Journal of Modern Processes in Manufacturing and Production
Volume:11 Issue: 1, Winter 2022

New nano and micro thermoplastic-based composites are prepared with zeolite filler in this study. The method involves using zeolite in powder form, the preparation of zeolite powder from ores by crushing it into small-sized granules. The characteristics of the zeolite powder are determined. The physical properties and chemical composition (XRD) are evaluated before impeding it into the thermoplastic. Thermoplastics powder is added to the zeolite powder as granules in different sizes, the particles sizes ranging from the size of a millimeter to a nanometer.  The manufacturing quality parameters are optimized at volume percentages of filler in the range of 20 to 25%, composite material is formed into molds.  New Composite material is characterized by easy deformation into different shapes besides machineability. The characteristics of new composites such as SEM, EDX, and FTIR in absorption and transmission mode are evaluated and compared with the standard characteristics of Zeolite ores. The performance and characteristics of the new composite are completely different. The new composite is hard, solid, and does not absorb water.

This study looks into the various forms of corrosion that affect various elements of the South Pars Gas Company's first refinery's desalination plant, such as water compartments, tubular plates, support tubes, and the self-tube. To investigate the corrosion variables, a thorough analysis of the device's structure and process, as well as the material, was conducted. During repairs, damaged tubes were sampled and subjected to scanning electron microscopy, X-ray diffraction, and X-ray fluorescence testing. Evaluating scanning electron microscopy pictures from the inner surface of the tube reveals deformation and a rise in the tube's inner diameter. The X-ray diffraction patterns and elemental analysis by X-ray fluorescence show that the inner surface is corroded. The external surface of the tube and analysis of the diffraction patterns in this region reveal the formation of copper oxides on the outer surface of the tubes, which, when compared to electron microscopic images, distinguishes pitting corrosion caused by acid condensation collision on the outer surface of the tube. Finally, the major cause of the fracture was pitting corrosion.

In this paper bending and buckling characteristics of third-order shear, and deformation nanoplates were investigated using the modified couple stress theory and Navier type solution. It can be useful for designing and manufacturing micro-electromechanical and nano-electromechanical systems. The modified couple stress theory was applied to provide the possibility of considering the effects of small scales that have only one material length scale parameter. In this theory, the strain energy density is a function of the strain tensor components, curvature tensor, stress tensor, and the symmetric part of the couple stress tensor. After obtaining the strain energy, external work, and buckling equations, the Hamilton principle is employed to derive the governing equations. Furthermore, by applying boundary and loading conditions in the governing equations, the bending and buckling of a third-order shear deformation nanoplate with simply-supported bearings are obtained and the Navier’s solution is used to solve the equations. The results indicate that the third-order nanoplate subjected to sinusoidal loading yields smaller values of dimensionless bending than it does while subjected to uniform surface traction. It was also found that by increasing the length to thickness ratio, the value of the dimensionless bending of nanoplate decreases but by increasing the aspect ratio of the plate, this value increases. Furthermore, it was shown that the critical buckling load of the third-order nanoplate under uniaxial loading increases by increasing the ratio of the length scale parameter to the thickness of the nanoplate but it decreases by increasing the length to thickness ratio of the nanoplate.

In the current study, the deflection-electro polishing method was used to evaluate through-thickness residual stresses. A modified equation was developed to calculate the non-uniform residual stresses of creep-feed ground plates concerning the three-order polynomial curve fitting of the deflection in the specimens. Employing the current density of 825 A/m2 for the specimens caused stressed materials to be removed from their surface with the corrosion rate of 1 µ/min, which facilitated estimating the thickness of the removed layers concerning corrosion time. To investigate residual stresses created by creep-feed grinding, three different cooling conditions, i.e. dry, flood, and small quantity cooling lubrication (SQCL) were tested. The literature review showed a dearth of research on through-thickness residual stresses under SQCL creep-feed grinding. The results demonstrated that due to a considerably lower flow rate of the SQCL compared to that of the flood cooling system, considerable performance was detected so that compressive residual stresses were observed in the depth beneath the surface.

A hypereutectic Al-Si alloy piston has great potential for use in the automotive industry, especially for engine components, due to its lightweight, excellent castability, good thermal conductivity, high strength and excellent corrosion resistance. The silicon content in the A390 is between 17-18%. This article presents various shapes of dimples that can be fabricated on a cylindrical shape part of A390 using the turning process with aid of dynamic assisted tooling (DATT). To minimize the number of the experiment, the Taguchi method, with an L8 orthogonal array, was used to accommodate two different sets of seven parameters used in the fabrication of dimpled structures, i.e. cutting speed of 2-9 m/min, feed rate of 0.4-0.6 mm/rev, DOC of 0.05-0.01 mm, frequency of 15-28 Hertz, the amplitude of 1-3 mm, using two different cutting tool i) rake angle of +4o and -8.5o, relief angle of 4o and 7o, and nose radius of 0.4 and 0.8 mm, ii) Rake angle of +9° and -20°, and relief angle of +7° and +17°, and nose radius 8 mm. By using these turning parameters, 3 dimple shapes were produced; spherical, short drop and long drop shapes, with almost square and hexagonal arrays.

Biodiesel is a bio-renewable fuel derived from vegetable oils and animal fats with less environmental pollution than fossil fuels. This research aims to design, fabricate, and evaluate a hydrodynamic reactor for biodiesel production. According to the fluid characteristic, the rotor and stator were designed and the electric engine was chosen. The cavities of the rotor were designed for optimal cavitation. The effect of reaction time and rotational speed were examined to assess the reactor. Speed rotor rotational speed of hydrodynamic cavitation reactors can intensify the transesterification reaction by increasing the occurrence of cavitation in the space between the rotor and the stator. Therefore, to investigate the effect of this variable on biodiesel production efficiency, three levels were selected (2000, 2500, and 3000 rpm). As the rotational speed of the hydrodynamic reactor increases, the cavitation operation increases, and as a result, the conversion percentage rises too. This experiment indicated that the rise of residence time from 30 s to 60 s increases methyl esters yield, but following the time up to 60 s, the methyl esters yield has no significant changes. The results showed that the biodiesel produced from waste oil in the hydrodynamic reactor could be a suitable alternative to diesel.