Pub Date : 2024-09-04DOI: 10.1177/09544089241272774
Rui Xia, Bei Liu, Bo Li, Xuewen Wang
To investigate the wear characteristics and mechanisms of the scraper and groove side friction pair under various factors, this study utilizes the scraper conveyor SGZ1000/2 × 1200 as the prototype and designs a test bench with a similarity ratio of 1:6. The Plackett–Burman experiment is used to examine the significant effects of five key factors (running speed, normal load, particle size, gangue content, and groove side clearance) on the groove side wear. It reveals that gangue content exerts the most significant impact, while the normal load is relatively minor. The interaction between factors is studied through the Box–Behnken experimental design. By analyzing the interaction through the obtained second-order regression model, it can be concluded that the interaction between running speed and groove side clearance, as well as the interaction between running speed and particle size, exacerbates groove side wear. The significant factors are validated through single-factor experiments. To further analyze the variations in wear under each factor, the changes from the second to the fourth level of each single factor are selected and compared with other factors. The running speed increasing from 0.06 m/s to 0.12 m/s results in a 102.67% wear amount increase. A 95.21% increase occurs when the particle size increases from 1.5 mm to 2.5 mm. Gangue content exhibits the most significant impact, where the content increases from 8% to 25%, marking a 205.73% rise. The wear morphology shifts from shallow pits and furrows to deeper ones, accompanied by a noticeable increase in quantity. Conversely, the wear amount and morphology changes least in groove side clearance, when the groove side clearance increases from 0 mm to +1 mm, a decline of 63.47%. The morphology shifts from numerous deep pits and furrows to shallower and smaller ones, indicating the mildest abrasive wear phenomenon.
为了研究刮板与槽边摩擦副在各种因素作用下的磨损特性和机理，本研究以刮板输送机 SGZ1000/2 × 1200 为原型，设计了相似比为 1:6 的试验台。采用 Plackett-Burman 实验来检验五个关键因素（运行速度、正常载荷、粒度、煤矸石含量和槽边间隙）对槽边磨损的显著影响。结果表明，煤矸石含量的影响最大，而正常载荷的影响相对较小。通过 Box-Behnken 实验设计研究了各因素之间的相互作用。通过得到的二阶回归模型对交互作用进行分析，可以得出结论：运行速度与沟槽侧间隙之间的交互作用以及运行速度与粒度之间的交互作用加剧了沟槽侧磨损。通过单因素实验验证了这些重要因素。为了进一步分析各因素下的磨损变化，选择了各单因素从第二级到第四级的变化，并与其他因素进行比较。运行速度从 0.06 米/秒增加到 0.12 米/秒时，磨损量增加了 102.67%。当粒度从 1.5 mm 增加到 2.5 mm 时，磨损量增加了 95.21%。煤矸石含量的影响最大，含量从 8% 增加到 25%，增加了 205.73%。磨损形态从浅坑和沟槽转向深坑和沟槽，同时磨损量也明显增加。相反，槽侧间隙的磨损量和磨损形态变化最小，当槽侧间隙从 0 mm 增加到 +1 mm 时，磨损量和磨损形态下降了 63.47%。其形态从大量的深坑和沟槽变为较浅和较小的坑和沟槽，表明磨料磨损现象最轻。
{"title":"Experimental study on the friction and wear of the scraper and groove side friction pair under variable factors","authors":"Rui Xia, Bei Liu, Bo Li, Xuewen Wang","doi":"10.1177/09544089241272774","DOIUrl":"https://doi.org/10.1177/09544089241272774","url":null,"abstract":"To investigate the wear characteristics and mechanisms of the scraper and groove side friction pair under various factors, this study utilizes the scraper conveyor SGZ1000/2 × 1200 as the prototype and designs a test bench with a similarity ratio of 1:6. The Plackett–Burman experiment is used to examine the significant effects of five key factors (running speed, normal load, particle size, gangue content, and groove side clearance) on the groove side wear. It reveals that gangue content exerts the most significant impact, while the normal load is relatively minor. The interaction between factors is studied through the Box–Behnken experimental design. By analyzing the interaction through the obtained second-order regression model, it can be concluded that the interaction between running speed and groove side clearance, as well as the interaction between running speed and particle size, exacerbates groove side wear. The significant factors are validated through single-factor experiments. To further analyze the variations in wear under each factor, the changes from the second to the fourth level of each single factor are selected and compared with other factors. The running speed increasing from 0.06 m/s to 0.12 m/s results in a 102.67% wear amount increase. A 95.21% increase occurs when the particle size increases from 1.5 mm to 2.5 mm. Gangue content exhibits the most significant impact, where the content increases from 8% to 25%, marking a 205.73% rise. The wear morphology shifts from shallow pits and furrows to deeper ones, accompanied by a noticeable increase in quantity. Conversely, the wear amount and morphology changes least in groove side clearance, when the groove side clearance increases from 0 mm to +1 mm, a decline of 63.47%. The morphology shifts from numerous deep pits and furrows to shallower and smaller ones, indicating the mildest abrasive wear phenomenon.","PeriodicalId":20552,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering","volume":null,"pages":null},"PeriodicalIF":2.4,"publicationDate":"2024-09-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142204776","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
The entropy analysis and flow behavior of a mixed convective hybrid nanofluid [Formula: see text] across an exponentially stretching sheet were examined in this article using Tiwari-Das model in presence of thermal radiation, Joule heating, viscous dissipation, velocity slip, and thermal slip at the boundary with the idea of variable thermal conductivity which was yet to be studied by any researcher. This attests to the novelty of our study. The non-linear partial differential equations have been transformed into non-dimensional ordinary differential equations using similarity transformations, and the MATLAB bvp4c algorithm is used to solve it numerically. Comparisons were made with previously published studies which were found to be in great agreement. The temperature profile increases with increasing Eckert number [Formula: see text], variable thermal conductivity parameter [Formula: see text], buoyancy parameter [Formula: see text], volume fraction of nanoparticle parameter [Formula: see text], and radiation parameter [Formula: see text]. However, the opposite trend is observed when suction parameter [Formula: see text] is increased. It was observed that the fluid motion decreases as velocity slip [Formula: see text] increases and thermal slip [Formula: see text] behaves in the same manner on temperature profile. It is observed that, for differing values of Eckert number and radiation parameter, the skin friction coefficient leads to increase while the Nusselt number values decrease. An increased by 9.39% is observed for entropy production [Formula: see text] for a change in Brinkmann number [Formula: see text] from 0.5 to 2.0 while entropy production profile reduced by [Formula: see text] for changing the variable thermal conductivity parameter from [Formula: see text] to 1.5. Similarly, an increased by [Formula: see text] is observed for temperature profile for a change in radiation parameter from Rd = 0.10 to 1.50. The current study discovered use for it in glass fiber production, wire drawing stretching, aerodynamic plastic sheet extrusion, metallic plate cooling, etc.
{"title":"Irreversibility analysis on a radiative hybrid nanofluid flow across an exponentially stretching sheet with multiple slips and variable thermal conductivity","authors":"Rajesh Chary Kandukoori, Pranitha Janapatla, Anomitra Chakraborty","doi":"10.1177/09544089241276350","DOIUrl":"https://doi.org/10.1177/09544089241276350","url":null,"abstract":"The entropy analysis and flow behavior of a mixed convective hybrid nanofluid [Formula: see text] across an exponentially stretching sheet were examined in this article using Tiwari-Das model in presence of thermal radiation, Joule heating, viscous dissipation, velocity slip, and thermal slip at the boundary with the idea of variable thermal conductivity which was yet to be studied by any researcher. This attests to the novelty of our study. The non-linear partial differential equations have been transformed into non-dimensional ordinary differential equations using similarity transformations, and the MATLAB bvp4c algorithm is used to solve it numerically. Comparisons were made with previously published studies which were found to be in great agreement. The temperature profile increases with increasing Eckert number [Formula: see text], variable thermal conductivity parameter [Formula: see text], buoyancy parameter [Formula: see text], volume fraction of nanoparticle parameter [Formula: see text], and radiation parameter [Formula: see text]. However, the opposite trend is observed when suction parameter [Formula: see text] is increased. It was observed that the fluid motion decreases as velocity slip [Formula: see text] increases and thermal slip [Formula: see text] behaves in the same manner on temperature profile. It is observed that, for differing values of Eckert number and radiation parameter, the skin friction coefficient leads to increase while the Nusselt number values decrease. An increased by 9.39% is observed for entropy production [Formula: see text] for a change in Brinkmann number [Formula: see text] from 0.5 to 2.0 while entropy production profile reduced by [Formula: see text] for changing the variable thermal conductivity parameter from [Formula: see text] to 1.5. Similarly, an increased by [Formula: see text] is observed for temperature profile for a change in radiation parameter from Rd = 0.10 to 1.50. The current study discovered use for it in glass fiber production, wire drawing stretching, aerodynamic plastic sheet extrusion, metallic plate cooling, etc.","PeriodicalId":20552,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering","volume":null,"pages":null},"PeriodicalIF":2.4,"publicationDate":"2024-09-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142204774","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-09-02DOI: 10.1177/09544089241274045
Sana Nasir, Sabir Ali Shehzad, Tabinda Khattab
The nanofluids have well-known implications in pharmaceutical industries, microelectronics, heat exchangers, engine cooling, hybrid-powered engines, thermal management of vehicles, refrigerator, machining, chillers, grinding, and in boiler fuel to reduce the gas temperature. Due to such dominant implications of nanofluids, the boundary layer Reiner-Rivlin nanomaterial flow over chemically reactive stretched sheet is considered. Radiation term is incorporated in the energy equation for heat transportation analysis. Newtonian thermal and solutal conditions are implemented at the boundaries of the surface. Similarity variables are utilized for the conversion of nonlinear partial differential equations into the system of one independent variable equations. The resulted system of equations is calculated analytically with the help of homotopy analysis method. Convergence of the calculated results is verified through plots and numeric benchmark. The results of various pertinent parameters on quantities of physical importance are drawn and discussed in detail. Results revealed that the incremented cross viscous constraint resulted higher velocity and lower temperature profiles. An augmentation in radiative constraint gives rise to temperature field. Concentration and temperature have reverse trends against the rising Brownian motion constraint values.
{"title":"Thermally radiative chemically reactive flow of Reiner-Rivlin nanofluid through porous medium with Newtonian conditions","authors":"Sana Nasir, Sabir Ali Shehzad, Tabinda Khattab","doi":"10.1177/09544089241274045","DOIUrl":"https://doi.org/10.1177/09544089241274045","url":null,"abstract":"The nanofluids have well-known implications in pharmaceutical industries, microelectronics, heat exchangers, engine cooling, hybrid-powered engines, thermal management of vehicles, refrigerator, machining, chillers, grinding, and in boiler fuel to reduce the gas temperature. Due to such dominant implications of nanofluids, the boundary layer Reiner-Rivlin nanomaterial flow over chemically reactive stretched sheet is considered. Radiation term is incorporated in the energy equation for heat transportation analysis. Newtonian thermal and solutal conditions are implemented at the boundaries of the surface. Similarity variables are utilized for the conversion of nonlinear partial differential equations into the system of one independent variable equations. The resulted system of equations is calculated analytically with the help of homotopy analysis method. Convergence of the calculated results is verified through plots and numeric benchmark. The results of various pertinent parameters on quantities of physical importance are drawn and discussed in detail. Results revealed that the incremented cross viscous constraint resulted higher velocity and lower temperature profiles. An augmentation in radiative constraint gives rise to temperature field. Concentration and temperature have reverse trends against the rising Brownian motion constraint values.","PeriodicalId":20552,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering","volume":null,"pages":null},"PeriodicalIF":2.4,"publicationDate":"2024-09-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142204777","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-09-02DOI: 10.1177/09544089241276353
VS Winstor Jebakumar, V Rajkumar, S Vijayan, A Veerakumar
Water scarcity within the world may be an enormous threat to living beings. Potable water can be produced by renewable energy using solar desalination. In the quest for efficient water desalination methods, researchers have turned to solar stills as a promising solution. One approach to enhancing the productivity of solar stills is the utilization of copper-coated sponge cubes. These cubes, when integrated into the still, provide extended heating periods, leading to higher temperature differences. This, in turn, improves freshwater production by improving the performance of the modified still. In this work, three basin-type solar stills of each 0.5 m2 area have been studied experimentally in the location of Coimbatore, Tamil Nadu. Comparative studies were done between the solar still modified with sponge materials and the modified solar still with sponges coated with copper powder. In these experimental studies, the various performance characteristics related to solar still efficiency have been examined. The sponges were placed inside the water of the basin. The commercially available copper powder was prepared like a paste and coated in the sponges, and it was increased in size to 0.005 m on all sides. The sponges pasted with copper powder reduce the energy losses from the still due to its high thermal conductivity and the evaporation rate also increased by the capillary action of the sponge. High heat transfer to water also occurred due to the addition of copper powder. From the comparative studies, the solar still with sponge materials coated with copper powder gives a higher yield. The proposed solar still with modifications improves efficiency. The solar still without modification gives a yield of 1.3 kg/day, the modified still with sponges gives an output of 1.5 kg/day and the modified still with copper-coated sponges gives an output of 2.35 kg/day. The copper-coated sponge cubes placed still produced an efficiency of 60.07%.
{"title":"The efficiency of solar stills with copper-coated sponge cubes for water desalination: A comparative study","authors":"VS Winstor Jebakumar, V Rajkumar, S Vijayan, A Veerakumar","doi":"10.1177/09544089241276353","DOIUrl":"https://doi.org/10.1177/09544089241276353","url":null,"abstract":"Water scarcity within the world may be an enormous threat to living beings. Potable water can be produced by renewable energy using solar desalination. In the quest for efficient water desalination methods, researchers have turned to solar stills as a promising solution. One approach to enhancing the productivity of solar stills is the utilization of copper-coated sponge cubes. These cubes, when integrated into the still, provide extended heating periods, leading to higher temperature differences. This, in turn, improves freshwater production by improving the performance of the modified still. In this work, three basin-type solar stills of each 0.5 m<jats:sup>2</jats:sup> area have been studied experimentally in the location of Coimbatore, Tamil Nadu. Comparative studies were done between the solar still modified with sponge materials and the modified solar still with sponges coated with copper powder. In these experimental studies, the various performance characteristics related to solar still efficiency have been examined. The sponges were placed inside the water of the basin. The commercially available copper powder was prepared like a paste and coated in the sponges, and it was increased in size to 0.005 m on all sides. The sponges pasted with copper powder reduce the energy losses from the still due to its high thermal conductivity and the evaporation rate also increased by the capillary action of the sponge. High heat transfer to water also occurred due to the addition of copper powder. From the comparative studies, the solar still with sponge materials coated with copper powder gives a higher yield. The proposed solar still with modifications improves efficiency. The solar still without modification gives a yield of 1.3 kg/day, the modified still with sponges gives an output of 1.5 kg/day and the modified still with copper-coated sponges gives an output of 2.35 kg/day. The copper-coated sponge cubes placed still produced an efficiency of 60.07%.","PeriodicalId":20552,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering","volume":null,"pages":null},"PeriodicalIF":2.4,"publicationDate":"2024-09-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142204778","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
As an aluminum-based reinforcement, Mg2Si particles have excellent properties such as high hardness, high melting point, and high elastic modulus compared with other reinforcements and are widely used in aerospace and automobile fields. However, there is little research on the cutting mechanism of this material. In order to explore the surface grinding mechanism of Mg2Si/Al composites, Grinding simulation of low-volume fraction Mg2Si/Al composites was carried out by ABAQUS, and the influence of different positions of matrix and particle removal on the surface quality of Mg2Si/Al composites was expounded. The plane reverse grinding test was carried out by using CBN (boron nitride) grinding wheel. The L16(43) orthogonal test and three groups of single factor tests were designed. The orthogonal results show that the linear velocity of the grinding wheel has the greatest influence on the surface roughness, and the feed rate and grinding depth are significantly smaller. The range analysis shows that the optimal grinding parameters are: vs = 35 m/s, vw = 0.75 m/min, ap = 0.015 mm. The regression equation for surface roughness was established by using MATLAB. The single factor results show that the surface quality is obviously improved by increasing the linear velocity of the grinding wheel and reducing the feed rate and grinding depth through the observation of the morphology of the processed specimen. The analysis results show that defects such as pits, protrusions, burrs, and a small amount of fish-scale-like on the machined surface are mainly caused by the linear velocity of the grinding wheel, the pulling force of the grinding wheel, and the adhesion of the debris. The defects such as particle micro-cracks, particle pull-out, and matrix cracking on the subsurface, are mainly caused by the compressive stress of the grinding wheel and the stress concentration of the particles. The research results have guiding significance for future composite material cutting research and actual cutting processing.
{"title":"Experimental study on grinding process of Al-Mg2Si aluminum matrix composites","authors":"Hailong Sun, Qi Gao, Quanzhao Wang, Bintong Zhao, Dake Yun","doi":"10.1177/09544089241272755","DOIUrl":"https://doi.org/10.1177/09544089241272755","url":null,"abstract":"As an aluminum-based reinforcement, Mg<jats:sub>2</jats:sub>Si particles have excellent properties such as high hardness, high melting point, and high elastic modulus compared with other reinforcements and are widely used in aerospace and automobile fields. However, there is little research on the cutting mechanism of this material. In order to explore the surface grinding mechanism of Mg<jats:sub>2</jats:sub>Si/Al composites, Grinding simulation of low-volume fraction Mg<jats:sub>2</jats:sub>Si/Al composites was carried out by ABAQUS, and the influence of different positions of matrix and particle removal on the surface quality of Mg<jats:sub>2</jats:sub>Si/Al composites was expounded. The plane reverse grinding test was carried out by using CBN (boron nitride) grinding wheel. The L<jats:sub>16</jats:sub>(4<jats:sup>3</jats:sup>) orthogonal test and three groups of single factor tests were designed. The orthogonal results show that the linear velocity of the grinding wheel has the greatest influence on the surface roughness, and the feed rate and grinding depth are significantly smaller. The range analysis shows that the optimal grinding parameters are: v<jats:sub>s </jats:sub>= 35 m/s, v<jats:sub>w </jats:sub>= 0.75 m/min, a<jats:sub>p </jats:sub>= 0.015 mm. The regression equation for surface roughness was established by using MATLAB. The single factor results show that the surface quality is obviously improved by increasing the linear velocity of the grinding wheel and reducing the feed rate and grinding depth through the observation of the morphology of the processed specimen. The analysis results show that defects such as pits, protrusions, burrs, and a small amount of fish-scale-like on the machined surface are mainly caused by the linear velocity of the grinding wheel, the pulling force of the grinding wheel, and the adhesion of the debris. The defects such as particle micro-cracks, particle pull-out, and matrix cracking on the subsurface, are mainly caused by the compressive stress of the grinding wheel and the stress concentration of the particles. The research results have guiding significance for future composite material cutting research and actual cutting processing.","PeriodicalId":20552,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering","volume":null,"pages":null},"PeriodicalIF":2.4,"publicationDate":"2024-09-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142204775","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
The significance of welded connections in steel structures necessitates precise structural designs and processing adaptations to ensure robust mechanical strength and durability. Gas metal arc welding (GMAW) employing controlled curves presents advantages over conventional methods, offering enhanced weld bead properties, improved aesthetics, and reduced thermal inputs. This research investigates the impact of GMAW parameters using controlled curves on the microstructure and geometry of welds between dissimilar structural steels—duplex stainless steel 2205 and stainless steel 316L grade 50—commonly employed in construction. The aim is to optimize the GMAW welding process with controlled curves and surface tension transfer between these dissimilar steels. Through a 23-factorial experimental design encompassing feed speed (Va), arc focus (FC), and peak-to-base amplitude (APB), the study examines welding energy, geometry, deposition efficiency, microstructure, microhardness, tensile strength, and corrosion properties. Optimal welding energy fosters refined microstructures and uniform hardness, aiding in predicting weld throat area. Higher energy levels expand the heat-affected zone and coarse grains, while lower energies escalate variability. Predictive models facilitate fine-tuning welding energy and throat area for desirable properties and penetration while minimizing disruptions. This process optimization can be achieved by employing derived equations that limit welding energy and curve parameters, striking a desired balance between cost, structural integrity, and reliability.
{"title":"Optimization of gas metal arc welding parameters for dissimilar steel welds: A case study on duplex stainless steel 2205 and stainless steel 316L","authors":"Veerakumar Sengottaiyan, Krishnamurthy Kasilingam, Meenakshipriya Balasubramaniam, Arunkumar Munimathan","doi":"10.1177/09544089241272807","DOIUrl":"https://doi.org/10.1177/09544089241272807","url":null,"abstract":"The significance of welded connections in steel structures necessitates precise structural designs and processing adaptations to ensure robust mechanical strength and durability. Gas metal arc welding (GMAW) employing controlled curves presents advantages over conventional methods, offering enhanced weld bead properties, improved aesthetics, and reduced thermal inputs. This research investigates the impact of GMAW parameters using controlled curves on the microstructure and geometry of welds between dissimilar structural steels—duplex stainless steel 2205 and stainless steel 316L grade 50—commonly employed in construction. The aim is to optimize the GMAW welding process with controlled curves and surface tension transfer between these dissimilar steels. Through a 2<jats:sup>3</jats:sup>-factorial experimental design encompassing feed speed (Va), arc focus (FC), and peak-to-base amplitude (APB), the study examines welding energy, geometry, deposition efficiency, microstructure, microhardness, tensile strength, and corrosion properties. Optimal welding energy fosters refined microstructures and uniform hardness, aiding in predicting weld throat area. Higher energy levels expand the heat-affected zone and coarse grains, while lower energies escalate variability. Predictive models facilitate fine-tuning welding energy and throat area for desirable properties and penetration while minimizing disruptions. This process optimization can be achieved by employing derived equations that limit welding energy and curve parameters, striking a desired balance between cost, structural integrity, and reliability.","PeriodicalId":20552,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering","volume":null,"pages":null},"PeriodicalIF":2.4,"publicationDate":"2024-09-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142226206","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-08-30DOI: 10.1177/09544089241276329
G Suganya Priyadharshini, M Vijayan, Indran Suyambulingam, Suchart Siengchin, A Eakambaram
The increasing demand for sustainable and eco-friendly materials in engineering and construction industries has led to extensive research in the development of alternative fibers for composite materials. This study explores the potential of combining jute and basalt fibers to create a novel composite material with enhanced mechanical and environmental properties. The present investigation focused on developing a Jute/basalt hybrid composite by adding a Zirconium carbide filler using compression molding technique. The filler percentage was varied as 0 wt.%, 0.5 wt.%, 1 wt.%, 1.5 wt.% and 2 wt.% in an epoxy resin matrix. Mechanical tests were performed to determine the tensile strength, flexural strength, and impact resistance of the composite materials. The composites’ microstructure was studied using FESEM to understand fiber-matrix interactions. Preliminary results indicate that the combination of jute and basalt fibers in composite materials can yield a balance between strength and sustainability. The present work indicates promising developments in composite materials, with 1.5 wt.% demonstrating a significant 37.7% increase in tensile strength when compared to pure jute/basalt composite. In terms of flexural strength, the addition of 1.5 wt.% nanofiller resulted in a remarkable 112.4% enhancement in flexural strength compared to the absence of ZrC laminate. In addition, the presence of ZrC significantly enhances the impact strength. Specifically, the addition of 1 wt.% and 1.5 wt.% results in increased strengths of 98.2 J/m and 99.2 J/m, respectively.
{"title":"Sustainable engineering applications using jute-basalt fiber reinforced composites: A material characterization study","authors":"G Suganya Priyadharshini, M Vijayan, Indran Suyambulingam, Suchart Siengchin, A Eakambaram","doi":"10.1177/09544089241276329","DOIUrl":"https://doi.org/10.1177/09544089241276329","url":null,"abstract":"The increasing demand for sustainable and eco-friendly materials in engineering and construction industries has led to extensive research in the development of alternative fibers for composite materials. This study explores the potential of combining jute and basalt fibers to create a novel composite material with enhanced mechanical and environmental properties. The present investigation focused on developing a Jute/basalt hybrid composite by adding a Zirconium carbide filler using compression molding technique. The filler percentage was varied as 0 wt.%, 0.5 wt.%, 1 wt.%, 1.5 wt.% and 2 wt.% in an epoxy resin matrix. Mechanical tests were performed to determine the tensile strength, flexural strength, and impact resistance of the composite materials. The composites’ microstructure was studied using FESEM to understand fiber-matrix interactions. Preliminary results indicate that the combination of jute and basalt fibers in composite materials can yield a balance between strength and sustainability. The present work indicates promising developments in composite materials, with 1.5 wt.% demonstrating a significant 37.7% increase in tensile strength when compared to pure jute/basalt composite. In terms of flexural strength, the addition of 1.5 wt.% nanofiller resulted in a remarkable 112.4% enhancement in flexural strength compared to the absence of ZrC laminate. In addition, the presence of ZrC significantly enhances the impact strength. Specifically, the addition of 1 wt.% and 1.5 wt.% results in increased strengths of 98.2 J/m and 99.2 J/m, respectively.","PeriodicalId":20552,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering","volume":null,"pages":null},"PeriodicalIF":2.4,"publicationDate":"2024-08-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142204802","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-08-30DOI: 10.1177/09544089241278080
Pujari Chinna Peddaiah, Srihari Dodla
Aerospace materials like Ti6Al4V and Inconel 718 have exceptional abilities such as high strength, good corrosion resistance, and low specific weight. These properties make them difficult to machine due to rapid tool wear, high cutting forces, and heat generation. Microstructural characterization has been performed for these alloys to identify the phases and precipitates. With the help of machining simulations, experimental trial and error can be avoided. Numerical simulations predict the behavior of materials like Ti6Al4V and Inconel 718 under various machining conditions. They provide insights into stress distribution, temperature rise, and chip formation, which are crucial for understanding how these materials respond to machining. By simulating different cutting parameters (e.g. speed, feed rate, and depth of cut), optimal conditions can be identified to minimize tool wear, improve surface finish, and reduce machining time. Achieving a high-quality surface finish is challenging with these materials. Simulations can predict the impact of different machining parameters on surface integrity, allowing for adjustments before actual machining. Three-dimensional finite element-based machining simulations are performed using the ABAQUS. The current work includes Johnson-Cook damage model parameters included in the simulation with the aid of the program ABAQUS/EXPLICIT. The numerous sets of tests carried out are also stated, along with the workpiece and tool-optimized geometry. The outcomes for cutting forces about time for Ti6Al4V and Inconel 718 are retrieved. The arbitrary Lagrangian–Eulerian approach has been used for these simulations. A coupled thermo-mechanical study is conducted on different sets of materials under various machining conditions. In addition, ultrasonic-assisted cutting on aerospace materials is also being studied, along with a comparison of the cutting forces used by conventional cutting. On the surfaces of aerospace materials that have been machined, temperature and von Mises stress distribution are discussed for both ultrasonic-assisted cutting and conventional cutting. The reaction forces generated for titanium alloy Ti6Al4V under conventional cutting are cutting force (RF3), and the thrust force (RF2) were 56 and 14 N, respectively. For the Inconel 718, the cutting and thrust forces are 75 and 27 N, respectively. The maximum temperature and stress under conventional cutting attained in Ti6Al4V are 670 K and 1.74 GPa, respectively. For the Inconel 718, the maximum temperature and stress under conventional cutting are 596 K and 1.65 GPa. There is a reduction in the forces, maximum temperature, and stress for the ultrasonic-assisted cutting.
航空航天材料（如 Ti6Al4V 和 Inconel 718）具有高强度、良好的耐腐蚀性和低比重等优异性能。这些特性使它们难以加工，因为刀具磨损快、切削力大、发热量高。已对这些合金进行了微结构表征，以确定相和析出物。在加工模拟的帮助下，可以避免实验试验和错误。数值模拟可预测 Ti6Al4V 和 Inconel 718 等材料在各种加工条件下的行为。它们提供了对应力分布、温升和切屑形成的深入了解，这对理解这些材料如何应对加工至关重要。通过模拟不同的切削参数（如速度、进给量和切削深度），可以确定最佳条件，从而最大限度地减少刀具磨损、提高表面光洁度并缩短加工时间。对于这些材料来说，实现高质量的表面光洁度是一项挑战。模拟可以预测不同加工参数对表面完整性的影响，以便在实际加工前进行调整。我们使用 ABAQUS 进行了基于有限元的三维加工模拟。目前的工作包括借助 ABAQUS/EXPLICIT 程序在模拟中加入约翰逊-库克损伤模型参数。此外，还说明了所进行的多组测试，以及工件和刀具的优化几何形状。对 Ti6Al4V 和 Inconel 718 的切削力随时间变化的结果进行了检索。这些模拟采用了任意的拉格朗日-欧勒方法。对不同加工条件下的不同材料进行了热机械耦合研究。此外，还对航空航天材料的超声波辅助切割进行了研究，并对传统切割所使用的切割力进行了比较。在已加工的航空航天材料表面上，讨论了超声波辅助切割和传统切割的温度和 von Mises 应力分布。钛合金 Ti6Al4V 在传统切削下产生的反作用力为切削力（RF3）和推力（RF2），分别为 56 N 和 14 N。Inconel 718 的切削力和推力分别为 75 N 和 27 N。Ti6Al4V 在传统切削条件下达到的最高温度和应力分别为 670 K 和 1.74 GPa。对于铬镍铁合金 718，常规切割下的最高温度和应力分别为 596 K 和 1.65 GPa。超声波辅助切割的作用力、最高温度和应力都有所降低。
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Pub Date : 2024-08-30DOI: 10.1177/09544089241276692
Saleh S Abdelhady, Ahmed Nabhan, Said H Zoalfakar, Rehab E Elbadawi
The present study is an attempt to investigate the tribological behavior of friction stir processing (FSP) AA6061-T6 alloy reinforced with boron carbide (B4C) particles. The surface composites were developed to investigate wear performance and surface roughness under dry sliding conditions. The experiments were conducted using response surface methodology (RSM) to examine the effects of various B4C volume fractions, applied loads, and sliding distances. All combinations of reinforcements in AA6061-T6 hybrid composites show a good improvement in the wear properties. The results show that the wear behavior of composites is significantly impacted by the incorporation of B4C particles. This is mostly owing to the uniformity that the B4C particles developed when they distributed the reinforcements evenly in the AA 6061-T6 matrix. Analysis of variance, main effect and three-dimensional plots were used to quantify the effects of dry sliding parameters on tribological properties. The findings showed that the optimal parameters for the effective reduction of specific wear rate and coefficient of friction were a volume fraction of 10%, an applied load of 20 N, and a sliding distance of 500 m. To minimize surface roughness, the optimal test conditions were found to be 10% volume fraction, 40 N applied load, and 2500 m sliding distance. The wear surface was analyzed using energy dispersive spectroscopy (EDX) and scanning electron microscopy (SEM). The results showed that oxide layer formation was present on the wear surface and adhesive wear was the primary wear mechanism.
本研究试图研究用碳化硼（B4C）颗粒增强的摩擦搅拌加工（FSP）AA6061-T6 合金的摩擦学行为。表面复合材料的开发是为了研究干滑动条件下的磨损性能和表面粗糙度。实验采用响应面方法 (RSM) 来研究各种 B4C 体积分数、外加载荷和滑动距离的影响。AA6061-T6 混合复合材料中的所有增强剂组合都能很好地改善磨损性能。结果表明，B4C 颗粒的加入对复合材料的磨损行为有显著影响。这主要是由于 B4C 颗粒在 AA 6061-T6 基体中均匀分布增强材料时产生的均匀性。采用方差分析、主效应和三维图来量化干滑动参数对摩擦学特性的影响。研究结果表明，有效降低比磨损率和摩擦系数的最佳参数是 10%的体积分数、20 N 的外加载荷和 500 米的滑动距离；要使表面粗糙度最小，最佳试验条件是 10%的体积分数、40 N 的外加载荷和 2500 米的滑动距离。使用能量色散光谱（EDX）和扫描电子显微镜（SEM）对磨损表面进行了分析。结果表明，磨损表面有氧化层形成，粘着磨损是主要的磨损机制。
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Pub Date : 2024-08-30DOI: 10.1177/09544089241275860
Dushyant Dubey, Satinder Paul Singh, Bijoya Kumar Behera
This review paper systematically classifies additive manufacturing (AM) or 3D printing techniques according to American Society for Testing and Materials (ASTM) standards, which categorize these technologies into seven main groups: vat photopolymerization, material extrusion, powder-bed fusion, material jetting (MJT), binder jetting, direct energy deposition, and sheet lamination. Each of these categories is further subdivided into specific subcategories, providing a comprehensive framework to understand the diverse landscape of AM technologies. By leveraging these ASTM standards, our review aims to offer a structured and detailed overview of the capabilities and advancements within each AM technique. Recent studies and developments are incorporated to highlight the evolution of these technologies, showcasing innovations that have improved precision, material compatibility, and efficiency in manufacturing processes. Furthermore, the review critically examines the materials used, advantages, and limitations associated with each technique, exploring their applications across various industries such as aerospace, automotive, healthcare, defense, and consumer goods.
本综述论文根据美国材料与试验协会 (ASTM) 标准对增材制造 (AM) 或三维打印技术进行了系统分类，将这些技术分为七大类：大桶光聚合、材料挤压、粉末床熔融、材料喷射 (MJT)、粘合剂喷射、直接能量沉积和薄片层压。每个类别又进一步细分为特定的子类别，为了解 AM 技术的多样性提供了一个全面的框架。通过利用这些 ASTM 标准，我们的综述旨在对每种 AM 技术的能力和进步进行结构化的详细概述。最新的研究和发展被纳入其中，以突出这些技术的演变，展示提高了制造工艺的精度、材料兼容性和效率的创新。此外，该综述还严格审查了与每种技术相关的所用材料、优势和局限性，探讨了它们在航空航天、汽车、医疗保健、国防和消费品等各个行业的应用。
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