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Formation of Compressive Residual Stress by Face Milling Steel AISI 1045
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Abstract

     Machining residual stresses correlate very closely with the cutting parameters and the tool geometries. This research work aims to investigate the effect of cutting speed, feed rate and depth of cut on the surface residual stress of steel AISI 1045 after face milling operation. After each milling test, the residual stress on the surface of the workpiece was measured by using X-ray diffraction technique. Design of Experiment (DOE) software was employed using the response surface methodology (RSM) technique with a central composite rotatable design to build a mathematical model to determine the relationship between the input variables and the response. The results showed that both the feed rate and the cutting speed are the significant factors controlling the surface residual stress, while the depth of cut had no influence. A quadratic empirical model was developed with a 95% confidence level, and a good agreement was found between the experimental and predicted results. A numerical optimization was then conducted through DOE program to find the optimum surface residual stress at the optimum cutting parameters, depending on the maximum desirability obtained. The optimum compressive surface residual stress (-224.361 MPa) was found at cutting speed of 69.2 m/min, feed rate of 0.4 m/min and depth of cut of 0.4 mm.

Keywords: Face milling, Cutting parameters, Steel AISI 1045, Residual stresses, XRD; DOE, RSM, Modeling and Numerical optimization.

 

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Publication Date
Sat Aug 21 2021
Journal Name
Engineering, Technology & Applied Science Research
The Response of a Highly Skewed Steel I-Girder Bridge with Different Cross-Frame Connections
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Braces in straight bridge systems improve the lateral-torsional buckling resistance of the girders by reducing the unbraced length, while in horizontally curved and skew bridges, the braces are primary structural elements for controlling deformations by engaging adjacent girders to act as a system to resist the potentially large forces and torques caused by the curved or skewed geometry of the bridge. The cross-frames are usually designed as torsional braces, which increase the overall strength and stiffness of the individual girders by creating a girder system that translates and rotates as a unit along the bracing lines. However, when they transmit the truck’s live load forces, they can produce fatigue cracks at their connection

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Publication Date
Sun Dec 09 2018
Journal Name
Baghdad Science Journal
Anticorrosion Behavior of Deposited Magnetite on Galvanized Steel in Saline Water Using RF-Magnetron Sputtering
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Thin films of Magnetite have been deposited on Galvanized Steel (G-S) alloy using RF-reactive magnetron sputtering technique and protection efficiency of the corrosion of G-S. A Three-Electrodes Cell was used in saline water (3.5 % NaCl) solution at different temperatures (298, 308, 318 & 328K) using potentiostatic techniques with. Electrochemical Impedance Spectroscopy (EIS) and fitting impedance data via Frequency Response Analysis (FRA) were applied to G-S alloy with Fe3O4 and tested in 3.5 % NaCl solution at 298K.Results taken from Nyquist and Bode plots were analyzed using software provided with the instrument. The results obtained show that the rate of corrosion of G.S alloy increased with increasing the temperatures from 298 t

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Publication Date
Fri May 01 2020
Journal Name
International Journal Of Geomate
METHODOLOGY FOR MONITORING THE FLEXURAL BEHAV-IOR OF STRUCTURAL CONCRETE MEMBERS WITH UNBONDED INTERNAL STEEL
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Publication Date
Tue Feb 01 2022
Journal Name
Journal Of Engineering Science And Technology
CORROSION of STEEL REINFORCEMENT in INTERNALLY CURED SELF-COMPACTING CONCRETE USING WASTE BRICK and THERMOSTONE
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Internal curing is a method that has been advised to decrease the primary age cracking, mainly of concrete mixes using low (water to cementitious materials - w/cm) ratios corresponding to the self-compacting concrete-(SCC). This research aims to study the effect of the internal curing using saturated lightweight aggregate- (LWA) on the steel reinforcing corrosion in SCC. In this research, crushed bricks or thermostone were partially replaced by (20%) by the weight of sand and volumetrically measured. The results showed that the steel reinforcement of internally cured concrete showed a slight increase in corrosion up to 300 days of exposure to the saline solution (containing 3.5% NaCl). The ability of using the crushed bricks or thermostone

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Publication Date
Wed Dec 01 2010
Journal Name
Al-khwarizmi Engineering Journal
Improvement of Surface Roughness Quality for Stainless Steel 420 Plate Using Magnetic Abrasive Finishing Method
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     An experimental study was carried out to improve the surface roughness quality of the stainless steel 420 using magnetic abrasive finishing method (MAF). Four independent operation parameters were studied (working gap, coil current, feed rate, and table stroke), and their effects on the MAF process were introduced. A rotating coil electromagnet was designed and implemented to use with plane surfaces. The magnetic abrasive powder used was formed from 33%Fe and 67% Quartz of (250µm mesh size). The lubricant type SAE 20W was used as a binder for the powder contents. Taguchi method was used for designing the experiments and the optimal values of the selected parameters were found. An empirical equation representing the r

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Publication Date
Tue Feb 01 2022
Journal Name
Journal Of Engineering Science And Technology
CORROSION of STEEL REINFORCEMENT in INTERNALLY CURED SELF-COMPACTING CONCRETE USING WASTE BRICK and THERMOSTONE
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Internal curing is a method that has been advised to decrease the primary age cracking, mainly of concrete mixes using low (water to cementitious materials - w/cm) ratios corresponding to the self-compacting concrete-(SCC). This research aims to study the effect of the internal curing using saturated lightweight aggregate- (LWA) on the steel reinforcing corrosion in SCC. In this research, crushed bricks or thermostone were partially replaced by (20%) by the weight of sand and volumetrically measured. The results showed that the steel reinforcement of internally cured concrete showed a slight increase in corrosion up to 300 days of exposure to the saline solution (containing 3.5% NaCl). The ability of using the crushed bricks or thermostone

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Publication Date
Fri Nov 01 2019
Journal Name
Civil Engineering Journal
Experimental and Numerical Investigations of Composite Concrete–Steel Plate Shear Walls Subjected to Axial Load
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This research is presented experimental and numerical investigations of composite concrete-steel plate shear walls under axial loads to predicate the effect of both concrete compressive strength and aspect ratio of the wall on the axial capacity, lateral displacement and axial shortening of the walls. The experimental program includes casting and testing two groups of walls with various aspect ratios. The first group with aspect ratio H/L=1.667 and the second group with aspect ratio H/L=2. Each group consists of three composite concrete -steel plate wall with three targets of cube compressive strength of values 39, 54.75 and 63.3 MPa. The tests result obtained that the increase in concrete compressive strength results in increasing

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Publication Date
Mon Sep 01 2025
Journal Name
Civil Engineering Journal
Pre- and Post-Cracking Resistance of Steel Fiber Reinforced Concrete Flexural Members with GFRP Bars
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This research investigates the pre- and post-cracking resistance of steel fiber-reinforced concrete specimens with Glass Fiber Reinforced Polymer (GFRP) bars subjected to flexural loading. The purpose is to modify the ductility and cracking resistance of GFRP-reinforced beams, which are prone to early cracking and excessive deflections instigated by the low modulus of elasticity of GFRP. Six self-compacting concrete specimens (1500×240×200 mm), incorporating steel fibers of two lengths (25 mm and 40 mm) with varying distribution depths, were tested to assess their structural performance. The results indicate significant enhancements in cracking resistance, stiffness, energy absorption, ductility, and flexural strength. Tested beam

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Publication Date
Sat Oct 01 2022
Journal Name
Structures
Behaviour and design of the ‘lockbolt’ demountable shear connector for sustainable steel-concrete composite structures
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In order to promote sustainable steel-concrete composite structures, special shear connectors that can facilitate deconstruction are needed. A lockbolt demountable shear connector (LB-DSC), including a grout-filled steel tube embedded in the concrete slab and fastened to a geometrically compatible partial-thread bolt, which is bolted on the steel section's top flange of a composite beam, was proposed. The main drawback of previous similar demountable bolts is the sudden slip of the bolt inside its hole. This bolt has a locked conical seat lug that is secured inside a predrilled compatible counter-sunk hole in the steel section's flange to provide a non-slip bolt-flange connection. Deconstruction is achieved by demounting the tube from the t

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Publication Date
Wed Mar 19 2025
Journal Name
Chemical Papers
Natural deep eutectic solvents as a green inhibitor of carbon steel corrosion in sulphuric acid
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