Optimization of Activated Tungsten Inert Gas welding process parameters using heat transfer search algorithm: with experimental validation using case studies

The Activated Tungsten Inert Gas welding (A-TIG) technique is characterized by its capability to impart enhanced penetration in single pass welding. Weld bead shape achieved by A-TIG welding has a major part in deciding the final quality of the weld. Various machining variables influence the weld bead shape and hence an optimum combination of machining variables is of utmost importance. The current study has reported the optimization of machining variables of A-TIG welding technique by integrating Response Surface Methodology (RSM) with an innovative Heat Transfer Search (HTS) optimization algorithm, particularly for attaining full penetration in 6 mm thick carbon steels. Welding current, length of the arc and torch travel speed were selected as input process parameters, whereas penetration depth, depth-to-width ratio, heat input and width of the heat-affected zone were considered as output variables for the investigations. Using the experimental data, statistical models were generated for the response characteristics. Four different case studies, simulating the real-time fabrication problem, were considered and the optimization was carried out using HTS. Validation tests were also carried out for these case studies and 3D surface plots were generated to confirm the effectiveness of the HTS algorithm. It was found that the HTS algorithm effectively optimized the process parameters and negligible errors were observed when predicted and experimental values compared. HTS algorithm is a parameter-less optimization technique and hence it is easy to implement with higher effectiveness

Relationship between pressure and output parameters in belt grinding of steels and nickel alloy

Belt grinding of flat surfaces of typical parts made of steel and alloys, such as grooves, shoulders, ends, and long workpieces, is a good alternative to milling. Several factors can influence the belt grinding process of flat surfaces of metals, such as cutting speed and pressure. In this work, the importance of pressure in the belt grinding was investigated in terms of technological and experimental aspects. The grinding experiments were performed on structural alloy steel 30KhGSN2/30KhGSNA, structural carbon steel AISI 1045, corrosion-resistant and heat-resistant stainless steel AISI 321, and heat-resistant nickel alloy KHN77TYuR. The performance of the grinding belt was investigated in terms of surface roughness, material removal rate (MRR), grinding belt wear, performance index. Estimated indicators of the belt grinding process were developed: cutting ability; reduced cutting ability for belt grinding of steels and heat-resistant alloy. It was found that with an increase in pressure p, the surface roughness of the processed surface Ra decreased while the tool wear and MRR increased. With a decrease in plasticity and difficulty of machinability, the roughness, material removal rate, reduced cutting capacity (Performance index), material removal decreased, and the tool wear increased. The obtained research results can be used by technologists when creating belt grinding operations for steels and alloys to ensure the required performance is met

3D Finite Element Modelling of Cutting Forces in Drilling Fibre Metal Laminates and Experimental Hole Quality Analysis

Machining Glass fibre aluminium reinforced epoxy (GLARE) is cumbersome due to distinctively different mechanical and thermal properties of its constituents, which makes it challenging to achieve damage-free holes with the acceptable surface quality. The proposed work focuses on the study of the machinability of thin (~2.5 mm) GLARE laminate. Drilling trials were conducted to analyse the effect of feed rate and spindle speed on the cutting forces and hole quality. The resulting hole quality metrics (surface roughness, hole size, circularity error, burr formation and delamination) were assessed using surface profilometry and optical scanning techniques. A three dimensional (3D) finite-element (FE) model of drilling GLARE laminate was also developed using ABAQUS/Explicit to help understand the mechanism of drilling GLARE. The homogenised ply-level response of GLARE laminate was considered in the FE model to predict cutting forces in the drilling process

Optical coherence tomography angiography and multifocal electroretinogram findings in paracentral acute middle maculopathy

Paracentral acute middle maculopathy (PAMM) is an optical coherence tomography (OCT) finding seen in patients with retinal capillary ischemia. In this case report, we present a case of PAMM after a transient central retinal artery occlusion and the multifocal electroretinogram (mfERG) and other multimodal imaging findings. Clinical examination, OCT angiography, OCT en face, fluorescein angiography, and visual fields were performed at the baseline and follow-up examinations. As a result, we identified in this PAMM case evidence of hypoperfusion in both the choriocapillaris as well as the deep capillary plexus. To the best of our knowledge, the involvement of choriocapillaris has not been reported previously in the literature. Moreover, we concluded that mfERG constitutes a useful investigation in PAMM and this is the first mfERG findings to be presented for a PAMM case specifically. © 2020 Wolters Kluwer Medknow Publications. All rights reserved

Multi-scale analysis of the damage and contamination in abrasive water jet drilling of GLARE fibre metal laminates

International audienceThe goal of this study is to investigate the influence of Abrasive Water Jet (AWJ) parameters (standoff distance, water pressure and abrasive flow rate) on the machining quality (diameter, circularity, abrasive contamination, surface roughness and types of damage) during drilling of thick hybrid material viz. GLARE (Glass Laminate Aluminium Reinforced Epoxy) Fibre Metal Laminates (FML). The novelty of this work is the use of X-ray tomography and image post-processing for the quantification of abrasive contamination in function of the machining parameters. Moreover, the indicator called 'power of erosion' (E), depending on the AWJ drilling parameters chosen, has permitted to estimate a threshold below which no delamination is found. The results have shown that oversized holes (up to 6.2 mm in diameter) were produced under all cutting parameters regardless of their level. Increasing the standoff distance increased the hole size and cylindricity. The main types of damage consecutive AWJ drilling are in form of barrelling at plies level and delamination with embedded particles. For 'power of erosion' (E) values below 0.17, no delamination is found. As increasing this indicator further, delamination occurs in-between plies closer to the jet entry and more contamination is observed (up to 4 % of the total scanned surface). The surface roughness was found to be in a similar range to that reported in conventional drilling studies of GLARE (<6 μm), which suggests that AWJC could provide a similar machining performance suitable for aerospace applications

Multi-Response Optimization of Al2O3 Nanopowder-Mixed Wire Electrical Discharge Machining Process Parameters of Nitinol Shape Memory Alloy

Shape memory alloy (SMA), particularly those having a nickel&ndash;titanium combination, can memorize and regain original shape after heating. The superior properties of these alloys, such as better corrosion resistance, inherent shape memory effect, better wear resistance, and adequate superelasticity, as well as biocompatibility, make them a preferable alloy to be used in automotive, aerospace, actuators, robotics, medical, and many other engineering fields. Precise machining of such materials requires inputs of intellectual machining approaches, such as wire electrical discharge machining (WEDM). Machining capabilities of the process can further be enhanced by the addition of Al2O3 nanopowder in the dielectric fluid. Selected input machining process parameters include the following: pulse-on time (Ton), pulse-off time (Toff), and Al2O3 nanopowder concentration. Surface roughness (SR), material removal rate (MRR), and recast layer thickness (RLT) were identified as the response variables. In this study, Taguchi&rsquo;s three levels L9 approach was used to conduct experimental trials. The analysis of variance (ANOVA) technique was implemented to reaffirm the significance and adequacy of the regression model. Al2O3 nanopowder was found to have the highest contributing effect of 76.13% contribution, Ton was found to be the highest contributing factor for SR and RLT having 91.88% and 88.3% contribution, respectively. Single-objective optimization analysis generated the lowest MRR value of 0.3228 g/min (at Ton of 90 &micro;s, Toff of 5 &micro;s, and powder concentration of 2 g/L), the lowest SR value of 3.13 &micro;m, and the lowest RLT value of 10.24 (both responses at Ton of 30 &micro;s, Toff of 25 &micro;s, and powder concentration of 2 g/L). A specific multi-objective Teaching&ndash;Learning-Based Optimization (TLBO) algorithm was implemented to generate optimal points which highlight the non-dominant feasible solutions. The least error between predicted and actual values suggests the effectiveness of both the regression model and the TLBO algorithms. Confirmatory trials have shown an extremely close relation which shows the suitability of both the regression model and the TLBO algorithm for the machining of the nanopowder-mixed WEDM process for Nitinol SMA. A considerable reduction in surface defects owing to the addition of Al2O3 powder was observed in surface morphology analysis

Three-dimensional finite element modeling of drilling-ınduced damage in S2/FM94 glass-fiber-reinforced polymers (GFRPs)

WOS:000872852500001PubMed ID36295118Considering that the machining of composites particularly fiber-reinforced polymer composites (FRPCs) has remained a challenge associated with their heterogeneity and anisotropic nature, damage caused by drilling operations can be considerably mitigated by following optimum cutting parameters. In this work, we numerically evaluated the effects of cutting parameters, such as feed rate and spindle speed, on the thrust force and torque during the drilling of glass-fiber-reinforced polymers (GFRPs). A meso-scale, also known as unidirectional ply-level-based finite element modeling, was employed assuming an individual homogenized lamina with transversely isotropic material principal directions. To initiate the meso-scale damage in each lamina, 3D formulations of Hashin’s failure theory were used for fiber damage and Puck’s failure theory was implemented for matrix damage onset via user subroutine VUMAT in ABAQUS. The developed model accounted for the complex kinematics taking place at the drill–workpiece interface and accurately predicted the thrust force and torque profiles as compared with the experimental results. The thrust forces for various drilling parameters were predicted with a maximum of 10% error as compared with the experimental results. It was found that a combination of lower feed rates and higher spindle speeds reduced the thrust force, which in turn minimized the drilling-induced damage, thus providing useful guidelines for drilling operations with higher-quality products. Finally, the effect of coefficient of friction was also investigated. Accordingly, a higher coefficient of friction between the workpiece and drill-bit reduced the thrust force

Parametric Optimization and Influence of Near-Dry WEDM Variables on Nitinol Shape Memory Alloy

Nitinol-shape memory alloys (SMAs) are widely preferred for applications of automobile, biomedical, aerospace, robotics, and other industrial area. Therefore, precise machining of Nitinol SMA plays a vital role in achieving better surface roughness, higher productivity and geometrical accuracy for the manufacturing of devices. Wire electric discharge machining (WEDM) has proven to be an appropriate technique for machining nitinol shape memory alloy (SMA). The present study investigated the influence of near-dry WEDM technique to reduce the environmental impact from wet WEDM. A parametric optimization was carried out with the consideration of design variables of current, pulse-on-time (Ton), and pulse-off-time (Toff) and their effect were studied on output characteristics of material removal rate (MRR), and surface roughness (SR) for near-dry WEDM of nitinol SMA. ANOVA was carried out for MRR, and SR using statistical analysis to investigate the impact of design variables on response measures. ANOVA results depicted the significance of the developed quadratic model for both MRR and SR. Current, and Ton were found to be major contributors on the response value of MRR, and SR, respectively. A teaching&ndash;learning-based optimization (TLBO) algorithm was employed to find the optimal combination of process parameters. Single-response optimization has yielded a maximum MRR of 1.114 mm3/s at Ton of 95 &micro;s, Toff of 9 &micro;s, current of 6 A. Least SR was obtained at Ton of 35 &micro;s, Toff of 27 &micro;s, current of 2 A with a predicted value of 2.81 &micro;m. Near-dry WEDM process yielded an 8.94% reduction in MRR in comparison with wet-WEDM, while the performance of SR has been substantially improved by 41.56%. As per the obtained results from SEM micrographs, low viscosity, reduced thermal energy at IEG, and improved flushing of eroded material for air-mist mixture during NDWEDM has provided better surface morphology over the wet-WEDM process in terms of reduction in surface defects and better surface quality of nitinol SMA. Thus, for obtaining the better surface quality with reduced surface defects, near-dry WEDM process is largely suitable