Pub Date : 2024-08-19DOI: 10.1177/09544089241271882
Raj Kumar, Mohammad Mursaleen, G.A. Harmain
This study investigates the monotonic tensile behavior of magnesium (Mg) alloy AZ31B across a temperature range from ambient (25 °C) to elevated (up to 300 °C) with varying strain rates (SR) (1.5 × 10−2 to 1.5 × 10−4 s−1). Mechanical properties such as ultimate tensile strength ( σu), tensile yield strength ( σy), strain to failure ( εf), plastic anisotropy ( r-value), strain rate sensitivity ( m) and strain hardening exponent ( n) were investigated in this study for these strain rates. As the temperature increased from 25 to 300 °C, the following changes in mechanical properties were observed: the yield strength ( σy) decreased by 84.50%, the ultimate tensile strength ( σu) decreased by 87%, the modulus of elasticity ( E) decreased by 63.0%, and the elongation increased by 72.0%. The reduction factors (RF) were proposed for the above-mentioned mechanical properties for varying temperature ranges. The impact of varying temperatures and strain rates on fracture surfaces was investigated using field emission scanning electron microscopy (FE-SEM). The results revealed the presence of tenacity nets, cleavage patterns, and an increasing number of dimples as temperatures increased.
{"title":"Varying strain rates and elevated temperatures effects on the mechanical properties of AZ31B magnesium alloy","authors":"Raj Kumar, Mohammad Mursaleen, G.A. Harmain","doi":"10.1177/09544089241271882","DOIUrl":"https://doi.org/10.1177/09544089241271882","url":null,"abstract":"This study investigates the monotonic tensile behavior of magnesium (Mg) alloy AZ31B across a temperature range from ambient (25 °C) to elevated (up to 300 °C) with varying strain rates (SR) (1.5 × 10<jats:sup>−2</jats:sup> to 1.5 × 10<jats:sup>−4</jats:sup> s<jats:sup>−1</jats:sup>). Mechanical properties such as ultimate tensile strength ( σ<jats:sub>u</jats:sub>), tensile yield strength ( σ<jats:sub>y</jats:sub>), strain to failure ( ε<jats:sub>f</jats:sub>), plastic anisotropy ( r-value), strain rate sensitivity ( m) and strain hardening exponent ( n) were investigated in this study for these strain rates. As the temperature increased from 25 to 300 °C, the following changes in mechanical properties were observed: the yield strength ( σ<jats:sub>y</jats:sub>) decreased by 84.50%, the ultimate tensile strength ( σ<jats:sub>u</jats:sub>) decreased by 87%, the modulus of elasticity ( E) decreased by 63.0%, and the elongation increased by 72.0%. The reduction factors (RF) were proposed for the above-mentioned mechanical properties for varying temperature ranges. The impact of varying temperatures and strain rates on fracture surfaces was investigated using field emission scanning electron microscopy (FE-SEM). The results revealed the presence of tenacity nets, cleavage patterns, and an increasing number of dimples as temperatures increased.","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":"2024-08-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142204850","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 : 2024-08-19DOI: 10.1177/09544089241271825
N Vijay Krishna, S Manikandan
The thermal performance of a Peltier thermoelectric cooler (TEC) can be enhanced by multi-staging, modifying the geometry of the thermoelement, and using new material with improved thermoelectric properties. This study utilizes COMSOL multiphysics to simulate thermomechanical analyses of various geometries of thermoelectric coolers under pulse current conditions. This investigation explores the influence of pulse current parameters, such as pulse width, pulse ratio, and hot-side convective heat transfer coefficient, on a thermoelectric cooler with different leg geometries. Additionally, the impact of the TEC cold-side temperature, hot-side temperature, and thermal stress on both sides is discussed. The results indicate that TEC leg shapes, such as pin and trapezoid, exhibit the minimum cold-side temperature. Increasing the pulse ratio leads to a decrease in the cold-side temperature and an increase in the hot-side temperature. A notable improvement in the cold-side temperature is also observed with higher pulse ratios, with the pin geometry achieving a minimum cold-side temperature of 276 K. Furthermore, the cooling load affects the temperature on both sides of the TEC. These findings provide valuable insights for optimizing thermoelectric coolers for electronic cooling applications using pulse current methods.
{"title":"Computational study of pulse current and thermal stress on thermoelectric cooler","authors":"N Vijay Krishna, S Manikandan","doi":"10.1177/09544089241271825","DOIUrl":"https://doi.org/10.1177/09544089241271825","url":null,"abstract":"The thermal performance of a Peltier thermoelectric cooler (TEC) can be enhanced by multi-staging, modifying the geometry of the thermoelement, and using new material with improved thermoelectric properties. This study utilizes COMSOL multiphysics to simulate thermomechanical analyses of various geometries of thermoelectric coolers under pulse current conditions. This investigation explores the influence of pulse current parameters, such as pulse width, pulse ratio, and hot-side convective heat transfer coefficient, on a thermoelectric cooler with different leg geometries. Additionally, the impact of the TEC cold-side temperature, hot-side temperature, and thermal stress on both sides is discussed. The results indicate that TEC leg shapes, such as pin and trapezoid, exhibit the minimum cold-side temperature. Increasing the pulse ratio leads to a decrease in the cold-side temperature and an increase in the hot-side temperature. A notable improvement in the cold-side temperature is also observed with higher pulse ratios, with the pin geometry achieving a minimum cold-side temperature of 276 K. Furthermore, the cooling load affects the temperature on both sides of the TEC. These findings provide valuable insights for optimizing thermoelectric coolers for electronic cooling applications using pulse current methods.","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":"2024-08-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142226080","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 : 2024-08-19DOI: 10.1177/09544089241271822
Kamal Kumar Mittal, Alok Vardhan
Various manufacturing companies produce different components, parts, or entire products based on market demands. These needs are met by a variety of manufacturing systems. However, in today's dynamic environment where production capacities and company capabilities are subject to change, reconfigurable manufacturing systems (RMS) have emerged as crucial resources. At the heart of RMS lies the reconfigurable machine tool (RMT), which is designed with modular components to adapt to varying requirements. Evaluating the performance of RMS requires an index. This paper employs weighted sum theory to map various characteristics of RMS and develop a cumulative reconfigurability index. To illustrate the applicability of this methodology, a case study is presented, examining both machine and system levels. There are four configurations having eight RMTs arranged in different manner. The cumulative reconfigurability index is calculated for each configuration and the optimal configuration is selected. From this research, it has been observed that the reconfigurability index of system (d) is the highest, with system (a) having a value close to that of system (d).
{"title":"Optimal configuration selection in reconfigurable manufacturing system considering variable production rate","authors":"Kamal Kumar Mittal, Alok Vardhan","doi":"10.1177/09544089241271822","DOIUrl":"https://doi.org/10.1177/09544089241271822","url":null,"abstract":"Various manufacturing companies produce different components, parts, or entire products based on market demands. These needs are met by a variety of manufacturing systems. However, in today's dynamic environment where production capacities and company capabilities are subject to change, reconfigurable manufacturing systems (RMS) have emerged as crucial resources. At the heart of RMS lies the reconfigurable machine tool (RMT), which is designed with modular components to adapt to varying requirements. Evaluating the performance of RMS requires an index. This paper employs weighted sum theory to map various characteristics of RMS and develop a cumulative reconfigurability index. To illustrate the applicability of this methodology, a case study is presented, examining both machine and system levels. There are four configurations having eight RMTs arranged in different manner. The cumulative reconfigurability index is calculated for each configuration and the optimal configuration is selected. From this research, it has been observed that the reconfigurability index of system (d) is the highest, with system (a) having a value close to that of system (d).","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":"2024-08-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142204849","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 : 2024-08-16DOI: 10.1177/09544089241270849
Prajwal Agrawal, Shivam Kenche, T Sampath Kumar
In recent years, super duplex stainless steel (SDSS) has gained a lot of importance due to its strength and excellent resistance to corrosion cracking for applications in marine and chemical processing industries, etc. In spite of various progress in the field, the drilling of SDSS leads to the formation of chips that are very strong and abrasive, which makes it challenging to have proper drilling. To overcome this issue by utilizing suitable parameters such as drill bit coating, environmental conditions and parameters for drilling. The SDSS machining output results were compared for both dry and minimum quantity lubrication (MQL) conditions using coated and uncoated drill bits. A scalable pulse power plasma (S3P) technique was utilized to deposit the titanium silicon nitride (TiSiN) and aluminum titanium nitride (AlTiN) coatings on solid carbide drill bits. In the experiments, three levels of drilling parameters have been chosen, including spindle speed (550, 700, 850 rpm), feed rate (0.035, 0.045, 0.060 m/min), and drill bit types. The experiment was designed using Taguchi's orthogonal L9 array. The influence of machining parameters such as cutting force, surface roughness, and circularity error were examined using variance analysis (ANOVA) and signal-to-noise (S/N) ratios. To enhance the drilling process parameters through a single comprehensive output measure, the obtained results were taken as an input to the fuzzy logic networks using multi-factor analysis. At the L7 trial, the least cutting force was observed at 525.7 N for dry conditions and 227.6 N for MQL conditions and gave cone-spiral and continuous chips. In order to analyze the signal-to-noise ratio effectively, high value correspond to better-quality characteristics. In accordance with ANOVA results pertaining to cutting force, a percentage contribution variance of 48.92% was obtained for the feed rate, which contributed to cutting force to a greater extent, followed by 36.82% for spindle speed and 14.19% for the type of drill bit.
{"title":"Drilling performance analysis on super duplex stainless steel (AISI 2507) using scalable pulse power plasma TiSiN- and AlTiN-coated tools and optimizing machining parameters through Taguchi–Fuzzy approach","authors":"Prajwal Agrawal, Shivam Kenche, T Sampath Kumar","doi":"10.1177/09544089241270849","DOIUrl":"https://doi.org/10.1177/09544089241270849","url":null,"abstract":"In recent years, super duplex stainless steel (SDSS) has gained a lot of importance due to its strength and excellent resistance to corrosion cracking for applications in marine and chemical processing industries, etc. In spite of various progress in the field, the drilling of SDSS leads to the formation of chips that are very strong and abrasive, which makes it challenging to have proper drilling. To overcome this issue by utilizing suitable parameters such as drill bit coating, environmental conditions and parameters for drilling. The SDSS machining output results were compared for both dry and minimum quantity lubrication (MQL) conditions using coated and uncoated drill bits. A scalable pulse power plasma (S3P) technique was utilized to deposit the titanium silicon nitride (TiSiN) and aluminum titanium nitride (AlTiN) coatings on solid carbide drill bits. In the experiments, three levels of drilling parameters have been chosen, including spindle speed (550, 700, 850 rpm), feed rate (0.035, 0.045, 0.060 m/min), and drill bit types. The experiment was designed using Taguchi's orthogonal L9 array. The influence of machining parameters such as cutting force, surface roughness, and circularity error were examined using variance analysis (ANOVA) and signal-to-noise (S/N) ratios. To enhance the drilling process parameters through a single comprehensive output measure, the obtained results were taken as an input to the fuzzy logic networks using multi-factor analysis. At the L7 trial, the least cutting force was observed at 525.7 N for dry conditions and 227.6 N for MQL conditions and gave cone-spiral and continuous chips. In order to analyze the signal-to-noise ratio effectively, high value correspond to better-quality characteristics. In accordance with ANOVA results pertaining to cutting force, a percentage contribution variance of 48.92% was obtained for the feed rate, which contributed to cutting force to a greater extent, followed by 36.82% for spindle speed and 14.19% for the type of drill bit.","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":"2024-08-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142204851","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 : 2024-08-02DOI: 10.1177/09544089241264173
Yuan Xiaodan, Yu Kun, Li Zhijun, Wang Jinlong, Zhang Yuan
The critical problem in accurately characterising the defects in nickel-based alloy weld is the skewing of the ultrasonic beam due to the heterogeneity. This article aims to address this problem by utilising microstructure analysis and mode techniques to account for the skewing of the ultrasonic beam and the formation of root signals in the weld. The macroscopic and microscopic metallography of the weld is quantitatively described, focusing on the GH3535 alloy weld. The mean grain size of the base metal and the weld are 60 and 400 μm, respectively. The local crystal orientation map of the weld is obtained using the electron backscatter diffraction technique, revealing a preferred orientation of the grains in the <100> direction. The propagation of the ultrasonic beam in GH3535 alloy weld was visualised by CIVA software. The beam's degree of skewing and splitting is related to the grain's angle of orientation difference. Phased array ultrasonic tests were conducted using a 64 L linear array probe with a centre frequency of 2.25 MHz to inspect the weld and side-drilled holes with a diameter of 3 mm. The echo signals from side-drilled holes in different depths were analysed in both the simulation and tests. The quantitative deviation of depth at the centre and lower end of the weld is 2.6% and 6%. The signal–noise ratio of the side-drilled holes in the weld in the test is 12.5–15.8 dB. The root signals were observed in the weld but not in the base metal. The forming mechanism of the root signal was elucidated by analysing the vertical orientation of the grains.
{"title":"Microstructure quantification and phased array ultrasonic inspection of GH3535 alloy weld","authors":"Yuan Xiaodan, Yu Kun, Li Zhijun, Wang Jinlong, Zhang Yuan","doi":"10.1177/09544089241264173","DOIUrl":"https://doi.org/10.1177/09544089241264173","url":null,"abstract":"The critical problem in accurately characterising the defects in nickel-based alloy weld is the skewing of the ultrasonic beam due to the heterogeneity. This article aims to address this problem by utilising microstructure analysis and mode techniques to account for the skewing of the ultrasonic beam and the formation of root signals in the weld. The macroscopic and microscopic metallography of the weld is quantitatively described, focusing on the GH3535 alloy weld. The mean grain size of the base metal and the weld are 60 and 400 μm, respectively. The local crystal orientation map of the weld is obtained using the electron backscatter diffraction technique, revealing a preferred orientation of the grains in the <100> direction. The propagation of the ultrasonic beam in GH3535 alloy weld was visualised by CIVA software. The beam's degree of skewing and splitting is related to the grain's angle of orientation difference. Phased array ultrasonic tests were conducted using a 64 L linear array probe with a centre frequency of 2.25 MHz to inspect the weld and side-drilled holes with a diameter of 3 mm. The echo signals from side-drilled holes in different depths were analysed in both the simulation and tests. The quantitative deviation of depth at the centre and lower end of the weld is 2.6% and 6%. The signal–noise ratio of the side-drilled holes in the weld in the test is 12.5–15.8 dB. The root signals were observed in the weld but not in the base metal. The forming mechanism of the root signal was elucidated by analysing the vertical orientation of the grains.","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":"2024-08-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141883482","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 : 2024-08-02DOI: 10.1177/09544089241262945
Ângela Semitela, André Ferreira, António Completo, Nuno Lau, José P Santos
Seeking a total automation of the existing industrial processes, manual product quality control systems have been gradually replaced by automated ones, to significantly improve efficiency and speed, and ultimately, increase industrial productivity. In this regard, an automated inspection system was developed in this work to detect and classify defects on the painted surfaces of Bosch Thermotechnology water heaters. This system comprised a deflectometry-based image acquisition module, two light deep learning models built and trained from scratch for defect detection and classification in the painted surfaces and a visual interface. The experimental results confirmed that: (1) deflectometry techniques were crucial for an accurate defect detection; (2) the two lightweight models – for detection and classification – rapidly achieved high accuracies, even in the testing stage, demonstrating their high performance regardless of their small size; (3) the developed system was able to correctly and quickly predict the status of a painted surface, and then successfully send this status information to a user-friendly visual interface, validating its suitability for an industrial setting. Overall, this system demonstrated great potential as a suitable alternative to the existing manual inspection of the painted surfaces of Bosch Thermotechnology water heaters.
{"title":"Detecting and classifying defects on the surface of water heaters: Development of an automated system","authors":"Ângela Semitela, André Ferreira, António Completo, Nuno Lau, José P Santos","doi":"10.1177/09544089241262945","DOIUrl":"https://doi.org/10.1177/09544089241262945","url":null,"abstract":"Seeking a total automation of the existing industrial processes, manual product quality control systems have been gradually replaced by automated ones, to significantly improve efficiency and speed, and ultimately, increase industrial productivity. In this regard, an automated inspection system was developed in this work to detect and classify defects on the painted surfaces of Bosch Thermotechnology water heaters. This system comprised a deflectometry-based image acquisition module, two light deep learning models built and trained from scratch for defect detection and classification in the painted surfaces and a visual interface. The experimental results confirmed that: (1) deflectometry techniques were crucial for an accurate defect detection; (2) the two lightweight models – for detection and classification – rapidly achieved high accuracies, even in the testing stage, demonstrating their high performance regardless of their small size; (3) the developed system was able to correctly and quickly predict the status of a painted surface, and then successfully send this status information to a user-friendly visual interface, validating its suitability for an industrial setting. Overall, this system demonstrated great potential as a suitable alternative to the existing manual inspection of the painted surfaces of Bosch Thermotechnology water heaters.","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":"2024-08-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141883488","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 : 2024-08-02DOI: 10.1177/09544089241264186
Gurwinder Singh, Rupinder Singh, P Sudhakar Rao
Electrochemical machining is an established non-conventional machining process in which material removal during electrolysis relies on the quantity of electricity passed through the electrolyte. The amount of electricity passed further depends on several factors, such as electrochemical reactivity/dissolution, penetration rate, tool properties (profile, surface area, and material), electrical conductivity, chemical composition, temperature sensitivity, crystal structure, and initial surface roughness (Ra) of workpiece material, voltage, feed rate, electrolyte selection/concentration, etc. As per reported studies, a thermoplastic inter-electrode slit of rectangular/square profile between the tool and workpiece in modified electrochemical machining helps to generate the cavity with a better aspect (h/d) ratio without changing the tool profile. However, little has been reported on the effect of variation in interelectrode slit thickness on material removal rate/penetration rate. In this study, the results of experimental investigations for material removal rate/penetration rate with modified electrochemical machining using a square inter-electrode slit of variable thickness between the cathode (circular tool) and anode (workpiece) with 03 different materials (Al, Cu, and Ti) have been presented. Taguchi L18, orthogonal array-based design of experiments, has been used in parametric optimization of the modified electrochemical machining process. Overall, the best settings for material removal rate in modified electrochemical machining are electrolyte concentration 150 g/L, voltage 21 V, tool material Cu, workpiece Al, interelectrode slit thickness 1.5 mm, and tool feed rate 132 µm/min. The outcomes have been braced by scanning electron microscopy, energy dispersive spectroscopy, and Ra analysis.
{"title":"On electrochemical machining with an interelectrode slit for a partially insulating cathode","authors":"Gurwinder Singh, Rupinder Singh, P Sudhakar Rao","doi":"10.1177/09544089241264186","DOIUrl":"https://doi.org/10.1177/09544089241264186","url":null,"abstract":"Electrochemical machining is an established non-conventional machining process in which material removal during electrolysis relies on the quantity of electricity passed through the electrolyte. The amount of electricity passed further depends on several factors, such as electrochemical reactivity/dissolution, penetration rate, tool properties (profile, surface area, and material), electrical conductivity, chemical composition, temperature sensitivity, crystal structure, and initial surface roughness (Ra) of workpiece material, voltage, feed rate, electrolyte selection/concentration, etc. As per reported studies, a thermoplastic inter-electrode slit of rectangular/square profile between the tool and workpiece in modified electrochemical machining helps to generate the cavity with a better aspect (h/d) ratio without changing the tool profile. However, little has been reported on the effect of variation in interelectrode slit thickness on material removal rate/penetration rate. In this study, the results of experimental investigations for material removal rate/penetration rate with modified electrochemical machining using a square inter-electrode slit of variable thickness between the cathode (circular tool) and anode (workpiece) with 03 different materials (Al, Cu, and Ti) have been presented. Taguchi L<jats:sub>18</jats:sub>, orthogonal array-based design of experiments, has been used in parametric optimization of the modified electrochemical machining process. Overall, the best settings for material removal rate in modified electrochemical machining are electrolyte concentration 150 g/L, voltage 21 V, tool material Cu, workpiece Al, interelectrode slit thickness 1.5 mm, and tool feed rate 132 µm/min. The outcomes have been braced by scanning electron microscopy, energy dispersive spectroscopy, and Ra analysis.","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":"2024-08-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141883666","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 : 2024-08-02DOI: 10.1177/09544089241267130
KG Saravanan, S Gokulraj, M Rajesh, S Ram Prakash
In recent years, the inclusion of biochar fillers in the polymer matrix has been used to enhance the mechanical, dielectric and dynamic properties of the composite. High-performance structural components are often made using polymer composites. This work focuses on the development of glass fibre interleaved almond biochar filler (ABC-5, 10 and 15%) reinforced polymer composites through a hand layup process. The machinability of the composite was then investigated in abrasive water jet machining by considering the biochar filler quantity, water pressure (WP), traverse speed (TS) and standoff distance (SOD). The kerf angle (KA) and surface roughness (SR) were used to assess the machining performance. The addition of a biochar filler in the composite increases the SR and KA quality. The machining performance of the biochar-filled composite is better when there is an increase in water pressure and a decrease in SOD and TS. Analysis of Variance (ANOVA) reveals that the ABC% significantly influence the SR and KA trialed by JP. The combination of WP 200 MPa with ABC10% composite laminate results in decreased values of KA (1.09o) and SR (2.754 µm). The ideal parameters for achieving lower SR and KA are TS of 20 mm/min, 3 mm of SOD, 200 bar of WP and 10% biochar composite in combination. Moreover, scanning electron microscopic (SEM) images ensure the smoothness of the surface texture at high water pressure (WP) with 10% almond biochar composite laminate, cutting and finishing are smooth. The biochar fillers reinforced in hybrid composites exhibited good surface quality, free of pullouts and fibre delamination.
近年来，在聚合物基体中加入生物炭填料已被用于提高复合材料的机械、介电和动态性能。高性能结构组件通常采用聚合物复合材料制造。这项工作的重点是通过手糊工艺开发玻璃纤维交错杏仁生物炭填料（ABC-5，10% 和 15%）增强聚合物复合材料。然后，通过考虑生物炭填料的数量、水压 (WP)、横移速度 (TS) 和间距 (SOD)，研究了复合材料在加砂水射流加工中的可加工性。切口角 (KA) 和表面粗糙度 (SR) 用于评估加工性能。在复合材料中添加生物炭填料可提高 SR 和 KA 质量。当水压增加、SOD 和 TS 下降时，生物炭填充复合材料的加工性能更好。方差分析（ANOVA）表明，ABC% 对 JP 试验的 SR 和 KA 有显著影响。WP 200 MPa 与 ABC10% 复合层压板的组合导致 KA 值（1.09o）和 SR 值（2.754 µm）降低。达到较低 SR 和 KA 值的理想参数是 20 毫米/分钟的 TS、3 毫米的 SOD、200 巴的 WP 和 10%的生物炭复合材料。此外，扫描电子显微镜（SEM）图像确保了 10%杏仁生物炭复合材料层压板在高水压（WP）下表面纹理的平滑性，切削和抛光都很顺畅。在混合复合材料中增强的生物炭填料显示出良好的表面质量，没有拉丝和纤维分层现象。
{"title":"Influencing the optimum AWJM key factors on drilling quality of biochar-interlaced glass fibre-reinforced epoxy composites: Multi-response optimisation approach","authors":"KG Saravanan, S Gokulraj, M Rajesh, S Ram Prakash","doi":"10.1177/09544089241267130","DOIUrl":"https://doi.org/10.1177/09544089241267130","url":null,"abstract":"In recent years, the inclusion of biochar fillers in the polymer matrix has been used to enhance the mechanical, dielectric and dynamic properties of the composite. High-performance structural components are often made using polymer composites. This work focuses on the development of glass fibre interleaved almond biochar filler (ABC-5, 10 and 15%) reinforced polymer composites through a hand layup process. The machinability of the composite was then investigated in abrasive water jet machining by considering the biochar filler quantity, water pressure (WP), traverse speed (TS) and standoff distance (SOD). The kerf angle (KA) and surface roughness (SR) were used to assess the machining performance. The addition of a biochar filler in the composite increases the SR and KA quality. The machining performance of the biochar-filled composite is better when there is an increase in water pressure and a decrease in SOD and TS. Analysis of Variance (ANOVA) reveals that the ABC% significantly influence the SR and KA trialed by JP. The combination of WP 200 MPa with ABC10% composite laminate results in decreased values of KA (1.09<jats:sup>o</jats:sup>) and SR (2.754 µm). The ideal parameters for achieving lower SR and KA are TS of 20 mm/min, 3 mm of SOD, 200 bar of WP and 10% biochar composite in combination. Moreover, scanning electron microscopic (SEM) images ensure the smoothness of the surface texture at high water pressure (WP) with 10% almond biochar composite laminate, cutting and finishing are smooth. The biochar fillers reinforced in hybrid composites exhibited good surface quality, free of pullouts and fibre delamination.","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":"2024-08-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141883474","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 : 2024-08-02DOI: 10.1177/09544089241263141
Fabian Kappe, Mathias Bobbert, Gerson Meschut
Climate change has led to a large number of countries deciding to reduce carbon dioxide (CO2) emissions significantly. As the mobility sector is a major contributor to CO2, various strategies are being pursued to achieve the climate targets set. An increasingly applied lightweight design method is the use of multi-material constructions. To join these structures, mechanical joining technologies such as self-pierce riveting are being used. As a result of the currently rigid tool systems, which cannot react to changing boundary conditions, a large number of rivet–die combinations is required to join the rising number of materials as well as material thickness combinations. Thus, new, versatile joining technologies are needed that can react to the described changes. The versatile self-piercing riveting (V-SPR) process is one possible approach. In this process, different material thicknesses can be joined by using a multi-range capable rivet which is set by a joining system with extended actuator technology. In this study, the V-SPR joining process is analysed numerically according to the influence of the geometrical rivet parameters on the joints characteristics as well as the resulting material flow. The investigations showed that the shank geometry has a decisive influence on the expansion of the rivet. Furthermore, the rivet length could be proven to be an influencing factor. By changing the head radii and the protrusion height, the forming behaviour of the rivet head onto the punch-sided joining part could be improved and thus the formation of air pockets was prevented. Based on the numerical investigations, a novel rivet geometry was developed and produced by machining. Subsequently, experimentally produced joints were analysed according to their joint formation and load-bearing capacity.
{"title":"Investigation of the influence of the rivet geometry on joint formation for a versatile self-piercing riveting process","authors":"Fabian Kappe, Mathias Bobbert, Gerson Meschut","doi":"10.1177/09544089241263141","DOIUrl":"https://doi.org/10.1177/09544089241263141","url":null,"abstract":"Climate change has led to a large number of countries deciding to reduce carbon dioxide (CO<jats:sub>2</jats:sub>) emissions significantly. As the mobility sector is a major contributor to CO<jats:sub>2</jats:sub>, various strategies are being pursued to achieve the climate targets set. An increasingly applied lightweight design method is the use of multi-material constructions. To join these structures, mechanical joining technologies such as self-pierce riveting are being used. As a result of the currently rigid tool systems, which cannot react to changing boundary conditions, a large number of rivet–die combinations is required to join the rising number of materials as well as material thickness combinations. Thus, new, versatile joining technologies are needed that can react to the described changes. The versatile self-piercing riveting (V-SPR) process is one possible approach. In this process, different material thicknesses can be joined by using a multi-range capable rivet which is set by a joining system with extended actuator technology. In this study, the V-SPR joining process is analysed numerically according to the influence of the geometrical rivet parameters on the joints characteristics as well as the resulting material flow. The investigations showed that the shank geometry has a decisive influence on the expansion of the rivet. Furthermore, the rivet length could be proven to be an influencing factor. By changing the head radii and the protrusion height, the forming behaviour of the rivet head onto the punch-sided joining part could be improved and thus the formation of air pockets was prevented. Based on the numerical investigations, a novel rivet geometry was developed and produced by machining. Subsequently, experimentally produced joints were analysed according to their joint formation and load-bearing capacity.","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":"2024-08-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141883476","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 : 2024-08-02DOI: 10.1177/09544089241263754
B Saravanan, MA Asokan
The novelty of the present work deals with the experimental investigation on the effects of varying injection pressure (IP) on CI engine characteristics using a novel Ceiba pentandra biodiesel at 20% by volume (B20). The key objective of this study is to enhance the engine characteristics by increasing the IP of the fuel blends without any major engine modifications This strategy could improve the performance of the engine as higher IP resulted in improved atomization and better air-fuel mixing. From the experimentation it was found that combined strategy of biodiesel blend (B20) and higher IP (260 bar) resulted in increased BTE (9%), CP (8.5%), HRR (2%) and reduced BSFC (9%), CO (14%), HC (16%), and Smoke (16%) than diesel (B0) at a standard IP of 200 bar. To overcome the challenges of higher NOx emission at higher IP, exhaust gas recirculation (EGR) technique is also implemented at lower rates. With the effect of 15% EGR, there was a subsequent 29% reduction in NOx emission achieved without affecting other emissions trade-offs.
本研究的新颖之处在于使用体积分数为 20% （B20）的新型 Ceiba pentandra 生物柴油，对不同喷射压力（IP）对 CI 发动机特性的影响进行了实验研究。这项研究的主要目的是在不对发动机进行任何重大改动的情况下，通过提高混合燃料的 IP 值来增强发动机的性能。实验发现，生物柴油混合燃料（B20）和更高的 IP 值（260 巴）的组合策略比标准 IP 值为 200 巴的柴油（B0）提高了 BTE（9%）、CP（8.5%）、HRR（2%），降低了 BSFC（9%）、CO（14%）、HC（16%）和烟尘（16%）。为了克服较高 IP 值下氮氧化物排放量较高的难题，还采用了废气再循环（EGR）技术，但废气再循环率较低。在 15%的 EGR 作用下，氮氧化物排放量随后减少了 29%，而不会影响其他排放权衡。
{"title":"Impact of varying injection pressure on CI engine characteristics fuelled with Ceiba pentandra biodiesel and NOx reduction strategy","authors":"B Saravanan, MA Asokan","doi":"10.1177/09544089241263754","DOIUrl":"https://doi.org/10.1177/09544089241263754","url":null,"abstract":"The novelty of the present work deals with the experimental investigation on the effects of varying injection pressure (IP) on CI engine characteristics using a novel Ceiba pentandra biodiesel at 20% by volume (B20). The key objective of this study is to enhance the engine characteristics by increasing the IP of the fuel blends without any major engine modifications This strategy could improve the performance of the engine as higher IP resulted in improved atomization and better air-fuel mixing. From the experimentation it was found that combined strategy of biodiesel blend (B20) and higher IP (260 bar) resulted in increased BTE (9%), CP (8.5%), HRR (2%) and reduced BSFC (9%), CO (14%), HC (16%), and Smoke (16%) than diesel (B0) at a standard IP of 200 bar. To overcome the challenges of higher NOx emission at higher IP, exhaust gas recirculation (EGR) technique is also implemented at lower rates. With the effect of 15% EGR, there was a subsequent 29% reduction in NO<jats:sub>x</jats:sub> emission achieved without affecting other emissions trade-offs.","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":"2024-08-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141883473","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}
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