This study presents a transient thermo-mechanical finite element framework for high-speed end milling of AISI 4340 steel. The model couples moving heat sources, rate- and temperature-dependent plasticity, and adaptive mesh refinement (AMR) triggered by temperature gradient, plastic strain rate, and contact pressure. It is integrated with a design of experiments/response surface methodology using cutting speed (VC), feed per tooth (fZ), radial depth of cut/width of cut (ae), axial depth of cut (ap), and coolant mode. Responses include peak interface temperature per tooth (Tpeak), predicted surface residual stress (?_xx^"surf" ), and depth of compressive residual stress layer (dcomp). Experiments provide X-ray diffraction-based surface/depth profiles and arithmetic mean surface roughness (Ra). AMR is applied in this study to minimize the cut compute cost by 41-52% and error by 35-45%. Across 12 validation cuts, root mean square errors were 24 °C of Tpeak, 33 MPa of ?_xx^"surf" , 0.07 µm of Ra, and 22 MPa of dcomp. The response surface methodology and analysis of variance identified VC as the main driver of thermal load, while fZ, ae, and ap controlled the sign and depth of the residual field; coolant modified heat partition. Multi-objective desirability optimization with a material removal rate constraint yielded a balanced minimum quantity lubrication. Overall, exit-edge cooling and subsurface plasticity jointly set residual sign and magnitude; AMR is essential to resolve these gradients efficiently. The framework offers a reproducible route for residual stress-aware process planning in fatigue-critical AISI 4340 components while preserving throughput and is readily transferable to allied high-strength steels.
Several previous investigations and studies utilized silica fume (SF) or (micro silica) particles as supplementary cementitious material added as a substitute to cement-based mortars and their effect on the overall properties, especially on physical properties, strength properties, and mechanical properties. This study investigated the impact of the inclusion of silica fume (SF) particles on the residual compressive strengths and microstructure properties of cement-based mortars exposed to severe conditions of elevated temperatures. The prepared specimens were tested and subjected to 25, 250, 450, 600, and 900 °C. Their residual compressive strengths and microstructure were evaluated and compared with control samples (C
... Show MoreThis work investigates the effect of the gas nitriding process on the surface layer microstructure and mechanical properties for steel 37, tool steel X155CrVMo12-1 and stainless steel 316L. Nitriding was conducted at a temperature of 550 °C for 2 hours during the first stage and at 750 °C for 4 hours during the second stage. SEM and X-ray diffraction tests were performed to evaluate the microstructural features and the major phases formed after surface treatment. SEM and X-ray diffraction tests were performed to assess the microstructural features and the primary phases formed after surface treatment. The new secondary precipitates were identified as γ′-Fe4N, ε (Fe2–3N), and α-Fe, exhibiting an uneven chain-like pattern wit
... Show MoreThis study investigates the implementation of Taguchi design in the estimation of minimum corrosion rate of mild-steel in cooling tower that uses saline solution of different concentration. The experiments were set on the basis of Taguchi’s L16 orthogonal array. The runs were carried out under different condition such as inlet concentration of saline solution, temperature, and flowrate. The Signal-to- Noise ratio and ANOVA analysis were used to define the impact of cooling tower working conditions on the corrosion rate. A regression had been modelled and optimized to identify the optimum level for the working parameters that had been founded to be 13%NaCl, 35ᴼC, and 1 l/min. Also a confirmation run to establish the p
... Show MoreDespite the broad approbation of additive manufacturing technologies over diverse industries, printed parts’ performance, quality, and related build time are still greatly influenced by printing parameters. These parameters majorly affect mechanical strength, surface finish, dimensional accuracy, and overall production time of the printed part. Customized 3D printing layer thickness, speed, and acceleration are crucial parameters that affect the speedy printing process and final product quality. The current work considers layer thickness in addition to speed and high acceleration values effect on the surface quality, surface roughness and productivity time of 3D printed Polylactic Acid (PLA). The experimental methodology implemented withi
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In the present work, thermal diffusivity and heat capacity measurements have been investigated in temperature range between RT and 1473 K for different duplex stainless steel supplied by Outokumpu Stainless AB, Sweden. The purpose of this study is to get a reliable thermophysical data of these alloys and to study the effect of microstructure on the thermal diffusivity and heat capacity value. Results show the ferrite content in the duplex stainless steel increased with temperature at equilibrium state. On the other hand, ferrite content increased with increasing Cr/Ni ratio and there is no significant effect of ferrite content on the thermal diffusivity value at room temperature. Furthermore, the heat capacity of all sam
... Show MoreTransient displacement of laminated plates under combined load based on Mantari' s displacement field are investigated. The solution is implemented under transient mechanical load (sinusoidal, step and triangular sinusoidal distributed pressures pulse) and thermal buckling for plates with different layer orientation and thickness ratio. Equations of motion based on higher-order theory are derived through Hamilton' s principle, and solved using Naviertype solution for simply supported laminated plates. The results are presented for many effective parameters such as the number of laminate and orientation on the dynamic response of plates. Results show the validity of this displacement field in studying response of laminated thick and
... Show Morehe paper presents the results of exposure of normal concrete to high temperatures (400 and 700°C). In addition to the exposure of steel reinforcement bar Ø 12 mm, where two types of steel reinforcement burning situations were performed. Directly exposed to high temperatures (400 and 700°C) and others were covered by concrete layer (15 mm). From the experimental results of fire exposure for 1 hour of 400 and 700°C and gradually cooled, it was found that the residual average percentage of compressive strength of concrete was 85.3 and 41.4%, while the residual average percentage of modulus of elasticity of concrete was 75 and 48%, respectively. The residual average percentage of yielding tensile stress (Ø 12 mm) after burning and cooling
... Show MoreIn this paper, the speed control of the real DC motor is experimentally investigated using nonlinear PID neural network controller. As a simple and fast tuning algorithm, two optimization techniques are used; trial and error method and particle swarm optimization PSO algorithm in order to tune the nonlinear PID neural controller's parameters and to find best speed response of the DC motor. To save time in the real system, a Matlab simulation package is used to carry out these algorithms to tune and find the best values of the nonlinear PID parameters. Then these parameters are used in the designed real time nonlinear PID controller system based on LabVIEW package. Simulation and experimental results are compared with each other and showe
... Show MoreLaser is a powerful device that has a wide range of applications in fields ranging from materials science and manufacturing to medicine and fibre optic communications. One remarkable