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TRANSIENT THERMAL–MECHANICAL SIMULATION AND EXPERIMENTAL VALIDATION OF RESIDUAL STRESS IN HIGH-SPEED END MILLING OF STEEL USING ADAPTIVE MESH REFINEMENT AND DESIGN OF EXPERIMENTS BASED PROCESS OPTIMIZATION
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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.

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Fri Dec 01 2023
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Iop Conference Series: Earth And Environmental Science
Effect of speed and die holes diameter in the machine on feed pellets quality
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Abstract<p>The study aimed to effect of speed and die holes diameter in the machine on feed pellets quality. In this study was measured pellet direct measurement (%), pellet lengths (%), pellet durability (%) and pellet water absorption (%). Three die speeds 280, 300, and 320 rpm, three diameters of die holes in the machine 3, 4, and 5 mm, have been used. The results showed that increasing the pellet die speeds from 280 to 300 then to 320 rpm led to a significant decrease in direct measurement, pellet durability, and pellet water absorption was increased, whereas it did not significantly affect the pellet lengths. Increasing the die holes diameter from 3 to 4 then to 5 mm led to a significant de</p> ... Show More
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Sun Dec 17 2017
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Al-khwarizmi Engineering Journal
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In the present investigation, bed porosity and solid holdup in viscous three-phase inverse fluidized bed (TPIFB) are determined for aqueous solutions of carboxy methyl cellulose (CMC) system using polyethylene and polypropylene as  a particles with low-density and diameter (5 mm) in a (9.2 cm) inner diameter with height (200 cm) of vertical perspex column. The effectiveness of gas velocity Ug , liquid velocity UL, liquid viscosity μL, and particle density ρs on bed porosity BP and solid holdups εg were determined. The bed porosity increases with "increasing gas velocity", "liquid velocity", and "liquid viscosity". Solid holdup decreases with increasing gas, liquid

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Protection of Galvanized steel from corrosion in salt media using sulfur nanoparticles
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   The corrosion rate was measured using both the weight loss and the electrochemical techniques. The weight loss results showed that PVA could serve as a corrosion inhibitor but its inhibition power was found to be low for the corrosion of carbon steel in the acidic media. Electrochemical analysis of the corrosion process of carbon steel in an electrochemical corrosion cell was investigated using 3-Electrode corrosion cell. Polarization technique was used for carbon steel corrosion in 0.2N H

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Beyond empiricism: a unified physics-based framework for resonance avoidance and carbon-efficient mass optimization of machine foundations
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Dynamic machine foundations can be considered as a necessary component of the industrial infrastructure. Design of the dynamic equipment foundations has, however, traditionally been grounded on a rule of thumb that is inaccurate and rigid to use at the discretion of the engineers. The conventional rule of thumb, which includes minimum weight ratios and resonance avoidance criteria, has been used singularly with two poles, which can be either conservatively designed systems that are too heavy, or systems that are going to experience too much vibration and fatigue. This paper presents a novel, analytical framework for the reinterpretation of traditional design practices, using a physics-based approach, and results in a single, unified overall

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