Abstract: Primary barrier of membrane type LNG containment system consist of corrugated 304L stainless steel. This 304L stainless steel is austenitic stainless steel which shows different material behaviors owing to phase transformation during the plastic work. Even though corrugated primary barriers are subjected to significant amounts of pre-strain due to press working, quantitative mechanical behavior on the effect of pre-straining at cryogenic temperatures are not available. In this study, pre-strain level and pre-strain temperature dependent tensile tests are carried to investigate mechanical behaviors. Also, constitutive equations with material parameters are suggested for a verification study.
Abstract: A transient finite element model has been developed
to study the heat transfer and fluid flow during spot Gas Tungsten
Arc Welding (GTAW) on stainless steel. Temperature field, fluid
velocity and electromagnetic fields are computed inside the cathode,
arc-plasma and anode using a unified MHD formulation. The
developed model is then used to study the influence of different
helium-argon gas mixtures on both the energy transferred to the
workpiece and the time evolution of the weld pool dimensions. It is
found that the addition of helium to argon increases the heat flux
density on the weld axis by a factor that can reach 6.5. This induces
an increase in the weld pool depth by a factor of 3. It is also found
that the addition of only 10% of argon to helium decreases
considerably the weld pool depth, which is due to the electrical
conductivity of the mixture that increases significantly when argon is
added to helium.
Abstract: The present work is concerned with the effect of turning process parameters (cutting speed, feed rate, and depth of cut) and distance from the center of work piece as input variables on the chip micro-hardness as response or output. Three experiments were conducted; they were used to investigate the chip micro-hardness behavior at diameter of work piece for 30[mm], 40[mm], and 50[mm]. Response surface methodology (R.S.M) is used to determine and present the cause and effect of the relationship between true mean response and input control variables influencing the response as a two or three dimensional hyper surface. R.S.M has been used for designing a three factor with five level central composite rotatable factors design in order to construct statistical models capable of accurate prediction of responses. The results obtained showed that the application of R.S.M can predict the effect of machining parameters on chip micro-hardness. The five level factorial designs can be employed easily for developing statistical models to predict chip micro-hardness by controllable machining parameters. Results obtained showed that the combined effect of cutting speed at it?s lower level, feed rate and depth of cut at their higher values, and larger work piece diameter can result increasing chi micro-hardness.
Abstract: In the present work, a study has been made on the combination of the electrical discharge machining (EDM) with ultrasonic vibrations to improve the machining efficiency. In experiments the graphite used as tool electrode and material of workpiece was AISIH13 tool steel. The parameters such as discharge peak current and pulse duration were changed to explore their effect on the material removal rate (MRR), relative tool wear ratio (TWR) and surface roughness. From the experimental result it can be seen that ultrasonic vibration of the workpiece can significantly reduces the inactive pulses and improves the stability of process. It was found that ultrasonic assisted EDM (US-EDM) is effective in attaining a high material removal rate (MRR) in finishing regime.
Abstract: Solidification cracking and hydrogen cracking are some defects generated in the fusion welding of ultrahigh carbon steels. However, friction stir welding (FSW) of such steels, being a solid-state technique, has been demonstrated to alleviate such problems encountered in traditional welding. FSW include different process parameters that must be carefully defined prior processing. These parameters included but not restricted to: tool feed, tool RPM, tool geometry, tool tilt angle. These parameters form a key factor behind avoiding warm holes and voids behind the tool and in achieving a defect-free weld. More importantly, these parameters directly affect the microstructure of the weld and hence the final mechanical properties of weld. For that, 3D finite element (FE) thermo-mechanical model was developed using DEFORM 3D to simulate FSW of carbon steel. At points of interest in the joint, tracking is done for history of critical state variables such as temperature, stresses, and strain rates. Typical results found include the ability to simulate different weld zones. Simulations predictions were successfully compared to experimental FSW tests. It is believed that such a numerical model can be used to optimize FSW processing parameters to favor desirable defect free weld with better mechanical properties.
Abstract: Deep cold rolling (DCR) and low plasticity burnishing (LPB) process are cold working processes, which easily produce a smooth and work-hardened surface by plastic deformation of surface irregularities. The present study focuses on the surface roughness and surface hardness aspects of AISI 4140 work material, using fractional factorial design of experiments. The assessment of the surface integrity aspects on work material was done, in order to identify the predominant factors amongst the selected parameters. They were then categorized in order of significance followed by setting the levels of the factors for minimizing surface roughness and/or maximizing surface hardness. In the present work, the influence of main process parameters (force, feed rate, number of tool passes/overruns, initial roughness of the work piece, ball material, ball diameter and lubricant used) on the surface roughness and the hardness of AISI 4140 steel were studied for both LPB and DCR process and the results are compared. It was observed that by using LPB process surface hardness has been improved by 167% and in DCR process surface hardness has been improved by 442%. It was also found that the force, ball diameter, number of tool passes and initial roughness of the workpiece are the most pronounced parameters, which has a significant effect on the work piece-s surface during deep cold rolling and low plasticity burnishing process.
Abstract: Fatigue is the major threat in service of steel structure
subjected to fluctuating loads. With the additional effect of corrosion
and presence of weld joints the fatigue failure may become more
critical in structural steel. One of the apt examples of such structural
is the sailing ship. This is experiencing a constant stress due to
floating and a pulsating bending load due to the waves. This paper
describes an attempt to verify theory of fatigue in fracture mechanics
approach with experimentation to determine the constants of crack
growth curve. For this, specimen is prepared from the ship building
steel and it is subjected to a pulsating bending load with a known
defect. Fatigue crack and its nature is observed in this experiment.
Application of fracture mechanics approach in fatigue with a simple
practical experiment is conducted and constants of crack growth
equation are investigated.
Abstract: The purpose of this research is to reduce the amount of incomplete coating of stainless steel washers in the electrodeposition painting process by using an experimental design technique. The surface preparation was found to be a major cause of painted surface quality. The influence of pretreating and painting process parameters, which are cleaning time, chemical concentration and shape of hanger were studied. A 23 factorial design with two replications was performed. The analysis of variance for the designed experiment showed the great influence of cleaning time and shape of hanger. From this study, optimized cleaning time was determined and a newly designed electrical conductive hanger was proved to be superior to the original one. The experimental verification results showed that the amount of incomplete coating defects decreased from 4% to 1.02% and operation cost decreased by 10.5%.
Abstract: To maximise furnace production it-s necessary to
optimise furnace control, with the objectives of achieving maximum
power input into the melting process, minimum network distortion
and power-off time, without compromise on quality and safety. This
can be achieved with on the one hand by an appropriate electrode
control and on the other hand by a minimum of AC transformer
switching.
Electrical arc is a stochastic process; witch is the principal cause
of power quality problems, including voltages dips, harmonic
distortion, unbalance loads and flicker. So it is difficult to make an
appropriate model for an Electrical Arc Furnace (EAF). The factors
that effect EAF operation are the melting or refining materials,
melting stage, electrode position (arc length), electrode arm control
and short circuit power of the feeder. So arc voltages, current and
power are defined as a nonlinear function of the arc length. In this
article we propose our own empirical function of the EAF and model,
for the mean stages of the melting process, thanks to the
measurements in the steel factory.
Abstract: Paper presents knowledge about types of test in area
of materials properties of selected methods of rapid prototyping
technologies. In today used rapid prototyping technologies for
production of models and final parts are used materials in initial state
as solid, liquid or powder material structure. In solid state are used
various forms such as pellets, wire or laminates. Basic range
materials include paper, nylon, wax, resins, metals and ceramics. In
Fused Deposition Modeling (FDM) rapid prototyping technology are
mainly used as basic materials ABS (Acrylonitrile Butadiene
Styrene), polyamide, polycarbonate, polyethylene and polypropylene.
For advanced FDM applications are used special materials as silicon
nitrate, PZT (Piezoceramic Material - Lead Zirconate Titanate),
aluminium oxide, hydroxypatite and stainless steel.
Abstract: In this paper by measuring the cutting forces the effect
of the tool shape and qualifications (sharp and worn cutting tools of
both vee and knife edge profile) and cutting conditions (depth of cut
and cutting speed) in the turning operation on the tool deflection and
cutting force is investigated. The workpiece material was mild steel
and the cutting tool was made of high speed steel. Cutting forces
were measured by a dynamometer (type P.E.I. serial No 154). The
dynamometer essentially consisted of a cantilever structure which
held the cutting tool. Deflection of the cantilever was measured by an
L.V.D.T (Mercer 122) deflection indicator. No cutting fluid was used
during the turning operations. A modern CNC lathe machine (Okuma
LH35-N) was used for the tests. It was noted that worn vee profile
tools tended to produce a greater increase in the vertical force
component than the axial component, whereas knife tools tended to
show a more pronounced increase in the axial component.
Abstract: Arc welding creates a weld pool to realize continuity between pieces of assembly. The thermal history of the weld is dependent on heat transfer and fluid flow in the weld pool. The metallurgical transformation during welding and cooling are modeled in the literature only at solid state neglecting the fluid flow. In the present paper we associate a heat transfer – fluid flow and metallurgical model for the 16MnD5 steel. The metallurgical transformation model is based on Leblond model for the diffusion kinetics and on the Koistinen-Marburger equation for Marteniste transformation. The predicted thermal history and metallurgical transformations are compared to a simulation without fluid phase. This comparison shows the great importance of the fluid flow modeling.
Abstract: In this paper, the experimental design of using the
Taguchi method is employed to optimize the processing parameters in
the plasma arc surface hardening process. The processing parameters
evaluated are arc current, scanning velocity and carbon content of
steel. In addition, other significant effects such as the relation between
processing parameters are also investigated. An orthogonal array,
signal-to-noise (S/N) ratio and analysis of variance (ANOVA) are
employed to investigate the effects of these processing parameters.
Through this study, not only the hardened depth increased and surface
roughness improved, but also the parameters that significantly affect
the hardening performance are identified. Experimental results are
provided to verify the effectiveness of this approach.