrication of micromixers with a shorter length and higher efficiency. Despite most of the passive micromixers that suffer from long mixing path and complicated geometry to increase the efficiency, our novel design suggests a highly efficient micromixer while taking advantage of having a short length. The novelty of our work stems from utilizing all three mixing techniques of injection, recombination, and zigzag mixing resulting in benefits such as multi-flow lamination and flow resistance reduction in microscale. Moreover, the contraction and expansion of the microchannel width improve mixing. The present work deals with the parametric study, numerical simulation, as well as experimental tests and characterization of small planar passive micromixer. The high mixing efficiency yield of 98.02 was obtained with the length of only 1857.8 microns which shows good agreement in comparison with numerical simulation.
Manufacturing Processes
Ebrahim Haghani; Ahmad Gheysarian; Mohammad Honarpisheh
Abstract
One of the methods for making prototypes is incremental forming process. In this method, the forming tool, performs a pre-programmed movement by the CNC machine and runs the desired path. This modernization process is used in the automotive, aerospace, military, medical and other industries. One of the ...
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One of the methods for making prototypes is incremental forming process. In this method, the forming tool, performs a pre-programmed movement by the CNC machine and runs the desired path. This modernization process is used in the automotive, aerospace, military, medical and other industries. One of the most influential parameters in this process is forming tool. This parameter is effective in forming forces, surface roughness, sheet formability and thickness distribution. In this study, the forming tool was investigated and rotating geometry tool was compared with a rigid tool. Also, the effects of step down, feed rate and spindle speed were investigated on the forming force, surface roughness and thickness distribution by comparing mentioned forming tools. The results indicate that the forming forces, sheet surface quality and thickness changes increase with increasing step down and feed rate. Using the rotary tools improves the forming forces, surface roughness and thickness distribution rather than the non-rotating tool.
Manufacturing Processes
Saman Khalilpourazary; jamal ahmadi
Abstract
Reaming is a common finishing process for improving the drilled holes surface quality. Choosing an appropriate finishing method in drilling process has a significant effect on the surface quality of holes and in decreasing the process total cost and time. In this study, four similar holes were drilled ...
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Reaming is a common finishing process for improving the drilled holes surface quality. Choosing an appropriate finishing method in drilling process has a significant effect on the surface quality of holes and in decreasing the process total cost and time. In this study, four similar holes were drilled on the AISI 4340 workpiece with different two pair feed rates. The drilling process was performed with a conventional cutting fluid, an emulsion of water and ECOCOOL 3015 GS-W. The surface roughness values after drilling process were measured using a portable roughness tester. Then, two distinct sizes of alumina micro-particles were used in the cutting fluid discretely to perform finishing process of the holes with a specific cylindrical tool. A comparison of the surface roughness measurements after the finishing process showed a significant decrease in the arithmetic surface roughness and ten-point mean roughness values of the drilled holes. The values were very close to the surface roughness limits in reaming process of the holes.
Manufacturing Processes
Mehdi Tajdari; Saeed Zare Chavoshi
Abstract
In the present study, five modeling approaches of RA, MLP, MNN, GFF, and CANFIS were applied so as to estimate the radial overcut values in electrochemical drilling process. For these models, four input variables, namely electrolyte concentration, voltage, initial machining gap, and tool feed rate, were ...
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In the present study, five modeling approaches of RA, MLP, MNN, GFF, and CANFIS were applied so as to estimate the radial overcut values in electrochemical drilling process. For these models, four input variables, namely electrolyte concentration, voltage, initial machining gap, and tool feed rate, were selected. The developed models were evaluated in terms of their prediction capability with measured values. It was clearly seen that the proposed models were capable of predicting the radial overcut. However, the MLP model predicted the radial overcut with higher accuracy than the other models. The statistical analysis showed how much the radial overcut was mainly influenced by voltage and electrolyte concentration during the electrochemical drilling process.
Manufacturing Processes
Mahdi Ghamami; Masoud Shariat Panahi; Maryam Rezaei
Abstract
In today's design, system complexity and increasing demand for safer, more efficient and less costly systems have created new challenges in science and engineering. Locomotives are products which are designed according to market order and technical needs of customers. Accordingly, targets of companies, ...
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In today's design, system complexity and increasing demand for safer, more efficient and less costly systems have created new challenges in science and engineering. Locomotives are products which are designed according to market order and technical needs of customers. Accordingly, targets of companies, especially designers and manufacturers of locomotives, have always been on the path of progress and seek to offer products with higher technology than other competitors. Quality of body structures is based on indicators such as natural frequency, displacement, fatigue life and maximum stress. Natural frequency of various components of the system and their adaption to each other are important for avoiding the phenomenon of resonance. In this study, body structures of ER24 locomotive (Iran Safir Locomotive) was studied. A combination of imperialist competitive algorithm (ICA) and artificial neural network was proposed to find optimal weight of structures while natural frequencies were in the determined range. Optimization of locomotive's structure was performed with an emphasis on maintaining locomotive abilities in static and dynamic fields. The results indicated that use of optimization techniques in the design process was a powerful and effective tool for identifying and improving main dynamic characteristics of structures and also optimizing performance in stress, noise and vibration fields.
Manufacturing Processes
S. Khalilpourazary; P. M. Kashtiban; N. Payam
Abstract
Nowadays, in order to reach minimum production cost in machining operations, various optimization methods have been proposed. Since turning operation has different parameters affecting the workpiece quality, it was selected as a complicated manufacturing method in this paper. To reach sufficient quality, ...
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Nowadays, in order to reach minimum production cost in machining operations, various optimization methods have been proposed. Since turning operation has different parameters affecting the workpiece quality, it was selected as a complicated manufacturing method in this paper. To reach sufficient quality, all influencing parameters such as cutting speed, federate, depth of cut and tool rake angle were selected as input parameters. Furthermore, both surface roughness and tool life were considered as the objectives. Also, ST37 steel and M1 high speed steel (HSS) were selected as workpiece material and tool, respectively. Subsequently, grey relational analysis was performed to elicit optimal values for the mentioned input data. To achieve this goal, first, degree of freedom was calculated for the system and the same experiments were performed based on the target values and number of considered levels, leading to calculating grey relational generating, grey relational coefficient and grey relational grade. As the next step, the grey relational graph was sketched for each level. Finally, optimum values of the parameters were obtained for better surface roughness and tool life. It was shown that the presented method in the turning operation of ST37 led to high surface quality and tool life.
Manufacturing Processes
I. Shivakoti; G. Kibria; S. Diyaley; B. B. Pradhan
Abstract
Correct selection of manufacturing condition is one of the most important aspects which should be considered in the majority of manufacturing processes, particularly in the process related to advanced machining process like electrical discharge machining. In electrical discharge machining (EDM), ...
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Correct selection of manufacturing condition is one of the most important aspects which should be considered in the majority of manufacturing processes, particularly in the process related to advanced machining process like electrical discharge machining. In electrical discharge machining (EDM), dielectric fluid plays an important role since machining characteristics are greatly influenced by the nature or characteristics of employed dielectric. Moreover, adding various types of abrasives or salt in the fluid at different concentrations also affect the machining performance because of changing dielectric strength property. The present paper addressed the influence of NaNO3 mixed de-ionized water as a dielectric fluid on micro-hole machining performance criteria such as material removal rate (MRR), tool wear rate (TWR), overcut (OC) and taper during machining of D3 die steel plate.
Manufacturing Processes
R. Arokiadass*; K. Palaniradja; N. Alagumoorthi
Abstract
Metal matrix composites have been widely used in industries, especially aerospace industries, due to their excellent engineering properties. However, it is difficult to machine them because of the hardness and abrasive nature of reinforcement elements like silicon carbide particles (SiCp).In the present ...
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Metal matrix composites have been widely used in industries, especially aerospace industries, due to their excellent engineering properties. However, it is difficult to machine them because of the hardness and abrasive nature of reinforcement elements like silicon carbide particles (SiCp).In the present study, an attempt has been made to investigate the influence of spindle speed (N), feed rate (f), depth of cut (d) and various %wt. of silicon carbide (S) manufactured through stir cast route on tool flank wear and surface roughness during end milling of LM25 Al-SiCp metal matrix composites. Statistical models based on second order polynomial equations were developed for the different responses. Analysis of variance (ANOVA) was carried out to identify the significant factors affecting the tool flank wear and surface roughness. The contour plots were generated to study the effect of process parameters as well as their interactions. The process parameters are optimized using desirability-based approach response surface methodology.
Manufacturing Processes
Ghader Faraji*; Mahmoud Mosavi Mashhadi; Karen Abrinia
Abstract
The current study conducted a finite element (FE) and experimental investigation on tubular channel angular pressing as a noble severe plastic deformation technique for producing ultrafine grained and nanostructure tubular components. To examine the effects of the TCAP process on the strain distribution ...
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The current study conducted a finite element (FE) and experimental investigation on tubular channel angular pressing as a noble severe plastic deformation technique for producing ultrafine grained and nanostructure tubular components. To examine the effects of the TCAP process on the strain distribution and deformation behavior, FE simulations were employed. The FE results demonstrated that equivalent plastic strain of 2.1-2.9 was developed after applying one pass TCAP. Analytical investigations were carried out to calculate the accumulated strain during the process. Tube thinning in the early stages of the process was observed as a result of tensile circumferential strains but this could be compensated for by the back pressure effect resulting from the next shear zones and also compressive circumferential strain resulting from decreasing the tube diameter. Microstructural observations showed significant grain refinement after one pass TCAP on AZ91 magnesium alloy at 300 ºC. Microhardness measurements demonstrated increasing hardness to 78 HV from the initial value of 51 HV.
Manufacturing Processes
Abstract
Laser bending is an advanced process in sheet metal forming in which a laser heat source is used to shape the metal sheet. In this paper, temperature distribution in a mild steel sheet metal is investigated numerically and experimentally. Laser heat source is applied through curved paths in square sheet ...
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Laser bending is an advanced process in sheet metal forming in which a laser heat source is used to shape the metal sheet. In this paper, temperature distribution in a mild steel sheet metal is investigated numerically and experimentally. Laser heat source is applied through curved paths in square sheet metal parts. Finite element (FE) simulation is performed with the ABAQUS/CAE standard software package. Material property of AISI 1010 is used in FE model and experiments. The aim of this study is to identify the response related to deformation and characterize the effect of laser power with respect to the bending angle for a square sheet part. An experimental setup including a Nd:YAG laser Model IQL-10 with maximum mean laser power of 500 W is used for the experiments to verify FE analysis results. It is observed that numerical results are relatively in good agreement with the experimental results. Results also show that increasing laser power increases the bending angle.
