International Journal of Advanced Design and Manufacturing Technology
Volume:14 Issue: 3, Sep 2021

In this paper, a new production method of aluminium/steel double-layered wire is proposed using a modified friction stir extrusion process. The core and coating were made of St37 steel and aluminium alloy, respectively. For extruded specimens, the effects of the main process parameters including tool rotational speed and feed rate were investigated on adhesion strength and surface cracks. The tool rotational speed was studied at two levels of 300 and 600 rpm, and the feed rate at two levels of 4 and 12 mm/min. Pull-out test was carried out using a tensile test machine to evaluate the adhesion strength. Surface cracks were evaluated by the liquid penetrant test. The results suggest that the modified friction stir extrusion process can be used successfully to produce dissimilar double-layered wires. With the right combination of tool rotational speed and feed rate levels, a dissimilar double-layered wire can be produced with a high adhesion strength and good surface quality. No cracks were observed in specimens produced with the feed rate of 12 mm/min and rotational speed of 600 rpm. The maximum adhesion strength was 2867.13 N that was achieved with a tool rotational speed of 300 rpm and feed rate of 12 mm/min.

One of the important parameters in electrical discharge machining is the presence of micro cracks on the workpiece surface (recast layer). Therefore, the aim of this study was to investigate the possibility of increasing the mechanical properties of aluminum surface by alloying elements (copper and nickel) diffusion to the recast layer and thus removing surface micro cracks. For this purpose, pulse on time and pulse current in with and without ultrasonic vibration have been considered as input parameters and the presence of surface micro cracks has been investigated using microscopic images. Also, the yield stress of the surface layer was calculated using the surface micro hardness. Based on the obtain results, surface without micro cracks has been created on the aluminum surface due to the diffusion of copper and nickel into the workpiece surface which increased aluminum surface yield strength from 90MPa to 280MPa without ultrasonic vibrations and to 310MPa while applying ultrasonic vibrations. In other words, ultrasonic vibrations cause an average of 20% increase in surface layer yield strength. In addition, according to the wear test, in the case of using ultrasonic vibration, improving the mechanical properties of the surface has caused thinner grooves on the aluminum surface.

In this study, Rotational Chemical Machining (RCM) as a novel machining process is introduced. The properties such as surface roughness and residual stress as well as fatigue strength of the RCM process are evaluated, discussed and compared to the conventional turning process. In this sense, Scanning Electron Microscope (SEM) and Atomic Force Microscope (AFM) were utilized. The results show the superiority of the RCM method over the conventional method and eliminate limits of process such as low surface quality and improve fatigue strength. The Amplitude Distribution Curve has a balanced Gaussian shape in RCM indicating the balanced distribution of peaks and valleys on machined surface. Due to the absence of machining force in the RCM process, in comparison to the turning process, maximum residual stress is significantly decreased from 363Mpa to 71Mpa; surface roughness reduced from 3.1µm to 1.5 µm as well as the fatigue strength improved 20% approximately.

In this paper, wollastonite glass-ceramics and composites of wollastonite glass– ceramics with 2.5, 5, 10 and 20 weight percent alumina with an average size of 2 microns and also wollastonite glass-ceramics with 2.5, 5, and 10 percent alumina with an average size of 40 nanometers were produced without pressure by Sintering and their physical properties (e.g. bulky density, the percentage of linear shrinkage and relative density) were measured. Sinter operation in the temperature range of 1030-1170 °С was performed for 3 hours. Existing phases in composites by X-ray Diffraction (XRD) and their structure were examined by Scanning Electron Microscopy (SEM) and while measuring mechanical properties of composites such as flexural strength, hardness and compared fracture toughness with base glass ceramic was performed. Results indicate that adding 2.5 percent micron-sized alumina to wollastonite glass-ceramics decreases the flexural strength from 8.01±120 to 10.26±50 MPa and its fracture toughness declines to 0.8±0.74, while by adding 2.5 percent nano-alumina to wollastonite glass – ceramics, the flexural strength increases from 8.01±120 to 20.7±133 MPa and its fracture toughness improves up to 1.40±10.

In this paper, a new method is introduced for evaluating effects of residual stress on fatigue life. The ability of ultrasonic method using longitudinal wave with critical angle of refraction or LCR wave in measuring and removing residual stresses due to welding was used. Two plates of alloy 2024-T351 were welded to each other. To measure their residual stress field acoustoelastic property was used and the changes in the speed of ultrasonic propagation of elastic waves when passing through the residual stress fields was investigated. In order to exert the effects of residual stress on fatigue life, the relations between the coefficients of effective stress intensity (SIF) and Fatigue Crack Propagation (FCP) rate in a state that the parts were welded together with residual stress under cyclic loading were obtained. Finally, ultrasonic waves with a certain frequency were used to remove the residual stresses. Also, the relationships between stress intensity factor and fatigue crack propagation rate were modified to predict fatigue life after removal of residual stresses. This method resulted in a 31% increase in fatigue life. The main reason for the increase in life was the plastic area created by the ultrasound wave. Therefore, it can be said that introduced method are suitable for using to remove residual stress due to welding.

Nowadays, different industries are using sheets, plates, and shells as important parts of their components. Because of their small thickness compare to other dimensions, their structural safety requires more attention. Therefore, increasing their strength and intensifying their resistance against any kind of failure type could be introduced as an important problem for enhancing the structural safety. Buckling is one of the most significant failure type that should be considered in the stability of any parts such as sheet metals. Thus, investigation of the buckling capacity of the sheet metals is remarkable. On the other hand, the existence of discontinuity like holes and notches in sheet metals can decrease their buckling capacity, significantly. In current study, based on Finite Element Method (FEM), ABAQUS/Explicit has been employed to determine the elastic buckling capacity in a perforated rectangular sheet metal with different boundary conditions on its edges. Afterward, the effect of the hole position and the plate aspect ratios (plate length/plate width) on the buckling capacity of sheet metal was studied. Finally, in order to enhance the sheet metal buckling capacity, two different types of stiffeners were used. The outcomes showed that the maximum buckling coefficient is related to the sheet metal which have four clamped edges. Moreover, For all boundary conditions, the buckling coefficient does not change significantly for the sheet metals with aspect ratio of more than 4. Also, stiffener type 2 increased the buckling capacity of sheet metal up to 83%.

In the present study, the hydraulic-thermal design and optimization of a gasketed-plate heat exchanger (GPHE) with an objective function of heat exchanger performance index (the amount of transferred heat exchange to pumping power ratio) is carried out. This process is made by considering 6 design parameters (the port diameter, plate thickness, the enlargement factor, the compressed plate pack length, the horizontal port distance, and the vertical port distance) and through the Bees Algorithm (BA). The present study achieved three solution sets for the design parameters by investigating the sensitivity of the design parameters heeded in the optimization of the GPHE. The design parameters in these three optimal solution sets were opted for in such a way that heat transfer increased by 41.6%, 34.55%, and 20.7%, and pressure drop decreased by 11.89%, 27%, and 83%, respectively.

 In this paper, the effect of the optimal position and minimum stiffness of the elastic middle support on increasing the fundamental frequency of a rotating cantilever beam is investigated based on the Courant’s maximum–minimum theorem using ABAQUS finite element software. First, the software analysis results are compared with the numerical analysis results for a non-rotating cantilever beam to confirm the accuracy of the software model. Next, by placing the middle elastic support at the optimal point selected based on the Courant theorem, the minimum stiffness of the elastic intermediate support for the maximum fundamental frequency of the rotating console beam was obtained. The results of this study prove that the Courant’s maximum–minimum theorem is completely valid for rotating cantilever beams and can be used to improve the vibrational behavior of rotating engineering components. Finally, the minimum diameter of damping wire for the turbomachine blade is calculated as a practical application of the minimum stiffness of the intermediate elastic support for the rotating beam.

In the present study, the effects of process and geometrical parameters on the maximum temperature of tool have been investigated. Simulation of mild steel machining process in different cutting depths, speed of rotation (SOR), feeding rates, and different rake angles was performed. To verify the simulation, numerical results were compared with experimental results. Based on the results, it was found that by increasing the speed of rotation at a constant cutting depth and a constant feed rate, the maximum temperature of the process experiences a significant increase. By increasing the depth of the cut, the geometric location of the workpiece maximum temperature was transmitted to the edge of the tool and surface changes occurred, which it was accompanied with increment in the depth of the cut. The tool with the rake angle of -10° and the depth of cutting of 2 mm had the highest recorded temperature due to the lack of sufficient space for removing chips from the work surface.

This study aims to the investigation of the effect of grid geometry on the modal response and buckling strength of a composite conical lattice structure under static axial loading by Finite Element Method (FEM). For this purpose, four structures with similar geometry have been designed through four grid structures. Abaqus finite element software has been used for modeling and analyzing the structures. The experimental results of Zamani and Ahmadifar study [1] have been used to validate the results of FEM. Given the results of numerical and experimental analysis, there is an accordance between the results and the FEM efficiency. The results show the contiguous natural frequency of the structures so that their negligible difference is due to the variations of structures’ weight and stiffness. Changing the grid does not affect the shape of the modes. The isogrid bears a higher buckling loading than the anisogrid. Reducing the rib angle is an effective parameter, which increases the buckling loading on the structure. Although peripheral ribs play a role in load bearing, adding their numbers increases the total weight of the structure, therefore, it has no significant effect on increasing the stability of the structure.