Thermo-Mechanical Effect on Poly Crystalline Boron Nitride Tool Life During Friction Stir Welding (Dwell Period)

Poly Crystalline Boron Nitride (PCBN) tool wear during the friction stir welding of high melting alloys is an obstacle to commercialize the process. This work simulates the friction stir welding process and tool wear during the plunge/dwell period of 14.8 mm EH46 thick plate steel. The Computational Fluid Dynamic (CFD) model was used for simulation and the wear of the tool is estimated from temperatures and shear stress profile on the tool surface. Two sets of tool rotational speeds were applied including 120 and 200 RPM. Seven plunge/dwell samples were prepared using PCBN FSW tool, six thermocouples were also embedded around each plunge/dwell case in order to record the temperatures during the welding process. Infinite focus microscopy technique was used to create macrographs for each case. The CFD result has been shown that a shear layer around the tool shoulder and probe-side denoted as thermo-mechanical affected zone (TMAZ) was formed and its size increase with tool rotational speed increase. Maximum peak temperature was also found to increase with tool rotational speed increase. PCBN tool wear under shoulder was found to increase with tool rotational speed increase as a result of tool’s binder softening after reaching to a peak temperature exceeds 1250 °C. Tool wear also found to increase at probe-side bottom as a result of high shear stress associated with the decrease in the tool rotational speed. The amount of BN particles revealed by SEM in the TMAZ were compared with the CFD model

Modelling of friction stir welding of DH36 steel

A 3-D computational fluid dynamics (CFD) model was developed to simulate the friction stir welding of 6-mm plates of DH36 steel in an Eulerian steady-state framework. The viscosity of steel plate was represented as a non- Newtonian fluid using a flow stress function. The PCBN-WRe hybrid tool was modelled in a fully sticking condition with the cooling system effectively represented as a negative heat flux. The model predicted the temperature distribution in the stirred zone (SZ) for six welding speeds including low, intermediate and high welding speeds. The results showed higher asymmetry in temperature for high welding speeds. Thermocouple data for the high welding speed sample showed good agreement with the CFD model result. The CFD model results were also validated and compared against previous work carried out on the same steel grade. The CFD model also predicted defects such as wormholes and voids which occurred mainly on the advancing side and are originated due to the local pressure distribution between the advancing and retreating sides. These defects were found to be mainly coming from the lack in material flow which resulted from a stagnant zone formation especially at high tra- verse speeds. Shear stress on the tool surface was found to in- crease with increasing tool traverse speed. To produce a “sound” weld, the model showed that the welding speed should remain between 100 and 350 mm/min. Moreover, to prevent local melt- ing, the maximum tool’s rotational speed should not exceed 550 RPM

Design Optimization of a Customized Dental Implant Manufactured via Electron Beam Melting®

Finite Element Analysis (FEA) is a commonly used tool to evaluate biomechanics of traditional dental implants. Biomechanics help predict bone response and implant retention which strongly affects the longevity of the implant. The current research utilizes an analogues approach with FEA, to evaluate the biomechanics of a customized dental implant design built by Electron Beam Melting®, and to contribute towards the implant’s design optimization. The analysis consists of three distinct simulation models. The first model is established in order to get an insight of the biomechanics produced by a biting force of 400 N on a second human molar in the mandible, its corresponding superposed mate and the surrounding biomaterial. In the second model, the lower jaw molar is replaced by a Ti-6Al-4V customized dental implant with a solid surface at the root. In the third model, the customized dental implant has a modified outer-layer at the root with adjustable elasticity. By using a deterministic optimization technique in the FEA, an elasticity of the modified layer can be selected in a manner to minimize stress shielding from occurring.Mechanical Engineerin

REVIEW OF THE RECLAIMING OF RUBBER WASTE AND RECENT WORK ON THE RECYCLING OF ETHYLENE–PROPYLENE–DIENE RUBBER WASTE

This document is the Accepted Manuscript version of a Published Work that appeared in final form in Journal of Rubber Chemistry and Technology, copyright © American Chemical Society after peer review and technical editing by the publisher. To access the final edited and published work see http://dx.doi.org/10.5254/rct.15.84850.Rubbers do not decompose easily and therefore disposal of rubber waste is a serious environmental concern. Raw material costs, diminishing natural resources, and the growing awareness of environmental issues and sustainability have made rubber recycling a major area of concern. Reclaiming and recycling rubber waste is a major scientific and technological challenge facing rubber scientists today. This paper reviews a number of important areas related to the reclaiming, characterizing, testing and recycling of rubber waste. These include: chemical and microbial devulcanization with particular emphasis on main chain scission and kinetics of chemical devulcanization reactions; the cutting-edge techniques for reclaiming devulcanized rubber waste by the action of large shearing forces, heat and chemical agents: and analytical techniques and methods for characterizing composition and testing of devulcanized rubber waste, respectively. In addition, some aspects of the recycling of devulcanized ethylene-propylene-diene rubber (EPDM) waste will be reported. EPDM is used extensively in automotive components world-wide and recycling the rubber at the end of its useful service life is of major importance to manufacturers of automotive components

A review of numerical analysis of friction stir welding

Friction stir welding is a relatively new solid-state joining technique which is widely adopted in different industry fields to join different metallic alloys that are hard to weld by conventional fusion welding. Friction stir welding is a highly complex process comprising several highly coupled physical phenomena. The complex geometry of some kinds of joints and their three dimensional nature make it difficult to develop an overall system of governing equations for theoretical analyzing the behavior of the friction stir welded joints. The experiments are often time consuming and costly. To overcome these problems, numerical analysis has frequently been used since the 2000s. This paper reviews the latest developments in the numerical analysis of friction stir welding processes, microstructures of friction stir welded joints and the properties of friction stir welded structures. Some important numerical issues such as materials flow modeling, meshing procedure and failure criteria are discussed. Numerical analysis of friction stir welding will allow many different welding processes to be simulated in order to understand the effects of changes in different system parameters before physical testing, which would be time-consuming or prohibitively expensive in practice. The main methods used in numerical analysis of friction stir welding are discussed and illustrated with brief case studies. In addition, several important key problems and issues remain to be addressed about the numerical analysis of friction stir welding and opportunities for further research are identified