Abstract: Gas Metal Arc Welding (GMAW) processes is an
important joining process widely used in metal fabrication
industries. This paper addresses modeling and optimization of this
technique using a set of experimental data and regression analysis.
The set of experimental data has been used to assess the influence
of GMAW process parameters in weld bead geometry. The
process variables considered here include voltage (V); wire feed
rate (F); torch Angle (A); welding speed (S) and nozzle-to-plate
distance (D). The process output characteristics include weld bead
height, width and penetration. The Taguchi method and regression
modeling are used in order to establish the relationships between
input and output parameters. The adequacy of the model is
evaluated using analysis of variance (ANOVA) technique. In the
next stage, the proposed model is embedded into a Simulated
Annealing (SA) algorithm to optimize the GMAW process
parameters. The objective is to determine a suitable set of process
parameters that can produce desired bead geometry, considering
the ranges of the process parameters. Computational results prove
the effectiveness of the proposed model and optimization
procedure.
Abstract: This paper gives an overview of a deep drawing
process by pressurized liquid medium separated from the sheet by a
rubber diaphragm. Hydroforming deep drawing processing of sheet
metal parts provides a number of advantages over conventional
techniques. It generally increases the depth to diameter ratio possible
in cup drawing and minimizes the thickness variation of the drawn
cup. To explore the deformation mechanism, analytical and
numerical simulations are used for analyzing the drawing process of
an AA6061-T4 blank. The effects of key process parameters such as
coefficient of friction, initial thickness of the blank and radius
between cup wall and flange are investigated analytically and
numerically. The simulated results were in good agreement with the
results of the analytical model. According to finite element
simulations, the hydroforming deep drawing method provides a more
uniform thickness distribution compared to conventional deep
drawing and decreases the risk of tearing during the process.
Abstract: Abrasive waterjet is a novel machining process capable of processing wide range of hard-to-machine materials. This research addresses modeling and optimization of the process parameters for this machining technique. To model the process a set of experimental data has been used to evaluate the effects of various parameter settings in cutting 6063-T6 aluminum alloy. The process variables considered here include nozzle diameter, jet traverse rate, jet pressure and abrasive flow rate. Depth of cut, as one of the most important output characteristics, has been evaluated based on different parameter settings. The Taguchi method and regression modeling are used in order to establish the relationships between input and output parameters. The adequacy of the model is evaluated using analysis of variance (ANOVA) technique. The pairwise effects of process parameters settings on process response outputs are also shown graphically. The proposed model is then embedded into a Simulated Annealing algorithm to optimize the process parameters. The optimization is carried out for any desired values of depth of cut. The objective is to determine proper levels of process parameters in order to obtain a certain level of depth of cut. Computational results demonstrate that the proposed solution procedure is quite effective in solving such multi-variable problems.
Abstract: Activated carbon was prepared from agricultural waste “almond (Prunus amygdalus) nut shells" by chemical activation with phosphoric acid as an activating agent at 450 °C for 24 hr soaking time. The physical and chemical properties were analyzed. The adsorption of chromium VI from aqueous solution on almond nut shell activated carbon (ASAC) was investigated. The adsorption process parameters pH, agitation speed, agitation time, adsorbent dose were optimized. 98% of Cr VI was sorbed at pH 2 and stirring speed 200 rpm.. Surface structure showed that ASAC has a spongy type structure showing large number of pores
Abstract: During the last few years, several sheet hydroforming
processes have been introduced. Despite the advantages of these
methods, they have some limitations. Of the processes, the two main
ones are the standard hydroforming and hydromechanical deep
drawing. A new sheet hydroforming die set was proposed that has the
advantages of both processes and eliminates their limitations. In this
method, a polyurethane plate was used as a part of the die-set to
control the blank holder force. This paper outlines the Taguchi
optimization methodology, which is applied to optimize the effective
parameters in forming cylindrical cups by the new die set of sheet
hydroforming process. The process parameters evaluated in this
research are polyurethane hardness, polyurethane thickness, forming
pressure path and polyurethane hole diameter. The design of
experiments based upon L9 orthogonal arrays by Taguchi was used
and analysis of variance (ANOVA) was employed to analyze the
effect of these parameters on the forming pressure. The analysis of
the results showed that the optimal combination for low forming
pressure is harder polyurethane, bigger diameter of polyurethane hole
and thinner polyurethane. Finally, the confirmation test was derived
based on the optimal combination of parameters and it was shown
that the Taguchi method is suitable to examine the optimization
process.
Abstract: In the present study, an attempt was made to examine
the potential of aerobic mixed culture for decolourization of Remazol Black B dye in batch reactors. The effect of pH, temperature, inoculum, initial concentration of dye and initial concentration of
glucose was studied with an aim to determine the optimal conditions
required for maximum decolourization and degradation. The culture
exhibited maximum decolourization ability at pH between 7-8 and at
30°C. A 10% (v/v) inoculum and 1% (w/v) glucose concentration
were found to be the optimum for decolourization. A maximum of
98% decolourization was observed at 25 ppm initial concentration of
dye after 18 hours of incubation period. At higher dye concentration
of 300 ppm, the removal in colour was found to be 75% in 48 hours of incubation period. The results show that the enriched mixed culture from activated sludge has good potential in removal of Remazol Black B dye from wastewater under aerobic conditions.
Abstract: Wheat germ has a balanced amino acid composition of the protein, which is well digested by enzymes in the gastrointestinal tract of humans, a high content of vitamins, minerals and unsaturated acids. Introduction components grain food products will enrich their biologically important substances, giving these products a number of valuable properties and reducing their caloric.
A complex natural system of substances in foods will help replenish the body's need of essential nutrients, increasing its resistance to the harmful effects of the environment, prolong life. In this regard, there was a need for the development of production technology of protein complexes from wheat germ and then applying them in food, particularly in the dairy industry. Experimental studies were conducted to determine the number of herbal supplements on the sensory characteristics of the product. Studies have been conducted to determine the optimal process parameters of water activity and moisture content of the investigational product.
Abstract: This work has been conducted to study on comfort level of drivers of suspended cabin tractor semitrailer. Some drivers suffer from low back pain caused by vibration. The practical significance of applying suspended cabin type of tractor semi trailer was tested at different road conditions, different speed as well as different load conditions for comfortable driver seat interface (x, y, z ) and the process parameters have been prioritized using Taguchi-s L27 orthogonal array. Genetic Algorithm (GA) is used to optimize the human comfort vibration of suspended cabin tractor semitrailer drivers. The practical significance of applying GA to human comfort to reaction of suspended cabin tractor semitrailer has been validated by means of computing the deviation between predicted and experimentally obtained human comfort to vibration. The optimized acceleration data indicate a little uncomfortable ride for suspended cabin tractor semitrailer.
Abstract: We propose photo-BJMOSFET (Bipolar Junction Metal-Oxide-Semiconductor Field Effect Transistor) fabricated on SOI film. ITO film is adopted in the device as gate electrode to reduce light absorption. I-V characteristics of photo-BJMOSFET obtained in dark (dark current) and under 570nm illumination (photo current) are studied furthermore to achieve high photo-to-dark-current contrast ratio. Two variables in the calculation were the channel length and the thickness of the film which were set equal to six different values, i.e., L=2, 4, 6, 8, 10, and 12μm and three different values, i.e., dsi =100, 200 and 300nm, respectively. The results indicate that the greatest photo-to-dark-current contrast ratio is achieved with L=10μm and dsi=200 nm at VGK=0.6V.
Abstract: In this paper, a set of experimental data has been used to assess the influence of abrasive water jet (AWJ) process parameters in cutting 6063-T6 aluminum alloy. The process variables considered here include nozzle diameter, jet traverse rate, jet pressure and abrasive flow rate. The effects of these input parameters are studied on depth of cut (h); one of most important characteristics of AWJ. The Taguchi method and regression modeling are used in order to establish the relationships between input and output parameters. The adequacy of the model is evaluated using analysis of variance (ANOVA) technique. In the next stage, the proposed model is embedded into a Simulated Annealing (SA) algorithm to optimize the AWJ process parameters. The objective is to determine a suitable set of process parameters that can produce a desired depth of cut, considering the ranges of the process parameters. Computational results prove the effectiveness of the proposed model and optimization procedure.
Abstract: Deep cold rolling (DCR) is a cold working process, which easily produces a smooth and work-hardened surface by plastic deformation of surface irregularities. In the present study, the influence of main deep cold rolling process parameters on the surface roughness and the hardness of AISI 4140 steel were studied by using fractional factorial design of experiments. The assessment of the surface integrity aspects on work material was done, in terms of identifying the predominant factor amongst the selected parameters, their order of significance and setting the levels of the factors for minimizing surface roughness and/or maximizing surface hardness. It was found that the ball diameter, rolling force, initial surface roughness and number of tool passes are the most pronounced parameters, which have great effects on the work piece-s surface during the deep cold rolling process. A simple, inexpensive and newly developed DCR tool, with interchangeable collet for using different ball diameters, was used throughout the experimental work presented in this paper.
Abstract: Manufacturing components of fiber-reinforced
thermoplastics requires three steps: heating the matrix, forming and
consolidation of the composite and terminal cooling the matrix. For
the heating process a pre-determined temperature distribution through
the layers and the thickness of the pre-consolidated sheets is
recommended to enable forming mechanism. Thus, a design for the
heating process for forming composites with thermoplastic matrices
is necessary. To obtain a constant temperature through thickness and
width of the sheet, the heating process was analyzed by the help of
the finite element method. The simulation models were validated by
experiments with resistance thermometers as well as with an infrared
camera. Based on the finite element simulation, heating methods for
infrared radiators have been developed. Using the numeric
simulation many iteration loops are required to determine the process
parameters. Hence, the initiation of a model for calculating relevant
process parameters started applying regression functions.
Abstract: Laser engraving is a manufacturing method for those applications where previously Electrical Discharge Machining (EDM) was the only choice. Laser engraving technology removes material layer-by-layer and the thickness of layers is usually in the range of few microns. The aim of the present work is to investigate the influence of the process parameters on the surface quality when machined by laser engraving. The examined parameters were: the pulse frequency, the beam speed and the layer thickness. The surface quality was determined by the surface roughness for every set of parameters. Experimental results on Al7075 material showed that the surface roughness strictly depends on the process parameters used.
Abstract: The plastic flow of metal in the extrusion process is
an important factor in controlling the mechanical properties of the
extruded products. It is, however, difficult to predict the metal flow
in three dimensional extrusions of sections due to the involvement of
re-entrant corners. The present study is to find an upper bound
solution for the extrusion of triangular sectioned through taper dies
from round sectioned billet. A discontinuous kinematically
admissible velocity field (KAVF) is proposed. From the proposed
KAVF, the upper bound solution on non-dimensional extrusion
pressure is determined with respect to the chosen process parameters.
The theoretical results are compared with experimental results to
check the validity of the proposed velocity field. An extrusion setup
is designed and fabricated for the said purpose, and all extrusions are
carried out using circular billets. Experiments are carried out with
commercially available lead at room temperature.
Abstract: Raisin Concentrate (RC) are the most important
products obtained in the raisin processing industries. These RC
products are now used to make the syrups, drinks and confectionery
productions and introduced as natural substitute for sugar in food
applications. Iran is a one of the biggest raisin exporter in the world
but unfortunately despite a good raw material, no serious effort to
extract the RC has been taken in Iran. Therefore, in this paper, we
determined and analyzed affected parameters on extracting RC
process and then optimizing these parameters for design the
extracting RC process in two types of raisin (round and long)
produced in Khorasan region. Two levels of solvent (1:1 and 2:1),
three levels of extraction temperature (60°C, 70°C and 80°C), and
three levels of concentration temperature (50°C, 60°C and 70°C)
were the treatments. Finally physicochemical characteristics of the
obtained concentrate such as color, viscosity, percentage of reduction
sugar, acidity and the microbial tests (mould and yeast) were
counted. The analysis was performed on the basis of factorial in the
form of completely randomized design (CRD) and Duncan's multiple
range test (DMRT) was used for the comparison of the means.
Statistical analysis of results showed that optimal conditions for
production of concentrate is round raisins when the solvent ratio was
2:1 with extraction temperature of 60°C and then concentration
temperature of 50°C. Round raisin is cheaper than the long one, and
it is more economical to concentrate production. Furthermore, round
raisin has more aromas and the less color degree with increasing the
temperature of concentration and extraction. Finally, according to
mentioned factors the concentrate of round raisin is recommended.
Abstract: This paper presents a methodical approach for designing and optimizing process parameters in oil blending industries. Twenty seven replicated experiments were conducted for production of A-Z crown super oil (SAE20W/50) employing L9 orthogonal array to establish process response parameters. Power law model was fitted to experimental data and the obtained model was optimized applying the central composite design (CCD) of response surface methodology (RSM). Quadratic model was found to be significant for production of A-Z crown supper oil. The study recognized and specified four new lubricant formulations that conform to ISO oil standard in the course of analyzing the batch productions of A-Z crown supper oil as: L1: KV = 21.8293Cst, BS200 = 9430.00Litres, Ad102=11024.00Litres, PVI = 2520 Litres, L2: KV = 22.513Cst, BS200 = 12430.00 Litres, Ad102 = 11024.00 Litres, PVI = 2520 Litres, L3: KV = 22.1671Cst, BS200 = 9430.00 Litres, Ad102 = 10481.00 Litres, PVI= 2520 Litres, L4: KV = 22.8605Cst, BS200 = 12430.00 Litres, Ad102 = 10481.00 Litres, PVI = 2520 Litres. The analysis of variance showed that quadratic model is significant for kinematic viscosity production while the R-sq value statistic of 0.99936 showed that the variation of kinematic viscosity is due to its relationship with the control factors. This study therefore resulted to appropriate blending proportions of lubricants base oil and additives and recommends the optimal kinematic viscosity of A-Z crown super oil (SAE20W/50) to be 22.86Cst.
Abstract: In this research, Response Surface Methodology (RSM) is used to investigate the effect of four controllable input variables namely: discharge current, pulse duration, pulse off time and applied voltage Surface Roughness (SR) of on Electrical Discharge Machined surface. To study the proposed second-order polynomial model for SR, a Central Composite Design (CCD) is used to estimation the model coefficients of the four input factors, which are alleged to influence the SR in Electrical Discharge Machining (EDM) process. Experiments were conducted on AISI D2 tool steel with copper electrode. The response is modeled using RSM on experimental data. The significant coefficients are obtained by performing Analysis of Variance (ANOVA) at 5% level of significance. It is found that discharge current, pulse duration, and pulse off time and few of their interactions have significant effect on the SR. The model sufficiency is very satisfactory as the Coefficient of Determination (R2) is found to be 91.7% and adjusted R2-statistic (R2 adj ) 89.6%.
Abstract: The main aim of this study is to identify the most
influential variables that cause defects on the items produced by a
casting company located in Turkey. To this end, one of the items
produced by the company with high defective percentage rates is
selected. Two approaches-the regression analysis and decision treesare
used to model the relationship between process parameters and
defect types. Although logistic regression models failed, decision tree
model gives meaningful results. Based on these results, it can be
claimed that the decision tree approach is a promising technique for
determining the most important process variables.
Abstract: The process parameters, temperature, pH and
substrate concentration, were optimized for the production of
gentamicin using Micromonouspora echinospora. Experiments were
carried out according to central composite design in response surface
method. The optimum conditions for the maximum production of
gentamicin were found to be: temperature – 31.7oC, pH – 6.8 and
substrate concentration – 3%. At these optimized conditions the
production of gentamicin was found to be – 1040 mg/L. The R2 value
of 0.9465 indicates a good fitness of the model.
Abstract: In this work, simulation algorithms for contact drying
of agitated particulate materials under vacuum and at atmospheric
pressure were developed. The implementation of algorithms gives a
predictive estimation of drying rate curves and bulk bed temperature
during contact drying. The calculations are based on the penetration
model to describe the drying process, where all process parameters
such as heat and mass transfer coefficients, effective bed properties,
gas and liquid phase properties are estimated with proper
correlations. Simulation results were compared with experimental
data from the literature. In both cases, simulation results were in good
agreement with experimental data. Few deviations were identified
and the limitations of the predictive capabilities of the models are
discussed. The programs give a good insight of the drying behaviour
of the analysed powders.