Process Optimization of Synchronizer Ring Gear Extrusion

Nowadays the immature of the precise synchronizer gear ring processing method have greatly impeded the development of the vehicle business in China. The extrusion process is a very important procedure in making precise synchronizer gear ring, but there is not any introductive and effective research yet to the issue of the optimal processing parameter in precise synchronizer gear ring procession. This research provides several processing parameters in precise synchronizer gear ring procession by means of simulating the processing in DEFORM-2D software and trying it in reality. The result shows that the whole three processing procedures have influence in the result of the gear ring. The second procedure is the most influential, followed by the fist procedure. Adjustment can be effectively conducted on the product of the first procedure by changing the fillet radius of the top die and the bottom die, R1, R2; adjustment can be effectively conducted on the product of the second procedure by changing the fillet radius of the top die and the bottom die and the angle of the upper inclination of the top die,α2. The result of this paper gives an instruction in precise synchronizer gear ring procession.

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Warpage Optimisation Using Recycled Polycar-bonates (PC) on Front Panel Housing

Materials ◽

10.3390/ma14061416 ◽

2021 ◽

Vol 14 (6) ◽

pp. 1416

Author(s):

Nur Aisyah Miza Ahmad Tamizi ◽

Shayfull Zamree Abd Rahim ◽

Abdellah El-hadj Abdellah ◽

Mohd Mustafa Al Bakri Abdullah ◽

Marcin Nabiałek ◽

...

Keyword(s):

Simulation Analysis ◽

Processing Parameters ◽

Front Panel ◽

Processing Parameter ◽

Mechanical Recycling ◽

Great Opportunity ◽

Average Value ◽

Optimal Processing ◽

Materials Used ◽

Optimisation Methods

Many studies have been done using recycled waste materials to minimise environmental problems. It is a great opportunity to explore mechanical recycling and the use of recycled and virgin blend as a material to produce new products with minimum defects. In this study, appropriate processing parameters were considered to mould the front panel housing part using R0% (virgin), R30% (30% virgin: 70% recycled), R40% (40% virgin: 60% recycled) and R50% (50% virgin: 50% recycled) of Polycarbonate (PC). The manufacturing ability and quality during preliminary stage can be predicted through simulation analysis using Autodesk Moldflow Insight 2012 software. The recommended processing parameters and values of warpage in x and y directions can also be obtained using this software. No value of warpage was obtained from simulation studies for x direction on the front panel housing. Therefore, this study only focused on reducing the warpage in the y direction. Response Surface Methodology (RSM) and Genetic Algorithm (GA) optimisation methods were used to find the optimal processing parameters. As the results, the optimal ratio of recycled PC material was found to be R30%, followed by R40% and R50% materials using RSM and GA methods as compared to the average value of warpage on the moulded part using R0%. The most influential processing parameter that contributed to warpage defect was packing pressure for all materials used in this study.

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Optimization of Hot Extrusion Process Parameters Using Taguchi Based Grey Relation Analysis

International Journal of Materials Forming and Machining Processes ◽

10.4018/ijmfmp.2019010101 ◽

2019 ◽

Vol 6 (1) ◽

pp. 1-18

Author(s):

Sarojini Jajimoggala

Keyword(s):

Process Parameters ◽

Low Cost ◽

Hot Extrusion ◽

Processing Parameters ◽

Extrusion Process ◽

Optimal Process ◽

Optimal Processing ◽

Processing Variables ◽

Extruded Products ◽

Processing Techniques

Enormous applications of aluminium alloys in various key industries necessitated the development and improvement of material processing techniques. Due to simplicity in making complex shapes and low cost of production, the extrusion process for aluminium has gained great popularity in recent years. As the processing variables/parameters during any manufacturing process significantly effects the yield and mechanical properties of extruded products, the development of optimal process parameters combination is found to be vital for the modern manufacturing industries. Hence, the present article addresses the conducting of hot extrusion experiments with AA6061 and evaluation of optimal process parameters using a Taguchi-based GRA. To check the significance of the processing variables on the output quality and quantity, ANOVA is used. A confirmation test was done at the selected optimal processing parameters combination to validate the experimental results.

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Optimisation of Shrinkage and Strength on Thick Plate Part Using Recycled LDPE Materials

Materials ◽

10.3390/ma14071795 ◽

2021 ◽

Vol 14 (7) ◽

pp. 1795

Author(s):

Norshahira Roslan ◽

Shayfull Zamree Abd Rahim ◽

Abdellah El-hadj Abdellah ◽

Mohd Mustafa Al Bakri Abdullah ◽

Katarzyna Błoch ◽

...

Keyword(s):

Tensile Strength ◽

Thick Plate ◽

Processing Parameters ◽

Processing Parameter ◽

Plastic Injection Moulding ◽

Optimal Setting ◽

Quality Of Products ◽

Validation Tests ◽

Plastic Injection

Achieving good quality of products from plastic injection moulding processes is very challenging, since the process comprises many affecting parameters. Common defects such as warpage are hard to avoid, and the defective parts will eventually go to waste, leading to unnecessary costs to the manufacturer. The use of recycled material from postindustrial waste has been studied by a few researchers. However, the application of an optimisation method by which to optimise processing parameters to mould parts using recycled materials remains lacking. In this study, Response Surface Methodology (RSM) and Particle Swarm Optimisation (PSO) methods were conducted on thick plate parts moulded using virgin and recycled low-density polyethylene (LDPE) materials (100:0, 70:30, 60:40 and 50:50; virgin to recycle material ratios) to find the optimal input parameters for each of the material ratios. Shrinkage in the x and y directions increased in correlation with the recycled ratio, compared to virgin material. Meanwhile, the tensile strength of the thick plate part continued to decrease when the recycled ratio increased. R30 (70:30) had the optimum shrinkage in the x direction with respect to R0 (100:0) material where the shrinkage increased by 24.49% (RSM) and 33.20% (PSO). On the other hand, the shrinkage in the y direction for R30 material increased by 4.48% (RSM) and decreased by 2.67% (PSO), while the tensile strength of R30 (70:30) material decreased by 0.51% (RSM) and 2.68% (PSO) as compared to R0 (100:0) material. Validation tests indicated that the optimal setting of processing parameter suggested by PSO and RSM for R0 (100:0), R30 (70:30), R40 (60:40) and R50 (50:50) was less than 10%.

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Binary Self-Assembly of Nanocolloidal Arrays using Concurrent and Sequential Spin Coating Techniques

Materials ◽

10.3390/ma14020274 ◽

2021 ◽

Vol 14 (2) ◽

pp. 274

Author(s):

Shih-Jyun Shen ◽

Demei Lee ◽

Yu-Chen Wu ◽

Shih-Jung Liu

Keyword(s):

Silicon Substrate ◽

Self Assembly ◽

Spin Coating ◽

Processing Parameters ◽

The Self ◽

Silicon Substrates ◽

Processing Conditions ◽

Polystyrene Spheres ◽

Optimal Processing ◽

Spin Coater

This paper reports the binary colloid assembly of nanospheres using spin coating techniques. Polystyrene spheres with sizes of 900 and 100 nm were assembled on top of silicon substrates utilizing a spin coater. Two different spin coating processes, namely concurrent and sequential coatings, were employed. For the concurrent spin coating, 900 and 100 nm colloidal nanospheres of latex were first mixed and then simultaneously spin coated onto the silicon substrate. On the other hand, the sequential coating process first created a monolayer of a 900 nm nanosphere array on the silicon substrate, followed by the spin coating of another layer of a 100 nm colloidal array on top of the 900 nm array. The influence of the processing parameters, including the type of surfactant, spin speed, and spin time, on the self-assembly of the binary colloidal array were explored. The empirical outcomes show that by employing the optimal processing conditions, binary colloidal arrays can be achieved by both the concurrent and sequential spin coating processes.

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Multiscale Copper-µDiamond Nanostructured Composites

Materials Science Forum ◽

10.4028/www.scientific.net/msf.730-732.925 ◽

2012 ◽

Vol 730-732 ◽

pp. 925-930

Author(s):

Daniela Nunes ◽

Vanessa Livramento ◽

Horácio Fernandes ◽

Carlos Silva ◽

Nobumitsu Shohoji ◽

...

Keyword(s):

Pure Copper ◽

Thermal Stabilization ◽

Hot Extrusion ◽

Processing Parameters ◽

High Energy ◽

X Ray Diffraction ◽

X Ray ◽

Optimal Processing ◽

Novel Approach ◽

Transmission Electron

Nanostructured copper-diamond composites can be tailored for thermal management applications at high temperature. A novel approach based on multiscale diamond dispersions is proposed for the production of this type of materials: a Cu-nDiamond composite produced by high-energy milling is used as a nanostructured matrix for further dispersion of micrometer sized diamond. The former offers strength and microstructural thermal stability while the latter provides high thermal conductivity. A series of Cu-nDiamond mixtures have been milled to define the minimum nanodiamond fraction suitable for matrix refinement and thermal stabilization. A refined matrix with homogenously dispersed nanoparticles could be obtained with 4 at.% nanodiamond for posterior mixture with mDiamond and subsequent consolidation. In order to define optimal processing parameters, consolidation by hot extrusion has been carried out for a Cu-nDiamond composite and, in parallel, for a mixture of pure copper and mDiamond. The materials produced were characterized by X-ray diffraction, scanning and transmission electron microscopy and microhardness measurements.

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Determination of optimal microwave curing cycle for fly ash mortars

Canadian Journal of Civil Engineering ◽

10.1139/l07-132 ◽

2008 ◽

Vol 35 (4) ◽

pp. 349-357 ◽

Cited By ~ 6

Author(s):

İlker Bekir Topçu ◽

Mehmet Uğur Toprak ◽

Devrim Akdağ

Keyword(s):

Fly Ash ◽

Processing Parameters ◽

Microwave Energy ◽

Strength Prediction ◽

Strength Development ◽

Microwave Curing ◽

Optimal Processing ◽

Cement Mortars ◽

Curing Cycle

Microwave energy can accelerate the hydration of cement, which results in the rapid strength development of concrete. In this paper, prediction of later age compressive strength of fly ash cement mortars, based on the accelerated strength of mortars cured with microwave energy, was investigated. To accelerate curing properly, optimal processing parameters of microwave curing (MC) on Portland cement mortars (CM) and fly ash cement mortars (FA) were first determined and then were applied to mortars. The possible early ages for the strength prediction were found to be at 6 and 8 h for CM and FA, respectively. The error percentages for prediction of CM were ±2.22% and 2.91% for 7 and 28 d, respectively. Error percentages for FA, on the other hand, were ±4.36% and 5.20% for 7 and 28 d, respectively.

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The Research on Natural Characteristic and Eigensensitivity of Ravingneaux Compound Planetary Gear Sets

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.446-447.590 ◽

2013 ◽

Vol 446-447 ◽

pp. 590-596

Author(s):

Bo Qian ◽

Shi Jing Wu

Keyword(s):

Natural Frequency ◽

Planetary Gear ◽

Torsional Stiffness ◽

Ring Gear ◽

Vibration Model ◽

Planetary Gear Sets ◽

Planet Gear ◽

Natural Characteristic ◽

Gear Ring ◽

The Moment

The dynamic model of Ravingneaux compound planetary gear sets has been built. Then the Natural frequency and vibration model have been solved in the Ravingneaux compound planetary gear sets. The eigensensitivity to parameters have been researched based on the dynamical model. The varying trend of natural frequency according to the varying of parameters have been researched, which include gear mass (sun gear, ring gear , or planet gear), the moment of inertia of gears, the support stiffness , the torsional stiffness.

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Dissimilar Friction Stir Lap Welding of AA2198 and AA7075 Sheets: Forces, Microstructure and Mechanical Properties

10.21203/rs.3.rs-252238/v1 ◽

2021 ◽

Author(s):

Antonello Astarita ◽

Fausto Tucci ◽

Alessia Teresa Silvestri ◽

Michele Perrella ◽

Luca Boccarusso ◽

...

Keyword(s):

Mechanical Properties ◽

Welding Process ◽

Processing Parameters ◽

Processing Parameter ◽

Friction Stir Lap Welding ◽

Friction Stir ◽

Lap Shear ◽

Microstructure And Mechanical Properties ◽

Lap Welding ◽

Factorial Design Of Experiments

Abstract This paper deals with the dissimilar friction stir lap welding of AA2198 and AA7075 sheets. The influence of processing parameters, namely welding speed and tool rotational speed on joint features, microstructure, and mechanical properties were investigated implementing a full factorial design of experiments. During the welding process, axial and transversal forces were continuously measured using a dedicated sensed fixture aiming at the correlation of this processing parameter with the quality of the achieved joints. The reported outcomes showed a very narrow processing window in which it was possible to avoid the formation of defects while the formation of an hook was observed for all the joints welded. The influence of the weld bead morphology on the lap shear strength was elucidated proving that the strength is ruled by the hook morphology. A correlation between the process parameters and the forces arising was also attempted. The final microstructure of the joints was studied and explained and also compared with the microhardness results.

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Low frequency vibratory cleaning of paint and rust contaminants from machines parts

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/09544054211031451 ◽

2021 ◽

pp. 095440542110314

Author(s):

Dieudonne Essola ◽

Achille Pandong Njomoue ◽

Florence Offole ◽

Cyrille Adiang Mezoue ◽

Crick Nelson Zanga ◽

...

Keyword(s):

Processing Time ◽

Low Frequency ◽

Processing Parameters ◽

Vibration Machine ◽

Optimal Processing ◽

Low Frequency Oscillations ◽

Experimental Parameters ◽

Process Fluid ◽

Full Factorial ◽

Fluid Parameters

This work investigates the effect of low frequency vibratory processing for cleaning and washing various machine components parts from rusts and old paints deposits. The experimental investigation was carried out with special prepared samples that were weighted and exposed to paints and rust contaminants. These samples were treated in universal horizontal vibration machine UVHM 4 × 10 with different combination of instrumental processing medium, process fluid, machine amplitude and frequency of oscillations. They were periodically reweighted after processing and compared to etalon with control of quantity of dust that have been removed, sample cleanliness and also other functional parameters. Statistical analysis has been used to characterize ongoing process and full factorial analysis to establish experimental parameters dependency. The result is showing the complex dependence of samples cleanliness to each processing parameters like processing time, amplitude of oscillations, frequency of oscillations, process fluid parameters, instrumental medium, etc. Between this parameters although the most important successively the amplitude of oscillations, the frequency of oscillations the processing medium and the processing fluid depending to his considered composition, the optimal processing time can be reach only by complex combination of all this parameters every of them carry an amplify coefficient. Low frequency oscillations can be used to monitor and optimize washing and cleaning operations of paints and rusts contaminations. That guarantees process automation, its effectiveness for a large industrial application.

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An Innovative Approach of Parameter Loading Path Design for Grain Refinement and Its Application in Ni80A Superalloy

Materials ◽

10.3390/ma14216703 ◽

2021 ◽

Vol 14 (21) ◽

pp. 6703

Author(s):

Guo-Zheng Quan ◽

Yan-Ze Yu ◽

Xue Sheng ◽

Kun Yang ◽

Wei Xiong

Keyword(s):

Strain Rate ◽

Grain Refinement ◽

Deformation Mechanism ◽

Processing Parameters ◽

Loading Path ◽

Processing Parameter ◽

Compression Process ◽

Innovative Method ◽

Path Design ◽

Loading Path Design

In order to obtain the desired mechanical properties of products, an innovative method of loading parameter designs for acquiring the desired grain refinement is proposed, and it has been applied in the compression process of Ni80A superalloy. The deformation mechanism maps derived from processing maps based on the Dynamic Materials Model (DMM) theory were constructed, since the critical indicator values corresponding to dynamic recrystallization (DRX) and dynamic recovery (DRV) mechanisms were determined. The processing-parameter domains with DRX mechanisms were separated from the deformation mechanism map, while such domains were chaotic and difficult to apply in innovative parameter loading path design. The speed-loading path derived from strain rate-loading path in a compression process was pursued. The grain refinement domains are discretized into a finite series of sub-domains with clear processing parameters, and the optimal strain rate of each sub-domain is determined by step-by-step finite element simulation. A 3D response surface of the innovative optimal loading path of strain rate was fitted by interpolating methods. Finally, the isothermal compression experiments for Ni80A superalloy were conducted, and the microstructure observations indicated that the desired grain refinement was achieved. This innovative method of parameter loading path design contributes to the microstructure adjustment of the alloys with DRX mechanism.

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