Multiscale Analogue Modelling of Clinching Process to Investigate Thickness Tolerance and Tool Misalignment

NEED—The effect of dimensional variability of sheet thickness (tolerance) and tool misalignment is poorly understood for the clinching process. Finite element analysis (FEA) is valuable but requires a lot of and is difficult to verify in this situation due to the asymmetrical geometry and nonlinear plasticity. OBJECTIVE—The objective of this work was to determine the effect of thickness tolerance, tool misalignment and sheet placement (top vs. bottom) in the clinching process, by use of analogue modelling with plasticine. METHOD—Experiments used a scaled-up punch and die, with plasticine as the analogue. Thickness tolerances were represented by sheet thicknesses of 11 and 7 mm, 12 and 8 mm, 8 and 12 mm and 13 and 9 mm for upper and lower sheets, respectively. Two types of lubricant were tested between sheets: glycerine and silicone oil. Angular variability was also introduced. Measured parameters were interlock (also called undercut) and neck thickness. Analogue results for deformation were compared with microscopy of metal clinching. FINDINGS—The results reveal that the multiscale analogue model is an efficient tool for studying the effect of dimensional deviation on a clinch joint. Thickness tolerance showed a critical relationship with interlock, namely a reduction to about half that of the nominal, for both maximum and least material conditions. Increased angular misalignment also reduced the interlock. Compared with glycerine, silicone oil tests showed reduced interlock, possibly the result of a lower coefficient of friction. ORIGINALITY—This work demonstrates the usefulness of analogue modelling for exploring process variability in clinching. The results also show that significant effects for sheet placement are ductility, lubricant (friction), thickness of samples and tool misalignment

Modeling BOD and COD removal from Palm Oil Mill Secondary Effluent in floating wetland by Chrysopogon zizanioides (L.) using response surface methodology

While the oil palm industry has been recognized for its contribution towards economic growth and rapid development, it has also contributed to environmental pollution due to the production of huge quantities of by-products from the oil extraction process. A phytoremediation technique (floating Vetiver system) was used to treat Palm Oil Mill Secondary Effluent (POMSE). A batch study using 40 L treatment tanks was carried out under different conditions and Response Surface Methodology (RSM) was applied to optimize the treatment process. A three factor central composite design (CCD) was used to predict the experimental variables (POMSE concentration, Vetiver plant density and time). An extraordinary decrease in organic matter as measured by BOD and COD (96% and 94% respectively) was recorded during the experimental duration of 4 weeks using a density of 30 Vetiver plants. The best and lowest final BOD of 2 mg/L was obtained when using 15 Vetiver plants after 13 days for low concentration POMSE (initial BOD = 50 mg/L). The next best result of BOD at 32 mg/L was obtained when using 30 Vetiver plants after 24 days for medium concentration POMSE (initial BOD = 175 mg/L). These results confirmed the validity of the model, and the experimental value was determined to be quite close to the predicted value, implying that the empirical model derived from RSM experimental design can be used to adequately describe the relationship between the independent variables and response. The study showed that the Vetiver system is an effective method of treating POMSE