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.
In this investigation, deep eutectic solvent based on propionic acid and choline chloride was used to prepare polyaniline, polypyrrole, and poly(aniline-co-pyrrole) samples using chemical oxidation and polymerization. Quantum mechanical calculations were conducted using time-dependent density functional theory to determine the electronic, spectroscopic properties and structure of homopolymers and the copolymer which were compared with the respective experimental data. Furthermore, the synthesized materials were characterized using Fourier transform IR spectroscopy, scanning electron microscopy (SEM), UV-visible spectroscopy, and thermogravimetric analysis. IR and UV-visible spectra confirmed copolymerization, and SEM revealed that the copol
... Show MoreMedian filter is adopted to match the noise statistics of the degradation seeking good quality smoothing images. Two methods are suggested in this paper(Pentagonal-Hexagonal mask and Scan Window Mask), the study involved modified median filter for improving noise suppression, the modification is considered toward more reliable results. Modification median filter (Pentagonal-Hexagonal mask) was found gave better results (qualitatively and quantitatively ) than classical median filters and another suggested method (Scan Window Mask), but this will be on the account of the time required. But sometimes when the noise is line type the cross 3x3 filter preferred to another one Pentagonal-Hexagonal with few variation. Scan Window Mask gave bett
... Show MoreIn the present research, a crane frame has been investigated by using finite element method. The damage is simulated by reducing the stiffness of assumed elements with ratios (10% and 20 %) in mid- span of the vertical column in crane frame. The cracked beam with a one-edge and non-propagating crack has been used. Six cases of damage are modeled for crane frame and by introducing cracked elements at different locations with ratio of depth of crack to the height of the beam (a/h) 0.1, 0.20. A FEM program coded in Matlab 6.5 was used to model the numerical simulation of the damage scenarios. The results showed a decreasing in the five natural frequencies from undamaged beam which means
... Show MoreIn this research, the performance of asphalt mixtures modified with polyethylene polymer (PE) by adding 2%, 4%, and 6% percentages was evaluated. Two kinds of PE are employed: Low-Density PE (LDPE) and High-Density PE (HDPE). The semi-wet mixing technique (SWM) was conducted to avoid stability issue for PE-modified binder during storage condition. Many experimental tests were conducted to evaluate the ability of these mixtures to withstand the effects of loads and moisture. The hardness index of these mixtures was also measured to determine their resistance to the effects of high temperatures without causing permanent deformations. The results showed that adding PE led to a remarkable enhancement in the performance of PE-modified mixtures.
... Show MoreIraq has a huge network of pipelines, transport crude oil and final hydrocarbon products as well as portable water. These networks are exposed to extensive damage due to the underground corrosion processes unless suitable protection techniques are used. In this paper we collect the information of cathodic protection for pipeline in practical fields (Oil Group in Al Doura), to obtain data base to understand and optimize the design which is made by simulation for the environmental factors and cathodic protection variables also soil resistivity using wenner four terminal methods for survey sites; and soil pH investigations were recorded for these selected fields were within 7-8, and recording the anodes voltage and its related currents for
... Show MoreDrones play a vital role in the fundamental aspects of Industry 4.0 by converting conventional warehouses into intelligent ones, particularly in the realm of barcode scanning. Various potential issues frequently arise during barcode scanning by drones, specifically when the drone camera has difficulty obtaining distinct images due to certain factors, such as distance, capturing the image whilst flying, noise in the environment and different barcode dimensions. In addressing these challenges, this study proposes an approach that combines a proportional–integral–derivative (PID) controller with image processing techniques. The PID controller is responsible for continuously monitoring the camera’s input, detecting the difference
... Show MoreVisualization of water flow around different bluff bodies at different Reynolds number ranging (1505 - 2492) was realized by designing and building a test rig which contains an open channel capable to ensure water velocity range (4-8cm/s) in this channel. Hydrogen bubbles generated from the ionized water using DC power supply are visualized by a light source and photographed by a digital camera. Flow pattern around a circular disk of (3.6cm) diameter and (3mm) thickness, a sphere of (3.8cm) diameter and a cylinder of
(3.2cm) diameter and (10cm) length are studied qualitatively. Parameters of the vortex ring generated in the wake region of the disk and the separation angle of water stream lines from the surface of the sphere are plott
This work introduces a newly synthesized triazole derivative, 5-([(2-furanyl)methyl]-thiomethyl)-4-(naphtha-2-yl)-3-hydroxyl-4H-1,2,4-triazole (FTNT), as an effective corrosion inhibitor for carbon steel A106 G/B in 0.1 M HCl solution. The structure of the novel derivative was confirmed by FTIR, 1 H NMR, and 13 C NMR spectra. Potentiodynamic polarization measurements reveal that FTNT markedly suppresses corrosion, with inhibition efficiency reaching 81.6% at 600 ppm. Thermodynamic analysis indicates spontaneous, physisorption/chemisorption-augmented adsorption of FTNT on the steel surface, best described by the Freundlich isotherm. Atomic force microscopy (AFM) surface examination demonstrated that a protective FTNT coating precipitated on
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